JPH07222388A - Coil for generator and manufacture thereof - Google Patents

Abstract

PURPOSE:To prevent failure, e.g. engine stall, due to disconnection of a lead by protecting the lead wire of coil being connected with the terminal of a generator coil. CONSTITUTION:The generator coil comprises a bobbin 1 where a rod core and a terminal 4 are integrally molded of plastic, and a coil 2 wound around the bobbin wherein a lead wire 5, on one end side of the coil 2, is connected with the terminal 4 and the coil 2 is bonded through a hard resin. In order to prevent the lead wire 5 from being caught between the coil 2 and the flange part 1a of bobbin 1, a groove part is made in the flange part 1a. Furthermore, wall parts 1b, 1c are also provided in order to prevent flow out of a soft resin 6 for sustaining electric insulation of the lead wire 5.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention mainly relates to a coil for a magnet generator such as a two-wheeled vehicle or an outboard motor in which vibration and temperature change largely due to an engine and the like and a method for manufacturing the same. More specifically, the present invention relates to a generator coil having an improved coil end structure and a method for manufacturing the same.

[0002]

2. Description of the Related Art FIG. 4 is an explanatory plan view showing an example of a terminal portion of a conventional generator coil, and FIG. 5 is a sectional view taken along line VV in FIG. 4 to 5, 1 is a bobbin, 2 is a coil, 3 is a rod-shaped core, 4 is a terminal, and 5 is a coil 2.
Is a leader wire, 6 is a flexible resin made of, for example, silicone rubber, and 7 is a hard resin.

The bobbin 1 is integrally formed by insulating a rod-shaped iron core 3 penetrating the center of the bobbin 1 and a terminal 4 provided on the collar 1a at the end of the bobbin 1 with an electrically insulating material such as plastics. Has been done. A coil 2 is formed by winding a conductive wire around the outer periphery of the bobbin 1.
The lead wire 5, which is one end of the wire, is wound around the terminal 4 and electrically connected by, for example, solder. The inner wall 1b is provided on the outer periphery of the collar 1a of the bobbin 1 at the end on the center side.
Are formed.

After that, the coil 2 is fixed to each other by dropping and impregnating the hard resin forming material into the coil 2 and hardening it. At the same time, the hard resin forming material also adheres to the lower portion of the terminal 4 and the lead wire 5 routed to the terminal 4, and the hard resin 7 is fixed to the collar portion 1a of the bobbin 1.

After that, a flexible resin forming material such as silicone rubber is poured into the terminal 4 and the portion of the lead wire 5 routed to the terminal 4 and solidified to form the flexible resin 6, and the terminal 4 is insulated and pulled out. The line is fixed.

[0006]

Since the terminal portion of the conventional generator coil is constructed as described above, a slight movement between the bobbin 1 and the coil 2 due to stress due to engine vibration and temperature change. Occurs. As a result, there is a problem that the lead wire 5 fixed between the bobbin 1 and the coil 2 is disconnected due to excessive stress.

Further, cracks may occur in the hard resin 7 itself due to the temperature cycle, and there is a problem that the lead wire 5 is broken due to the stress at that time.

Further, when a material having a low viscosity is used as the flexible resin forming material, since it has an inner wall on the central portion side, it serves as a stopper for the flexible resin forming material, but there is no stopper on the outer end side and it flows out. There is also a problem that the head of the terminal 4 is exposed and insulation is insufficient, and when a material having high viscosity is used, air bubbles remain around the lead wire 5 and the lead wire 5 is not sufficiently fixed.

The present invention has been made to solve the above problems, and it is an object of the present invention to provide a generator coil capable of preventing disconnection of a lead wire and reliably insulating a terminal portion without increasing the number of working steps. To aim.

Another object of the present invention is to provide a method of manufacturing a coil for a generator for preventing breakage of a lead wire and obtaining a terminal structure of a coil capable of reliably insulating a terminal part.

[0011]

SUMMARY OF THE INVENTION A generator coil according to the present invention comprises a bobbin made of an electrically insulating material in which an electrically conductive terminal is integrally fixed to a collar, and an electrically conductive material wound around the bobbin. A coil for a generator, which comprises a coil, one end side of which is connected to the terminal, and which is fixed by a hard resin, for pulling out one end of the coil to the collar of the bobbin. A groove is provided, a wall is provided around the terminal, and a lead wire of the coil in the groove and a connecting portion between the one end of the coil and the terminal are embedded with a flexible resin. is there.

