JPS5842213A - Manufacture of synthetic resin molded coil - Google Patents

Abstract

PURPOSE:To shorten the impregnation time and thus the manufacture time by inserting into a coil insulating layer a spacer of a polyester nonwoven fabric or an aromatic polyamide paper, etc., having good insulating properties and high adhesion to an impregnating insulation synthetic resin. CONSTITUTION:On a core 1 are wound 2-3 layers of a releasing paper, and as an inner insulating paper 2 an aromatic polyamide paper and a polyester nonwoven fabric are stack-wound thereupon. In this process tape-or rod-shaped spacers 3 of a polyester nonwoven fabric, 5-10mum in thickness, having good insulting properties and high adhesion to an impregnating insulation synthetic resin, are wound in the direction of the axis of the core 1 into the inner insulating paper 2 4-8 places/turn to form an inner insulating layer 4. On this insulation layer are wound one layer of a conductor, an insulating layer and the necessary layers of a blank coil. A leakage stop seal layer is formed on the circumference of the blank coil and one end surfaces. The coil is then put into an impregnating insulation synthetic resin tank where it is impregnated with an insulation resin. Then the coil is heated to harden the resin. This improves the impregnation speed and eliminates the use of a metal mold.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a synthetic resin molded coil, for example, impregnated with O such as epoxy resin, or impregnated with an insulating synthetic resin composition.

Conventionally, the method used to manufacture molded coils for use in dry-type transformers, etc. is to place a bare coil in a mold, pour insulating synthetic resin around and inside the bare coil, and then harden it. According to the mold casting method, the release sensitive layer of the mold, assembly, mold disassembly after resin curing,
Furthermore, manufacturing and maintenance of the molds requires a great deal of labor and expense, and it is difficult to repurpose the molds because it takes time for the resin to harden after casting, so a large number of molds are required. Furthermore, there were many disadvantages in that various types of molds were required for various specifications.

To address these drawbacks, many methods have been devised and implemented in order to obtain coils equivalent to those using a mold without using a mold.

To explain this method, a bare coil is constructed by winding a conductor and an insulating material around a metal core.

While rotating this, a synthetic resin composition containing an ultraviolet curable resin (commonly referred to as UV resin) that undergoes a curing reaction when irradiated with ultraviolet rays is applied to one of the outer periphery and end face of the element coil, for example, by using a seconds wheel. A sealing layer consisting of a cured product of an ultraviolet curable resin that is coated on the entire surface of the lower end surface and irradiated with ultraviolet rays to cure the ultraviolet curable resin, thereby making it mechanically strong and free from resin leakage. After that, it is immersed in an insulating synthetic resin bath to be impregnated, impregnated under pressure, and cured.

However, the impregnation of the impregnated insulating synthetic resin composition into the bare coil produced by the method described above is
Since the process is carried out only from the upper end surface where there is no sealing layer, in order to completely immerse the impregnated insulating synthetic resin composition into the bare coil at vCt, it is necessary to pressurize at a high pressure or to significantly lengthen the pressurization time. The purpose of this 11WR is to obtain a manufacturing method that eliminates the drawbacks of the conventional manufacturing method for synthetic resin molded coils, and in order to achieve this purpose, In the manufacturing method of the present invention, when winding any one of the inner insulating layer, the outer insulating layer, and the interlayer insulating layer, polyester nonwoven fabric, aromatic polyamide paper, etc. are added to the insulating layer. An insulating layer is formed by winding a tape-shaped or rod-shaped spacer made of an insulating material that is highly durable and highly adhesive to the impregnated insulating synthetic resin composition. It is characterized by the following.

Hereinafter, the method of the present invention will be explained based on FIG. 1 of the accompanying drawings showing an embodiment thereof, and FIG. Wound in 1 to 2 layers. Next, in step i, an inner insulation l1 composed of aromatic polyamide paper and polyester nonwoven fabric is placed on the release paper.
During the winding process of this inner insulating paper, for example, a tape with a thickness of 3 to 10 days is rolled.
A spacer 3 made of, for example, polyester nonwoven fabric, which is an insulating material with high insulation properties and high adhesiveness with the impregnated insulating synthetic resin composition, is placed in the axial direction of the winding core l with inner insulating paper.
141! ! An inner insulating sheet is formed by wrapping the hit sheets in at least one layer of the inner insulating paper in a proportion of the areas.

