JPS6019223B2 - Manufacturing method for wire-wound iron core armature - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a wire-wound ironless D-armature.

Conventionally, wire-wound ironless coils are made by winding self-fusing wires and then temporarily fixing the self-fusing wires to each other and between each segment. After shaping, it is made into a rigid body integral with the shaft, commutator, etc.

This method of making the coil into a rigid body can be roughly divided into making the coil itself into a rigid body after rectifying the current into a predetermined shape, and making the coil into an Okayama body between the coil and the shaft commutator, but generally a method of making the coil into a rigid body by resin molding is often used. For example, in the case of the armature of a cup motor or a flat fan motor, the wire-wound ironless coil that is the object of the present invention is seeking an ultra-thin structure due to its electrical design. A low-pressure sealing material based on saturated polyester resin or diallyl phthalate resin is used.The wire-wound ironless coil, which is embedded in the low-pressure sealing material, is connected to a commutator that has been bonded to the shaft in advance, and the resin During molding, the coil and the commutator bonded to the shaft in advance are made rigid at once.

Since low-pressure sealing material has high fluidity, it is possible to mold products with ultra-thin structures, but on the other hand, during resin molding, low-pressure sealing material flows between Toshikazu molds, commutator slits, risers, etc. Therefore, it was necessary to temporarily protect the area around the shaft and the commutator. Conventional methods for protecting these devices include coating the commutator with silicone resin or the like, or extremely narrowing the dimensional difference between the shaft and the mold. As a result, workability is significantly reduced in the resin molding process, and a process to protect the commutator in advance and a process to remove the commutator covering material after resin molding is required, and the resin molding process causes the coil to become an Okayama body. There was no point in trying to make the shaft, commutator, etc. rigid all at once, and simplifying the process of making the ironless armature rigid. on the other hand,
Due to the structure of wire-wound coreless coils, it was normal for a portion of the coil to be embedded in the molding resin to be exposed on the armature surface even after molding, so the low-voltage sealing materials used have been changing more and more in recent years. Products with improved characteristics have come to be widely used.
As a result, defects frequently occurred due to insufficient sealing of various parts during resin molding. In view of this background, the present invention aims to eliminate the drawbacks associated with the above-mentioned resin molding process.

That is, in a coreless coil formed by shaping a coil obtained by winding a predetermined number of self-fused wires into a predetermined shape, an insulating plate provided with a lead wire insertion portion is arranged at the terminal portion of the coil on the commutator side, and the It is characterized by making the coil into a rigid body by resin molding, and it is recommended to provide groove introduction holes when making the coil into a rigid body. Thereafter, the wire-wound coreless coil, which is electrically connected to the commutator through lead wires and made rigid by resin molding, is bonded to the shaft and commutator to form an armature. The material of the insulating plate having the lead wire insertion portion according to the present invention is preferably an injection molded product of thermoplastic resin such as phenoxy resin, polysulfone resin, polyamide resin, saturated polyester resin, polyvinylidene lacquer.

However, the purpose of the present invention cannot be achieved unless the resin is melted at the mold temperature during resin molding. The details will be explained below.

Fig. 1 is a configuration diagram of a cup motor using a wire-wound type ironless flea isogo, Fig. 2 is a drawing in which the insulating plate according to the present invention is rearranged on a cup-shaped ironless coil before resin molding, and Fig. 3 is FIG. 3 is a diagram illustrating an insulating plate according to the present invention arranged on a flat-sided ironless coil before resin molding.

In these figures, 1 is a wire-wound coreless coil; 1' is a single coil of the coil; 2 is a commutator; 3 is an armature shaft;
5 is a bearing, 5 is a brush, 6 is a magnet, 7 is a frame to 8 is an insulating plate according to the present invention, and 9 is a lead wire. FIG. 4 is a process flow diagram of the present invention shown in blocks. First, at A, a predetermined number of single coils 1' each made of a predetermined number of windings of a Miyami fusion-fused wire having a fusion layer on the wire surface are stacked and arranged. At B, the wires are rectified into a predetermined shape using a mold, and at the same time, the fusion layer on the wire surface is melted and solidified by heating or a solvent to bond the wires together to obtain a wire-wound coreless coil 1 having a predetermined shape. Thereafter, at step C, the lead wire of the coreless coil is inserted into the insulating plate 8 according to the present invention and installed in the mold.

After the mold is clamped at ◯ and resin molded using a low-pressure sealing material, the armature shaft 3 is press-fitted into the resin-molded coil and commutator 2 at E to mechanically integrate them.

In the final step F, connect the wires. FIG. 5 is a process progress diagram of a conventional example.

First, from A to B, a wire-wound type *iron core coil 1 having a predetermined shape is obtained in the same manner as in the example of the present invention. Separately, in step C, a protective coating of silicone resin is formed on the commutator, and in step D, the armature shaft is press-fitted and bonded to the commutator. At step 8, connect the lead wire of the wire-wound coreless coil and the commutator.

After setting it in the mold at F, the mold is clamped and resin molded with low pressure sealing material. Example of removing the protective covering material remaining on the commutator part of the armature that has been made into an integral rigid body with G After 7 coils are stacked and arranged, they are shaped into a predetermined shape using a mold, and heated to melt and solidify the fusion layer on the wire surface to bond the wires together L, inner diameter 19.50, outer diameter 20.80, height 3
0.0 cup-shaped ironless coil.

This coil and a polyvinylidene dielectric insulating plate having a structure according to the present invention and having a thickness of 1 layer are placed in a mold preheated to 150°C according to the manufacturing method of the present invention, and then an epoxy resin low-pressure sealing material ( Resin molding was performed using Hitachi Chemical's CEL-87). Next, the armature shaft was press-fitted into the resin-molded ironless ○ coil and the commutator, and the wires were then connected to obtain a wire-wound cup-shaped ironless armature. When the medullary adhesion strength of this armature was measured on five machines, it was found to be as high as 42.5 kg on average. Comparative Example The shaft adhesion strength of an armature manufactured using the same winding specifications, parts, and molding resin as in the example in accordance with the process flow diagram shown in Figure 5 was measured on five machines, and the average was 35k9. Ta.

As is clear from the above description, according to the present invention, it is possible to eliminate the conventional drawbacks associated with the resin molding process and to obtain a high-quality armature.

[Brief explanation of the drawing]

Fig. 1 is a cross-sectional view of a cup motor using a wire-wound ironless coil, Fig. 2 is a perspective view of a cup-shaped ironless coil before being molded with resin, and an insulating plate according to the present invention is arranged, and Fig. 3 is a resin-molded cup motor. A perspective view of an insulating plate according to the present invention placed on a flat fan-shaped ironless D coil before forming, Fig. 4 is a process progress diagram of the present invention shown in blocks, and Fig. 5 is a follow-up example shown in flocks. It is a process progress diagram. 1... Wire-wound coreless coil, 2... Commutator, 3... Armature shaft, 8... Insulating plate, 9
Lead. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5

Claims (1)

[Claims] 1. A coil obtained by winding a predetermined number of self-fused wires is shaped into a predetermined shape. An insulating plate with a lead wire insertion part is placed at the commutator side coil terminal of the coreless coil, and the insulating plate is provided with a lead wire insertion part. A wire-wound type ironless core characterized in that the lead wire is protected by a plate and the ironless coil is made into a rigid body by resin molding, and then the resin molded coil is mechanically integrated with the commutator and armature shaft, and then wired. Method of manufacturing armature.