JPH07103355A - Coil of solenoid valve and manufacture thereof - Google Patents

Abstract

PURPOSE:To prevent generation of disconnection in a position crossed enamelled wires each other, cope with change of an atmosphere such as temperature change, and improve a quality. CONSTITUTION:A silicon rubber layer 46 for covering an enamelled wire is formed on a cross part 41b where the winding start part IN side crosses winding final part OUT side of the enamelled wire wound on a bobbin 41. Then resin mold formation is carried out so as to form the coil of a solenoid valve.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a structure and manufacturing method of a coil used in a solenoid valve.

[0002]

2. Description of the Related Art In a conventional solenoid valve, a coil housing 1 is attached to a valve housing 6 as shown in FIG. A yoke portion 12 is provided at one end of the cylindrical portion 11 at the center of the coil housing 1. Tubular part 1
A ball bearing portion 31 is provided in the cylinder of No. 1, and a coil spring 73 is provided between the lower end of the ball bearing portion 31 and the inner peripheral step portion of the valve housing 6. A shaft 4 is provided at the center of the ball bearing portion 31 so as to penetrate therethrough, and the tip end of the shaft 4 of the spool valve 61 biased upward by a spring member (not shown) in the valve housing 6. It is in contact with the upper end.

The plunger 5 fitted on the outer periphery of the upper end of the shaft 4 is located in the opening of the thick-walled top portion of the cover body 71 which covers the coil 2 around the tubular portion 11 with a small gap. ing. The top of the cover body 71 is covered with a lid body 74. Further, the feeding end of the coil 2 reaches the connector 72 provided on the side surface of the cover body 71. With such a configuration, when the coil 2 is energized, magnetic force lines passing through the coil housing 1, the cover body 71, and the plunger 5 are generated, the plunger 5 is attracted to the yoke portion 12, and the shaft 4 moves downward (see FIG. 7). The left half portion) spool valve 61 is adapted to move downward.

The coil 2 has a structure in which an enamel wire 23 is wound around a bobbin 21, and thereafter the outer circumference is resin-molded with a resin 22 (thick hatched portion in FIG. 7). This resin molding is for reducing the size of the entire solenoid valve and improving the heat dissipation of the coil 2. In the solenoid valve as described above, the coil 2 will be described. 8A is a cross-sectional view taken along the arrow A in FIG. The bobbin 21 includes a winding portion 21a around which the enamel wire 23 is wound, a cross portion 21b where the enamel wire 23 is crossed, and a connector portion 21c to which the terminal 24 is attached. The cross portion 21b has a guide portion 21d formed with a minute gap from the upper surface of the cross portion 21b. At the cross portion 21b, the winding enameled wire 23 is a winding start portion of the enameled wire 23 so as not to loosen and unwind.
After the side 23a and the OUT side 23b, which is the winding end portion, are crossed, they are respectively connected to the terminals 24 of the connector portion 21c. Further, the IN side 23a is passed through the gap below the guide portion 21d, and the OUT side 23b is connected to the guide portion 2d.
By passing it through the upper side of 1d, both are in contact with each other and are prevented from rubbing.

[0005]

As described above, the coil 2 is formed by resin molding after winding the enameled wire 23 around the bobbin 21 and connecting it to the terminal 24. At the time of resin molding, when the resin is injected, the enamel wire 23 of the cross portion 21b may be pulled due to the flow of the resin. When the temperature change is repeated in such a state, the resin and the enameled wire 23 have different thermal expansion coefficients, so that a difference in the amount of thermal expansion occurs between the two and the enameled wire 23 is repeatedly stressed. As a result, there is a problem that the enamel wire 23 is broken in the cross portion 21b.

The present invention has been made in order to solve the above problems, prevents the occurrence of disconnection at the intersection of enameled wires, and copes with environmental changes such as temperature changes. It is an object of the present invention to provide a high quality solenoid valve coil that can be manufactured.

