JPS6343885B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION Field of the Invention This invention relates to insulating supports for electrical conductors, and more particularly to methods of making electrical coils.

BACKGROUND OF THE INVENTION Conventionally, conventional coils, such as transformer coils, and various conductor or winding layers are supported and insulated from each other by cellulosic insulation, such as oiled paper or cardboard. Other coil structures using conventional non-cellulose insulation materials to support and insulate the conductors;
For example, cast resin and cellulose-free coils have advantages insofar as they are resistant to short circuits, moisture degradation, mechanical vibrations and fire, and are less susceptible to gassing and heat aging. .
Unfortunately, non-cellulose coils of conventional design also have certain drawbacks.
The main ones are the relatively high cost of manual labor and loading, and the difficulty of removing the shrinkage cavity.

DISCLOSURE OF THE INVENTION The primary purpose of the present invention is to provide a method for alleviating the problems of non-cellulose structures as described above, and the present invention provides a winding support, a liquid resin applicator, and a resin coating system. providing a gelling device, applying relative rotational motion between the winding support and the liquid resin applicator and the resin gelling device; and winding the conductor on the winding support, forming a first winding layer with a layer of conductor windings, and applying an electrically insulating coating to a predetermined thickness on said first winding layer; In the method for manufacturing a wire-wound structure, the step of providing an electrical insulating film includes applying a thin film of a liquid resin insulator from a liquid resin coating device during each rotational movement due to the relative rotational movement, and immediately applying the thin film of a liquid resin insulating film on the spot. The applied liquid resin insulation film is gelled to a hardness sufficient to support the winding layer with each rotation, and the liquid resin insulation film is The gelled resin electrical insulation is formed by forming an electrically insulating layer through multiple rotations, by selecting a method to accommodate the shrinkage that occurs during gelling with each rotation and to adjust and limit the maximum dimension of the cavity due to the shrinkage. A substantially continuously operated, cellulose-free electrical winding structure characterized in that a second winding layer comprising at least one conductor winding layer is formed by winding a conductor over an object. It lies in the method of manufacturing the body.

The steps of the above-described procedure may be repeated as many times as necessary to obtain the desired number of conductive layers, the first conductive layer applied on the mandrel, insulating support member or insulating support member being a first liquid of insulating material. A coating layer is applied and gelled to provide a substrate, and each subsequent conductor layer supported by the gelled insulating coating layer provides a substrate for the next insulating liquid coating layer to be applied and gelled.

As used herein, the term "gelling" refers to a liquid insulation that is dense enough to provide mechanical support to a conductor, but which allows for some embedding of the conductor. This means that the material is partially polymerized to the extent that it retains sufficient plasticity so that it is immobilized so that it does not slide. Furthermore, since the liquid insulation coating is applied to the conductor layer and the conductor layer is applied to the gelled insulation coating, the conductor layer and all conductor parts of each layer are completely bonded by the insulation material, and shrinkage due to polymerization is avoided. As the insulating structures are formed, they are all adapted so that the insulation of the coil is a homogeneous and essentially void-free cured body, either on essentially the entire surface of the winding or embedded in the insulating cured body. Contributes to the production of coils that are in close physical contact with the windings.

The liquid insulating material is preferably gelled by irradiation with radiation from a suitable energy source, such as an infrared or ultraviolet device or an electron beam device. Currently, ultraviolet irradiation is considered the most practical,
Therefore, it is the most suitable.

The insulating material may be any suitable cross-linkable liquid resin, such as an acrylic epoxy, preferably a substantially unfilled resin that can readily gel upon exposure to radiation.

Depending on factors such as the viscosity of the liquid insulation before gelling and the desired thickness of each final coating, the The insulating coating may be applied as a single layer coating or in several thin layers by applying one thin liquid insulating layer and gelling before the next layer. The viscosity of the liquid insulation is designed to minimize the chance of entrained air bubbles and voids as the coating layer is formed, but also to minimize undesirable flow of the applied liquid insulation prior to gelation. It should have sufficient viscosity.

