JPS5891613A - Manufacture of resin molded coil - Google Patents

Abstract

PURPOSE:To prevent generation of a crack resulted from a resin clear layer between an outside circumferential insulating layer and an outest circumferential insulating layer on a terminal plate by a method wherein the terminal plate is exposed on the surface of the coil. CONSTITUTION:A base material and a conductor are alternately wound around a spool 1 to form the coil 2. Then terminals 4 are fixed to the terminal plate 3, and a mold releasing treated part 12 is formed on the upper faces of the terminal plate 3 and the terminals 4. After leads 5 are connected to the terminals 4, a filler 6 is filled up on the circumference of the leads 5, the outside circumferential insulating layer 7 and the outest circumferential insulating layer 8 are wound around, the winding finishing part is sealed to form a seal part 9, and the elemental coil 10 is constituted. After thermosetting resin containing photosetting resin is impregnated making the elemental coil 10 in condition putting the seal part 9 on the lower side, ultraviolet rays are irradiated to the circumferential face of the coil to apply the leakage preventing treatment by formation of a film, resin is heated to be hardened, and after resin is cooled gradually, the spool 1 is pulled out. Then the outside circumferential insulating layer 7 and the outermost circumferential insulating layer 8 on the terminal plate 3 are removed to expose the outside surface of the terminal plate 3.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a resin molded coil, and particularly to a method for manufacturing a resin molded coil without using a casting mold.

FIG. 1 is a partial side sectional view of a coil showing a conventional method of manufacturing a resin molded coil. In FIG. 1, first, a base material and a conductor are alternately wound around a winding core (1) to form a coil (2). Next, a terminal (4) having a screw hole (401) is attached to a terminal plate (3) made of a glass epoxy resin laminate, and a lead (5), which is the end of the coil (2), is attached to this terminal (4). After connecting, filler material (
6) are packed so that there are no gaps, and a non-woven fabric made of, for example, polyethylene terephthalate is wound several times to form an outer insulating layer (strength). is wound at least once to form the outermost insulation &<8), and the end of the winding is sealed to form a sealed part (9), and the bare coil (
10). Next, the bare coil (10) is impregnated with a thermosetting resin containing a photocurable resin, and the circumferential surface of the coil is irradiated with ultraviolet rays to form a film to prevent leakage, which is then heated and cured. After slow cooling, remove the winding core (1), drill a through hole that reaches the screw hole (401) of the terminal (4) in the outer insulating layer (right side) and the outermost insulating layer (8), and insert the terminal screw (Fig. (not shown) edict and make-up nut (not shown)
Install and complete manufacturing.

However, in the resin molded coil manufactured by the above-mentioned conventional method, the seal part (9) remains as a step on a part of the outer periphery of the coil, which impairs the aesthetic appearance compared to a coil manufactured using a mold. lower value. Also, the outer insulating layer (
7) Rebellion and outermost agony m Layer (8) has uniform winding tension on the coil surface and can be tightly wound, but on the upper part of the terminal board (3), tension is applied to the terminal board corner (301). On the terminal board (3) is the outer peripheral insulation layer (7)
The outermost insulating layer (8) is in a floating state and the gap (
11) occurs. Therefore, the resin enters the gap (11) during resin impregnation to impregnate the bare coil (10),
After manufacturing is completed, a clear resin layer remains and causes cracks. Furthermore, the outer insulating layer (
7), the outermost insulating layer (8), and the clear resin layer formed by the resin entering the gap (11).
) Cracks are likely to occur when drilling a through hole in the upper part using a drill or the like, and cracks may also occur when attaching a decorative nut (not shown). Furthermore, there was a drawback that it was difficult to position the through hole coaxially with the screw hole (401).

The present invention has been made to eliminate the drawbacks of the prior art as described above. An embodiment of the present invention will be described below with reference to the drawings.