The method of manufacturing the generator coil of the present invention is as follows:
A conductive terminal is integrally fixed to the collar portion, and a coil is formed by winding a conductive wire around a bobbin made of an electrically insulating material in which a groove portion for drawing out one end portion of the coil is formed in the collar portion, One end of the lead wire of the coil is electrically connected to the terminal, a flexible resin forming material is poured around the groove and the connection portion between the one end of the lead wire of the coil and the terminal, and then the bobbin It is characterized in that a hard resin forming material is poured into and fixed to a surrounding coil portion.

The flexible resin forming material has a viscosity of 10
It is preferable to adjust the flow rate to 0 to 1000 P (poise) before pouring, because the flexible resin forming material sufficiently flows into the gap between the lead wires wound around the terminal, no bubbles remain, and complete coating is possible.

A room temperature-curable flexible resin forming material is used as the flexible resin forming material which is poured into the groove and the connection portion, and after hardening, the hard resin forming material is poured to fix the coil. It is preferable because the resin can be easily cured by simply applying it, and the hard resin forming material for fixing the coil does not flow into the lead wire side.

Further, a thermosetting type flexible resin forming material is used as the flexible resin forming material which is poured into the groove portion and the connecting portion, and after the flexible resin forming material is poured, the thermosetting type resin is formed into the coil portion. It is preferable from the viewpoint of work efficiency that the hard resin forming material is poured and the flexible resin forming material and the hard resin forming material are simultaneously cured so that both resins can be simultaneously cured.

An ultraviolet-curable flexible resin-forming material is used as the flexible resin-forming material that is poured into the groove portion and the connection portion, and the flexible resin-forming material is poured into the flexible resin-forming material and then cured by being irradiated with ultraviolet rays. By pouring a hard resin forming material into the coil and curing it, the ultraviolet curable resin can be cured in a short time.
After the flexible resin forming material is cured, the hard resin forming material can be poured to fix the coil. As a result, the hard resin forming material does not flow into the lead wire side, which is preferable.

[0017]

In the generator coil according to the present invention, the lead wire is sandwiched between the bobbin and the coil because the groove portion is provided in the flange portion of the bobbin where the lead wire is drawn out at the end of the coil. And the leader is held softly by the flexible resin. Further, since the wall portion is provided around the terminal at the collar portion of the bobbin, the flexible resin forming material can be prevented from flowing out, and thus a material having a relatively low viscosity can also be used. As a result, the flexible resin forming material flows well even in a narrow space between the terminal and the wound lead wire to ensure reliable insulation, and the flexible resin cured against external stress due to thermal cycles. Absorbs stress to prevent damage.

Further, according to the method for manufacturing a coil for a generator of the present invention, a flexible resin forming material is poured into the lead-out portion (groove portion) which is one end of the coil and the connection portion with the terminal, and the flexible resin-forming material is coated and coated. Since the conductive wires of the coil are fixed to each other, the inflexible hard resin that fixes the coil is not fixedly formed around the leader line, and the circumference of the leader line is always covered with flexible resin and insulated. It is possible to secure the property and it is also protected against disconnection.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, a generator coil of the present invention and a method for manufacturing the coil will be described with reference to the drawings.

[Embodiment 1] FIG. 1 is an explanatory plan view showing an embodiment of a generator coil of the present invention, and FIG. 2 is a sectional view taken along line II-II of FIG. 1-2, the same or corresponding portions as those of the conventional generator coil shown in FIGS. 4-5 are designated by the same reference numerals.

A conductive wire is wound around the outer periphery of a bobbin 1 in which an iron core 3 penetrating through the central portion and a terminal 4 provided on the collar portion 1a are integrally molded with an electrical insulator such as plastics. The coil 2 is formed as a result, and the lead wire 5 which is one end of the coil 2 is wound around the terminal 4 and electrically connected by solder or the like, which is the same as the conventional structure.

In the present invention, the groove portion 8 is formed in the collar portion 1a of the portion where the lead wire 5 which is one end portion of the coil 2 is drawn out to the terminal 4, and the collar portion 1 is formed as shown in FIG.
It is characterized in that wall portions 1b and 1c are provided around the terminal 4 on the outer periphery of a and the entire portion of the lead wire 5 is covered with the flexible resin 6. That is, the inner wall 1b is conventionally provided on the center side of the bobbin 1 of the terminal 4, but in the present invention, the outer wall 1c is provided on the end side of the bobbin 1, and the terminal 4 has a wall. It has a shape surrounded by the portions 1b and 1c. Therefore, even if the connecting portion between the terminal 4 and the lead wire 5 is covered with the flexible resin forming material having a low viscosity, the flexible resin forming material does not flow out and the part of the lead wire 5 can be completely covered. As a result, the electrical insulation of the lead wire 5 and the terminal 4 is ensured, and the leader wire is not broken due to the absorption of stress against vibration and heat cycles.