In addition to the advantages previously mentioned, and others that will become apparent as the description progresses, it is also possible to provide the advantage that the coil structure to be manufactured is on a mandrel or coil former, and that the mandrel or coil former is suitable for industrial winding. Since the insulation of the winding layers is done in situ while rotating at line speed, the method according to the invention can be adapted very well to the coil manufacturing industry.

When using the present invention, the process is preferably carried out on a rotating mandrel or coil former by applying one or several layers of liquid insulating coating onto the rotating mandrel or coil former, and then immediately gelling each layer. or a step of forming an insulating coating on the coil former,
Furthermore, a conductive layer is wound on the above-mentioned insulating coating layer, a gelled insulating coating layer is formed on the conductive layer as described above, and another conductive layer is wound on top of the gelled insulating coating layer, and the coil manufacturing process is completed. This includes repeating the above steps until the process is completed. After the coil manufacturing process is completed, the final product is subjected to a suitable curing treatment to harden the gelled insulation. Optionally, cooling ducts may be provided by introducing into the liquid insulation strips of material that can be removed later from the final coil, such as polyethylene, which is melted by appropriate heating during the coil-forming operation. I can do it.

It is observed that the space factor of the coils produced according to the invention is much better than conventional, for example, paper-wound coils. The new coil winding method allows for a reduction in the average number of turns of conductor and overall coil size (which determines the core size required for the coil), and also eliminates costly coil gluing and drying operations, making it easier to Unlike insulation systems using cellulosic materials such as paper, the production of coils according to the method of the invention does not use oil for insulation purposes, thereby eliminating oil impregnation problems and, in all these respects, compared to prior art coil structures. The cost is much lower than that of

Furthermore, an important advantage in the coil winding according to the invention relates to the slope of the insulation. When electrical windings are manufactured by spirally winding a conductor between the ends of the coil around the coil axis to form successive layers of conductor, the dielectric stress from layer to layer is It is relatively low at the mutually connected ends of the two winding layers and increases gradually towards the mutually unconnected ends of these winding layers. In the case of conventional coil constructions in which the windings or winding layers are spaced uniformly over the length or axial dimension of the coil, the overall size of the coil must be such that the insulation between the winding layers can withstand the highest dielectric stresses. Determined by the required thickness. That is, it is determined by the required thickness at the non-connecting ends of the conductor winding layers.

In the method according to the invention, the total volume of the insulation layer, and therefore the total coil dimension, is determined by grading the thickness of the insulation material during coil winding, i.e., by adjusting the insulation between adjacent winding layers as the dielectric stress changes. It can easily be significantly reduced by varying the layer thickness.

According to a preferred embodiment of the invention, when applying and immediately gelling the overlapping layers of liquid insulation while rotating the coil structure described above, a high so that the width of the various insulation layers, when measured from the end of the stressed underlying winding section over the entire underlying winding section, gradually increases from one insulation layer to the subsequent insulation layer; By applying the insulation coating to the winding layer or the winding portion and gelling it so that the resulting insulation coating has a wedge-shaped or tapered cross section, that is, it has a slope, the sloped insulation coating can be used to form a coil structure. It is formed in the conductor winding layer, that is, the conductor portion. That is, the thickness of the insulating layer is maximum at the high stress end and gradually decreases toward the low stress end of the covered lower winding portion.

This gradual change in the width of the successively applied insulation layers is accomplished by relative axial movement between the insulation applicator and the coil structure as the coil structure is rotated.

In another embodiment according to the invention, the desired wedge-shaped cross-sectional shape or rectangular cross-sectional shape (which is subsequently reshaped with a wiper such as a rubber blade or the like to obtain the desired wedge-shaped cross-sectional shape) is provided. ) is extruded through a nozzle shaped to create an extruded layer of insulation material, a single layer or liquid insulation coating is applied over the conductor winding and gelled, and the insulation coating layer of varying thickness is formed into a coil structure. Formed on the conductor winding layer of the object.