[0007]

As a means for achieving the above-mentioned object, the present invention as claimed in claim 1 wraps a wire around a winding part and crosses the winding start part and the winding end part of the wire at the cross part. A coil of a solenoid valve having a bobbin connecting the winding start portion and the winding end portion to a terminal attached to a connector portion, and having a resin molded portion formed by resin molding on an outer surface of the bobbin,
A silicon rubber layer that covers a winding start portion and a winding end portion of the wire is provided between the cloth portion and the resin mold portion.

According to a second aspect of the present invention, a wire is wound around a winding portion, a winding start portion and a winding end portion of the wire material are crossed at a cross portion, and the winding start portion and the winding end portion are attached to a connector portion. In a method for manufacturing a coil of an electromagnetic valve, which comprises a bobbin connected to the outer surface of the bobbin, the winding start portion and the winding end portion of the wire rod in the cross portion are coated with silicone rubber, and then the cross is formed. After the cover that fits with the section is attached on the cross section, the resin molding is performed.

According to a third aspect of the present invention, a wire is wound around a winding portion, a winding start portion and a winding end portion of the wire material are crossed at a cross portion, and the winding start portion and the winding end portion are attached to a connector portion. In a method for manufacturing a coil of an electromagnetic valve, which comprises a bobbin connected to the outer surface of the bobbin, resin is molded on the outer surface of the bobbin. After mounting a cylindrical cover having a portion on the cross portion, silicone rubber is injected into the space portion of the cover, and then the resin molding is performed.

[0010]

According to the means of claim 1, since the silicon rubber layer covers the winding start portion and the winding end portion of the wire at the cross portion, when the resin is injected, the flow of the resin is received and the wire material of the cross portion is received. Can be prevented from being pulled. Further, since it is possible to prevent contact between the wire and the resin mold portion, it is possible to prevent repeated stress from being applied to the wire even if a difference in thermal expansion amount occurs between the two.

According to the second aspect of the present invention, since the cover is attached on the silicone rubber and the silicone rubber layer is sandwiched between the cross portion and the cover, the silicone rubber can be applied uniformly. In the means of claim 3, since the silicone rubber is injected into the space after the cover is attached on the cross portion, the silicone rubber reservoir can be formed and the wire can be surely covered.

[0012]

Embodiments of the present invention will be described with reference to the drawings. 1 to 4 show the structure of the coil of this embodiment. In FIG. 1, (a) is a view from the arrow B of (b), and FIG. 2 is a view from the arrow C of FIG. 1 (b). FIGS. 3 and 4 respectively show a case in which silicone rubber, which is a feature of this embodiment, is applied, and each corresponds to FIGS. 1 and 2.

The coil of this embodiment mainly comprises a bobbin 41 around which the enamel wire 43 is wound. After the enamel wire 43 is wound around the bobbin 41, resin molding is performed and the coil is assembled as a solenoid valve. The structure of such a solenoid valve is the same as that of the conventional art, and therefore its explanation is omitted. The bobbin 41 includes a winding portion 41 a around which the enamel wire 43 is wound and a cross portion 41 where the enamel wire 43 is crossed.
b and the connector portion 41 to which the terminal 44 is attached
It consists of c and. The winding portion 41a is a tubular member, and the enamel wire 43 is the winding start portion on the IN side 4
3a and the OUT side 43b, which is the winding end portion, are wound around the cross portion 41b with a slight amount left. Cross section 4
1b has a first guide portion 45a and a second guide portion 45b which are formed with a minute gap with respect to the upper surface of the cross portion 41b and have the same height. First guide part 4
5a and the second guide portion 45b are separated by a gap 45d. A third guide portion 45c is formed on the upper surface of the first guide portion 45a with a minute gap from the upper surface of the first guide portion 45a.

The connector portion 41c has two terminals 4
4 are erected. Further, notches 49 are formed at both ends of the connector portion 41c, and the circumference of the notches 49 is slightly lower than that of the cross portion 41b. The stepped portion formed between the periphery of the low cutout portion 49 and the upper surface of the cross portion 41b is formed with an arcuate R portion 48.

With respect to the bobbin 41 having such a structure, the IN side 43a, which is the winding start portion of the enamel wire 43, is
The cutout portion 49 passes through the gap on the lower surface side of the guide portion 45a.
Is located below the connector portion 41c via the and is coupled to the terminal end portion 44a of the one terminal 44. At this time, the terminal end portion 44a of the terminal 44 is joined by being heated and caulked (fusing).