The groove portion 8 may be formed in such a size that the lead wire 5 can be wired at a position leading from the lead-out portion of the lead wire 5 drawn from the coil 2 to the terminal 4, and the size is not particularly limited. . Further, as described above, this groove portion 8 can be formed at the same time when the bobbin 1 is manufactured by molding, and can be manufactured without particularly increasing the number of steps.

Further, as the flexible resin, any resin having elasticity capable of absorbing stress due to vibration or heat cycle may be used. Further, it is necessary to cover the portion where the lead wire 5 is wound around the terminal 4 and fixed by soldering or the like, and it is preferable that the gap between the wound lead wires 5 is also covered with the insulating resin forming material. . For that purpose, the viscosity at the time of pouring (JIS K 71
17: Rotational viscometer) is preferably adjusted to about 100 to 1000P, more preferably about 200 to 600P. Even if the viscosity is lowered to this extent, since the flexible resin forming material does not flow out because of the walls 1b and 1c around the terminal 4, the flexible resin forming material can be solidified and covered without any gap. As such a flexible resin forming material, one having a spring hardness according to JIS K 6301 of JIS A 10 to 60 after solidification or curing can be suitably used. Specifically, for example, a room temperature curable resin such as room temperature curable silicone rubber; an epoxy resin having flexibility after thermosetting, a thermosetting silicone rubber, a thermosetting hot melt adhesive, a thermosetting acrylic adhesive. Thermosetting resins such as; UV curing resins such as UV curing silicone rubber. In particular, each curable silicone rubber is preferable.

Further, the coil 2 is fixed by pouring a hard resin forming material between the windings of the coil 2 and curing by heating so that the winding does not break due to vibration or the like. As such a hard resin forming material, a thermosetting resin such as a polyester varnish or an epoxy varnish can be usually used.

[Embodiment 2] Next, an embodiment of a method for manufacturing the generator coil of the present invention will be described.

First, the iron core 3 is provided in the central portion as described above,
The bobbin 1 is formed by molding using an electrically insulating material such as plastics so that the collar portion 1a has the conductive terminal 4 and the collar portion 1a has the groove portion 8 and the wall portions 1b and 1c. Form. Then, a conductive wire is wound between the collar portions 1a on both sides of the bobbin 1 to form the coil 2. The lead wire 5 which is one end of the coil 2 is drawn out to the terminal 4 through the groove 8 of the bobbin 1 and wound around the terminal 4, and is electrically connected reliably by soldering or the like.

Next, a flexible resin forming material such as silicone rubber is poured into the groove 8 and around the terminal 4 and left to stand for about 15 hours to solidify. This flexible resin forming material has a viscosity of about 200 to 600 P, and flows into the gap of the lead wire wound around the terminal 4 without any gap, but hardly flows into the coil 2 that is tightly wound. It stays near the surface of the coil 2. On the other hand, it also flows into the outer periphery of the terminal 4, but since it is surrounded by the wall portions 1b and 1c, it stays in the space surrounded by the wall portions 1b and 1c. There are two types of silicone rubber: one that hardens by absorbing moisture in the air at room temperature, one that cures when the temperature rises, and one that cures when exposed to ultraviolet light. , Either can be used. Since the room temperature curing type cures only by leaving it to stand, it can be easily cured. Even at room temperature, a hard resin forming material may be poured into the coil portion before curing and then cured. Leader 5
Since the circumference of is already covered with a flexible resin forming material,
This is because the hard resin forming material does not enter. However, if the hard resin forming material of the coil portion is poured after the flexible resin forming material is hardened, the hard resin forming material for fixing the coil will not flow into the lead wire side more reliably.

When a thermosetting type flexible resin forming material is used as the flexible resin forming material, the flexible resin forming material is poured into the periphery of the terminal 4 and the groove portion 8 and then the coil 2 portion is thermoset type. Of the hard resin forming material is poured into the hard resin forming material, and then the ambient temperature is raised to the curing temperature to simultaneously heat and cure the flexible resin forming material around the terminal 4 and the hard resin forming material for coil fixing. Preferred for simplicity. In this case, it is preferable that the curing temperature is about the same, for example, if an epoxy resin is used as the flexible resin forming material and an epoxy varnish is used as the hard resin forming material for the coil 2, the same temperature of about 70 to 120 ° C. Can be cured at the same time.

When an ultraviolet curable resin forming material is used as the flexible resin forming material, after the flexible resin forming material is poured into the periphery of the terminal 4 and the groove portion 8, the ultraviolet ray is irradiated for about 1 to 5 minutes. And cure. After that, the coil is fixed as described above. If an ultraviolet curable resin forming material is used, it can be cured in a short time.