Next, one layer of conductor is wound on top of the inner insulation, then an interlayer insulation layer is wound on top of that, another layer of conductor is wound, and an interlayer insulation layer is wound on top of that, and this process is repeated. , wind the conductor in the required number of layers.

Next, an outer insulating layer is wound up on this to form a bare coil, and a leak-preventing sealing layer is applied to the outer circumference of the coil and one coil end face, for example, the lower end face, by the same method as the conventional method. After forming, it is immersed in an impregnating insulating synthetic resin bath to impregnate the bare coil with the impregnating insulating synthetic resin composition.Then, this is heated and cured to complete a synthetic resin molded coil.

By the way, is it great? It is not limited to polyester non-woven fabric, but may be made of aromatic polyamide paper, etc., and in the above embodiments, only the inner insulation layer was used, but it may be applied to other insulation layers. Also, depending on the shape and size of the coil, even if it is applied to all of the insulating layers,
Of course, there is no problem. Since the method of the present invention inserts the spacer J in the axial direction between the insulating layers as described above, the spacer 3 and the inner insulating paper coats on the upper and lower layers of the spacer 3 are placed on both sides of the spacer 30. A hole 11 formed by this is formed in the axial direction to form an impregnated insulating synthetic resin inlet S.

Therefore, the impregnated insulating synthetic resin composition is impregnated from the upper end surface of the coil, and at the same time enters through the impregnated insulating synthetic resin introduction port j and impregnated into the elementary coil from the entire length of the coil.

The method of the present invention is configured as described above, and since the impregnated insulating synthetic resin composition is impregnated, the impregnation distance is a long distance from the upper end surface of the coil to the lower end surface of the coil in the conventional method. The method of the present invention requires long pressurization times or high pressures to impregnate long distances.・If so, the impregnation distance is shortened to the distance between each impregnating insulating synthetic resin guide port, and therefore, the pressurization time during impregnation can be significantly shortened, and complete impregnation can be carried out in a short time. As a result, it is possible to provide a highly economical method of manufacturing a synthetic resin molded coil.

It has been confirmed through experiments that when the insulating synthetic resin is introduced into the impregnated resin, the size is reduced to a size that does not affect the mechanical properties due to shrinkage of the insulating material during hardening after impregnation.

[Brief explanation of drawings]

FIG. 1 is a perspective view showing an embodiment of a part of the coil winding process of the method of the present invention, and FIG. 1 is a right side view thereof. L: Winding core, K: Inner insulation paper, 3: Spacer, 3:
・Inner insulation layer, sFi-impregnated insulating synthetic resin guide port. Agent Makoto Kuzuno - Figure 1

Claims (1)

[Claims] (1) It has an inner bonding layer on the innermost circumference, seven outer bonding layers on the outermost circumference, and is constructed by winding the conductor so that an interlayer insulating layer is interposed between each layer conductor in the middle part. In the method for manufacturing a synthetic resin molded coil, a sealing layer is formed on one of the coil outer periphery and the coil end face of the bare coil, and the inner insulating layer is impregnated with an insulating synthetic resin composition. When winding at least one of the outer insulating layers and the interlayer insulating layer, an insulating synthetic resin composition impregnated with a polyester nonwoven fabric, an aromatic polyand paper part, and an insulating material is used in the M edge layer. Manufacture of a synthetic resin molded coil characterized in that an insulating layer is formed by winding a tape-shaped or rod-shaped spacer made of an insulating material with high adhesiveness to the coil. Method 0 (2) Involving the spacer in 1 layer per layer
8. The method of manufacturing a synthetic resin mode coil according to claim 7, wherein the synthetic resin mode coil is provided in at least one layer at += to l locations.