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION Hereinafter, preferred embodiments of the present invention will be described based on the drawings.

Referring to FIG. 1, this shows a portion of a conventional transformer coil on a coil-forming mandrel 4, with conductor winding layers 3a, 3b and 3c forming part of the windings of the coil; These are supported and insulated from each other by cellulose insulation in the form of paper wrappers or cardboard tubes 2a, 2b and 2c.
Typically such a coil is constructed by applying a first wrap or tube of cellulose insulation 2a on a mandrel 4, and then depositing thereon a first conductor winding layer 3a from one end of the coil to the other, as shown in FIG. Then, a second wrapping or tube 2b of insulator is applied on the conductor winding layer 3a, and then a second winding layer 3b is wound on top of it in the opposite direction to complete the coil. It is manufactured in a continuous process by repeating this process until it is completed.

FIG. 2 is a schematic diagram illustrating a method of manufacturing cellulose-free coils as shown in FIGS. 3 and 4 according to the present invention. In Figure 2, number 4 again indicates the mandrel, number 5 indicates the applicator, such as a paint roller, and number 6 indicates the winding section.
Number 7 indicates a conductor such as enamelled copper wire, number 9 indicates a gelling station, number 10 indicates the direction in which the coil structure on the mandrel 4 is rotated in the coil manufacturing operation, and number 17 indicates the direction in which the coil structure on the mandrel 4 is rotated by the applicator 5. The applied insulation coating layer is shown. As already mentioned, the gelling station 9 may contain any suitable radiation source, such as an infrared device or an ultraviolet device or an electron beam device, although an ultraviolet radiation device is preferred.

FIG. 2 shows the coil manufacturing operation in progress. FIG. 3 shows that the entire coil manufacturing operation of the embodiment of the invention consists of the following steps: applying the insulating base material 13 on the mandrel 4;
A primary or low voltage side coil is applied on top by rotating a mandrel, that is, several layers of insulation 15, such as enamel-coated conductor pieces, are layered one after another on the insulation base material 13, and gel is applied on the wound insulation layer 15. Applying an insulating coating 17, preferably an insulating coating, on the gelled coating 17 from one end of the coil to the other in order to form a layer of conductor winding 19 as part of the second or high voltage side coil. For example, a step of winding an enamel conductive wire in a spiral shape as shown in FIG. 2; a step of applying a gelled insulation coating 21 to this conductor winding layer 19; The step includes the step of spirally winding the conductor winding layer 23; and the step of covering the conductor winding layer 23 with an insulating coating 25, preferably a gelled coating. Insulating coating layer 1
7, 21 and 25 form overlapping sections 17', 21' and 25', respectively, as shown in FIG. At both ends of the insulating coating layer are a winding 15 and a winding layer 1, respectively.
Cover the ends of 9 and 23.

The substrate 13 on the mandrel 4 may be a prefabricated tubular member of a suitable resin material and slidably mounted on the mandrel, or the base material 13 on the mandrel 4 may be a prefabricated tubular member made of a suitable resin material and may be slidably mounted on the mandrel, or
1, and preferably further formed with an insulating coating layer similar to the coating layer 25, that is, the applicator 5
(FIG. 2), a viscous liquid insulating material may be applied, the mandrel 4 is rotated in the direction of arrow 10, the material is passed through a gelling station 9, and the liquid insulating material is immediately gelled by being exposed to radiation.

The thickness of each insulating coating layer 13, 17, 21 or 25 is determined by the required insulation strength of the coating, or withstand voltage.
Variations may be made depending on the mechanical strength, etc., such as single layer or multi-layer coating, depending on the desired total coating layer thickness, viscosity of the liquid insulation applied, coil winding speed, etc. Various coatings may be formed.