[Embodiment 3] FIG. 3 is a plan view showing a radial salient pole coil which is another embodiment of the generator coil of the present invention. In FIG. 3, for example, each of the poles provided with twelve convex poles has a coil 2 wound around a bobbin 1 as in the first embodiment, and a lead wire at the end thereof is electrically connected to the terminal 4. In addition, the walls 1b and 1c are provided around the terminal 4, and the region surrounded by the walls 1b and 1c is filled with a flexible resin to protect the leader line and the terminal 4.

The present embodiment is different from the first embodiment in that the terminal 4 is provided at the position closer to the center of the generator with respect to the coil 2, but the others are exactly the same. The present invention can be applied to the radial convex pole type coil as in the first embodiment. As a result, electrical insulation of the lead wire and prevention of disconnection can be effectively achieved.

[0033]

As described above, according to the present invention, since the wall portion is provided around the terminal, the flexible resin forming material poured around the lead wire is prevented from flowing out and the terminal portion is completely insulated. Can be secured. Moreover, since the outflow of the flexible resin forming material can be prevented, a material having a low viscosity can be used as the flexible resin forming material, and the flexible resin can be surely formed even in the narrow gap of the lead wire wound around the terminal. The material can be soaked in, greatly improving reliability.

Further, since the lead wire is provided with the groove at the lead-out portion, the lead wire is not pinched between the coil and the bobbin, and is flexible before the drip impregnation of the thermosetting resin forming the hard resin. Since the resin forming material is poured, the leader line can be held flexibly. As a result, even if a slight movement occurs between the coil and the bobbin, no stress is applied to a part of the leader line, and since the leader line is held flexibly,
Breakage can be prevented.

Further, according to the present invention, it is possible to manufacture at the same cost as the conventional one without adding any new materials and processing steps, and further, it is possible to achieve the great effect of preventing disconnection and achieving insulation of the terminal.

[Brief description of drawings]

FIG. 1 is a plan view of an embodiment of a generator coil of the present invention.

FIG. 2 is a sectional view taken along line II-II in FIG.

FIG. 3 is a plan view of another embodiment of the generator coil of the present invention.

FIG. 4 is a plan view illustrating an example of a conventional generator coil.

5 is a sectional view taken along line VV of FIG.

[Explanation of symbols]

 1 bobbin 1b wall part 1c wall part 2 coil 3 rod-shaped iron core 4 terminal 5 lead wire 6 flexible resin 8 groove part

Claims (6)

[Claims] 1. A conductive terminal comprises a bobbin made of an electrically insulating material integrally fixed to a collar portion, and a conductive coil wound around the bobbin, and one end of the coil is connected to the terminal. A generator coil connected to the coil and fixed to the coil with a hard resin, wherein a groove for pulling out one end of the coil is provided in the collar of the bobbin, and a wall is provided around the terminal. And a lead wire of the coil in the groove and a connecting portion between one end of the coil and the terminal are embedded with a flexible resin. 2. A conductive wire is wound around a bobbin made of an electrically insulating material in which a conductive terminal is integrally fixed to a collar portion and a groove portion for drawing out one end of a coil is formed in the collar portion. A coil is formed, one end of the lead wire of the coil is electrically connected to the terminal, and a flexible resin forming material is poured around the groove and the connection portion between the one end of the lead wire of the coil and the terminal, Then,
A method for manufacturing a coil for a generator, comprising pouring a hard resin forming material into a coil portion around the bobbin and fixing the material. 3. The flexible resin forming material is
The method for producing a coil for a generator according to claim 2, wherein the pressure is adjusted to 100 to 1000P and then poured. 4. A room temperature-curable flexible resin forming material is used as the flexible resin forming material which is poured into the groove and the connection portion, and after hardening, the hard resin forming material is poured to fix the coil. Claim 2 characterized by the above-mentioned.
Alternatively, the method for producing a coil for a generator according to 3 above. 5. A thermosetting type flexible resin forming material is used as the flexible resin forming material which is poured into the groove portion and the connection portion, and after the flexible resin forming material is poured into the coil portion, the thermosetting type flexible resin forming material is filled. The method for producing a coil for a generator according to claim 2 or 3, wherein a hard resin forming material is poured, and the flexible resin forming material and the hard resin forming material are simultaneously cured. 6. An ultraviolet-curable flexible resin-forming material is used as the flexible resin-forming material that is poured into the groove portion and the connection portion, and the flexible resin-forming material is poured and then cured by irradiation with ultraviolet rays, Then, a hard resin forming material is poured into the coil portion to be hardened, and the coil for a generator is manufactured according to claim 2 or 3.