Further, the OUT side 43b, which is the winding end portion of the enamel wire 43, passes through a gap formed between the lower surface side of the third guide portion 45c and the upper surface of the first guide portion 45a, and thereafter, one step further. It passes through the lower surface of the lower second guide portion 45b, is located below the connector portion 41c through the notch portion 49, and has an I at the end portion 44a of the other terminal 44.
It is coupled in the same manner as the N side 43a. At this time, IN side 43a
The OUT side 43b intersects when viewed from above,
Since they are substantially separated by the first guide portion 45a, they do not come into contact with each other. Also, the OUT side 43
Most of the surface of b also passes through the lower surfaces of the second guide portion 45b and the third guide portion 45c and is not exposed. Therefore, when the bobbin 41 is resin-molded, the flow of resin causes the enamel wire to flow. 43 is prevented from being pulled. Further, since the R portion 48 is formed around the cutout portion 49 on which the enamel wire 43 is hooked, the enamel wire 43 is cut off by the cutout portion 49.
To prevent disconnection.

Silicon rubber is applied to the bobbin 43 around which the enamel wire 43 is wound in this manner, as shown in FIGS. 3 and 4, to form a silicon rubber layer 46 (hatched portion surrounded by a thick line). . That is, the silicone rubber layer 46 includes the upper surface portion 46a extending from the entire upper surface of the cross portion 41b to the cutout portions 49 at both ends of the connector portion 41c, and the connector portion 41.
It is formed on the peripheral portion 46b of the terminal end portion 44a of the terminal 44, which is the lower surface side of c. The connector portion 41c
46c, which is a portion other than the upper surface portion 46a, is a portion that may or may not be coated with silicon rubber. Further, the silicone rubber does not necessarily have to be applied to the peripheral portion 46b of the terminal end portion 44a of the terminal 44. That is,
The entire upper surface of the cross portion 41b is the most important portion where the silicone rubber is applied.

With the above-mentioned structure, the coil of the present embodiment is applied with silicon rubber before resin molding so that the enamel wire is pulled by the flow of resin generated when the resin is poured. Can be prevented. In addition, since the part where the resin mold and the enameled wire come into direct contact with each other after resin molding can be minimized, the effect of repeated stress due to the difference in thermal expansion between the resin and the enameled wire when the temperature changes is prevented, and the breaking of the enameled wire is prevented can do. That is, the silicone rubber is hard to lose its elastic action regardless of the temperature change. Therefore, stress is unlikely to be generated between the enamel wire and the enamel wire, which prevents the enamel wire from breaking.

FIG. 5 shows a second embodiment. In the second embodiment, after the silicone rubber is applied, the silicone rubber is prevented from dripping before being hardened, and notches at both ends of the connector portion 41c are formed from the entire upper surface of the cross portion 41b shown in FIG. Upper surface portion 46 reaching the portion 49
Silicon rubber is uniformly applied to a. In order to achieve this, the cover 50 as shown in FIGS. 5C and 5D is applied to the cross portion 41b and the connector portion 41c after the silicone rubber is applied and then covered. The cover 50 is formed with a hole 50a through which the terminal 44 passes. By using such a cover 50, the silicone rubber can be easily and uniformly applied, so that the working efficiency can be improved. A two-dot chain line 51 in FIG. 5 shows an outer shape after resin molding is performed after applying silicon rubber.

FIG. 6 shows a third embodiment. This third embodiment is shown in FIG.
The ring-shaped cover 60 having the space portion 60a shown in (c) and (d) is attached to the cross portion 41b and the connector portion 41c (FIGS. 6A and 6B). Then, a silicone rubber reservoir is formed by injecting silicone rubber into the space 60a. In this way, by covering the cross portion 41b and the connector portion 41c with the silicone rubber reservoir, the enameled wire can be reliably protected. Therefore, according to the third embodiment, anyone can easily and surely apply the silicone rubber. In addition,
A chain double-dashed line 51 in FIG. 6 shows the outer shape of the resin mold portion after the resin molding is performed after the silicone rubber is applied.