FIG. 2 is a partial side sectional view of a coil showing an embodiment of the method for manufacturing a resin molded coil according to the present invention. In the figure, the same parts as in FIG. 1 are designated by the same reference numerals. In FIG. 2, a coil (2) is formed by alternately winding a base material and a conductor around a winding core (1). Next, a terminal board (3) made of a glass epoxy resin laminate board - a terminal (4) having a ζ screw hole (401) is attached, and a mold release treatment section (12) is attached to the upper surface of the terminal board (3) and terminal (4). form. Mold release treatment section (12
) is formed by applying, for example, a silicone-based grease-like mold release agent, and any mold release agent whose low heat resistance exceeds 130° C. may be used. Next, the terminal (
After connecting the lead (5) to the lead (5), the filler (6) is tied around the lead (5) without any gaps, and a nonwoven fabric made of polyethylene terephthalate, for example, is wound several times to form an outer insulating layer. (7), and wrap a small amount of non-woven fabric with poor permeability, such as aromatic polyamide non-woven fabric, over the outer circumferential insulating layer (7) on the same side to form the outermost insulating layer (8), and the end of the winding is used as a terminal. A sealed part (9) is formed by positioning the coil at the center of the plate (3) and sealing the end of the winding to form a raw coil (10).Next, the raw coil (10) is attached to the sealed part (9). After impregnating the coil with a thermosetting resin containing a photocurable resin, the coil surface is irradiated with ultraviolet rays to form a film to prevent leakage, and this is heated and cured to slowly cool down and then wind. Remove the core (1). Next, for example,
Insert the outer insulation layer (7) and the outermost insulation layer (8
) and remove the outer peripheral insulating layer (7) and the outermost insulating layer (8) on the terminal board (3) to expose the outer surface of the terminal board (3) and finish manufacturing the resin molded coil. .

In addition, explanations on how to attach the terminal (4) to the terminal handle (3), how to connect the terminal plate (3) and the lead (5), and processes such as finishing and painting after releasing the mold are in this book. This is omitted because it is not the gist of the invention. ' This invention has been made as described above, and by increasing the coil surface number of the terminal plate (3), the clear resin between the outer circumferential insulating layer (7) and the outermost circumferential insulating layer (8) on the terminal plate (3) is removed. There is no need to worry about cracks occurring due to different layers.
Reliability in terms of product characteristics is improved, and the work of drilling terminal holes and positioning work is omitted, reducing work time. In addition, by positioning the seal portion (9), which is the end of the winding of the outermost insulating layer (8), on the terminal plate (3) and finally removing the seal portion (9), the outer curved portion of the coil is smoothed. It is possible to obtain a seamless surface and improve the aesthetic appearance.

As described above, the present invention has various effects such as no cracking, improved reliability, reduced working time, and improved appearance.

[Brief explanation of drawings]

FIG. 1 is a partial side sectional view of a coil showing a conventional method for manufacturing a resin molded coil, and FIG. 2 is a partial side sectional view of a coil showing an embodiment of the method for manufacturing a resin molded coil according to the present invention. In the figure, (1) is the winding core, (2) is the coil, (3) is the terminal board, (301) is the terminal board corner, (4) is the terminal,
(51 is a lead, (6) is a filler, (7) is an outer peripheral insulating layer, (8) is an outermost peripheral insulating layer, (9) is a sealing part, (10)
A bare coil, and (12) a mold release treatment section. Note that the same parts in each figure are given the same reference numerals. Agent Patent Attorney Makoto Kuzuno -:' Figure 1 Procedural Amendment (Spontaneous) April 5, 1981 2, Title of invention: Method for manufacturing resin molded coils 3, Person making the amendment 5, Opposed details of the amendment Column 6 of the Detailed Description of the Invention of the Book, Contents of the Amendment (1) In the specification, page 2, line 18 and page 5, line 14, the term "thermosetting" has been replaced with "thermosetting". I am corrected. (2) On page 5, line 11 of the same document, ``a seal portion (9) is formed;
'' should be corrected to ``After forming the seal portion (9), seal one end face of the coil.'' (3) In lines 12 and 13 of page 5, the phrase [Next in the 1111 state] was replaced with ``Next, place the bare coil (10) with the unsealed end of the coil facing up. , in an upright position,” he corrected. that's all

Claims (1)

[Claims] 1. A first step of winding a conductor around a winding frame to create a coil, a second step of applying a mold release agent to the outer surface of the terminal board to be connected to the coil, and a step of forming a coil between the coil and the terminal board. A third step of forming a bare coil by applying an outer peripheral insulating layer and an outermost peripheral insulating layer to the periphery, and making the winding end portion of the outermost peripheral insulating layer the upper part of the terminal board, impregnating the raw coil with a resin; A fourth step of heating and curing, and a fifth step of removing the outer peripheral insulating layer and the outermost insulating layer on the terminal board after the heating and curing and slow cooling to expose the outer surface of the terminal board. A method for manufacturing a resin molded coil.