[0021]

According to the invention of claim 1, since the silicon rubber layer covers the winding start portion and the winding end portion of the wire at the cross portion, when the resin is injected, the cross portion receives the flow of the resin. It is possible to prevent the wire rod from being pulled. Further, since it is possible to prevent contact between the wire and the resin mold portion, it is possible to prevent repeated stress from being applied to the wire even if a difference in thermal expansion amount occurs between the two. Therefore, it is possible to provide the coil of the solenoid valve that does not break even when the temperature changes drastically.

According to the second aspect of the present invention, since the cover is attached on the silicone rubber and the silicone rubber layer is sandwiched by the cross portion and the cover, the silicone rubber layer can be uniformly formed by applying a small amount of the silicone rubber. .
Therefore, it is possible to provide the coil of the solenoid valve without dripping of silicone rubber or unevenness. In the invention of claim 3, since the silicone rubber is injected into the space after the cover is attached on the cross portion, the silicone rubber reservoir can be formed. Therefore, it is possible to reliably coat the wire rod, quantify the injection amount of the silicone rubber, and provide the coil of the solenoid valve with stable quality.

[Brief description of drawings]

FIG. 1 is an overall configuration diagram of a first embodiment of the present invention.

FIG. 2 is a view on arrow C of FIG. 1 (b) in the first embodiment.

FIG. 3 is a diagram showing application of silicone rubber corresponding to FIG. 1 in the first embodiment.

FIG. 4 is a diagram showing application of silicone rubber corresponding to FIG. 2 in the first embodiment.

FIG. 5 is an overall configuration diagram of a second embodiment of the present invention.

FIG. 6 is an overall configuration diagram of a third embodiment of the present invention.

FIG. 7 is a diagram for explaining a conventional solenoid valve.

FIG. 8 is a diagram for explaining a conventional coil.

[Explanation of symbols]

 41 bobbin 41a winding part 41b cross part 41c connector part 43 enamel wire 43a enamel wire IN side 43b enamel wire OUT side 44 terminal 46 silicon rubber layer 50 cover 51 resin mold part 60 cover 60a space part

Front page continued (72) Inventor Ikuo Okuda 1-1, Asahi-cho, Kariya city, Aichi prefecture Toyota Koki Co., Ltd. (72) Inventor Satoru Yamada 1-1, Asahi-cho, Kariya city Aichi prefecture Toyota machine

Claims (3)

[Claims] 1. A wire is wound around a winding part, and a winding start part and a winding end part of the wire are intersected at a cross part, and the winding start part and the winding end part are connected to a terminal attached to a connector part. Equipped with a bobbin,
In a coil of an electromagnetic valve having a resin molded portion formed by resin molding on the outer surface of the bobbin, a silicone rubber layer for covering a winding start portion and a winding end portion of the wire is provided between the cross portion and the resin molding portion. A coil of a solenoid valve, which is characterized in that 2. A wire rod is wound around a winding portion, a winding start portion and a winding end portion of the wire rod are crossed at a cross portion, and the winding start portion and the winding end portion are connected to a terminal attached to a connector portion. Equipped with a bobbin,
In a method of manufacturing a coil of an electromagnetic valve in which an outer surface of a bobbin is resin-molded, a winding start portion and a winding end portion of the wire in the cross portion are covered with silicone rubber, and then a cover that fits the cross portion is provided. A method for manufacturing a coil of an electromagnetic valve, which comprises performing resin molding after mounting on the cross portion. 3. A wire rod is wound around a winding portion, a winding start portion and a winding end portion of the wire rod are crossed at a cross portion, and the winding start portion and the winding end portion are connected to a terminal attached to a connector portion. Equipped with a bobbin,
In a method for manufacturing a coil of an electromagnetic valve in which an outer surface of a bobbin is resin-molded, a tubular cover having a space portion that fits the cross portion at a winding start portion and a winding end portion of the wire rod in the cross portion. Is attached to the cross portion, silicon rubber is injected into the space portion of the cover, and then the resin molding is performed, and a method for manufacturing a coil of a solenoid valve.