The mandrel 4 is rotated, and the applicator 5 applies several relatively thin layers of liquid insulation one on top of the other, and the gelling station 9 instantaneously gels them. During this time a multilayer coating is formed. The liquid layer of insulation immediately gels. For example, each 1.0mm (40mil)
5 to 10 liquid layers, each 0.1 mm (4 mil) thick, can be stacked on top of each other to create a coating about 5.0 to 10.0 mm (0.2 to 0.4 inch) thick, or each 0.1 mm (4 mil) thick. 3.0~ by stacking 30~50 liquid layers on top of each other
A 5.0 mm (0.1-0.2 inch) thick coating is created.

The creation of superimposed insulation coatings by applying one thin layer of liquid insulation over another and immediately gelling allows the liquid insulation applied to the thin film to form a layer between adjacent conductor sections. Easily flows into voids and voids, eliminating those voids, pores, and voids, reducing the breakdown strength of the finished coating if small contaminants are present, but completely covering it and effectively insulating it. Provide significant use insofar as possible. Of course, even if the insulating material is applied in layers on top of each other, when it is applied as a liquid and just gels rather than hardens, the gelled layer before applying the next layer will not be layered with the next layer but will be dense and homogeneous. It is thought that it provides a good covering. Thus, the term "multi-layer" as used herein as part of the expression "multi-layer coating" is based on the method of applying the coating and does not imply the structure of the finished coating.

If desired, when winding the conductor strip 15 of the pre-insulated winding in the prescribed manner,
A conductor strip of the first winding is formed by applying a liquid layer of insulating material according to the method shown in FIG. Extra insulation can be provided between layers 15.

In the embodiment shown in FIG. 3, the first winding layer is formed by winding a spiral or strip-shaped conductor in a layered manner, but it may also be made from a spirally wound conductor as shown in FIG. Although the wire is shown here as being helically wound from a conducting wire, it could be formed by winding a conductive strip material in layers, similar to the first winding layer 15 of this embodiment. Of course, the number of conductor layers 15 and conductor winding layers 19, 23 used in this embodiment should not be considered as limiting with respect to the scope of the invention.

When the winding 15 or each winding layer 19 or 23 is formed, the insulation coating is formed by immediately gelling the insulating layers at both ends of the winding layer 15 and each winding layer 19 or 23. The insulating overlaps 17', 21' and 25' can be produced independently of the coatings 17, 21, 25 in the same manner as described above.

Another preferred method is to over-apply the insulation over the ends of the winding or winding layer to be applied so that it overlaps, and to gel the resulting overlap with the rest of the coating. By doing so, it is also possible to create coatings 17', 21', 25' that overlap the respective insulation coatings 17, 21, 25 at the same time.

As can be seen in FIGS. 3 and 4, the cooling ducts can be easily constructed by wrapping the outer insulation sheathing 25 with a strip or strips 35 of a suitable material that can be removed when the coil structure is completed. can be built. That is, the strip 35 is appropriately placed at a desired position on the insulating coating 25 formed to a desired thickness,
The mandrel 4 is then continuously rotated and further covered with resin. When the coil winding operation is finished and the coil structure is completed, the strip 35 is removed, leaving behind a duct for the passage of cooling liquid, such as transformer oil. A suitable material from which the strips 35 are made is polyethylene, which can be melted later, for example by applying an electric current, before immersing the finished coil in the refrigerant.

5, 6 and 7 are partial cross-sectional views of electrical coils with graded insulation thickness according to the present invention;
FIG. 5 shows the coil mounted on the mandrel 4, with conductor winding layers 29a, 2 forming part of the winding.
9b and 29c, an insulated substrate or base coating 27a on the mandrel, graded thickness insulation coatings 27b and 27c, and insulation coating 34. The conductor winding layers 29a-29c of a single conductor 7 (FIG. 6), for example of copper wire, are formed by thin ends of insulation sheaths 27b and 27c, which are tapered in thickness to form a complete winding. Connect with . The invention is of course not limited to the three winding sections and four insulation sheaths shown in the embodiment; the number of windings or winding sections, and therefore the number of insulation sheaths, can in each case be adjusted to suit the desired coil. depends on the type.

FIG. 6 shows a method of manufacturing the coil shown in FIG. Except for the step of creating a gradient in the thickness of the insulation.
This method is similar to the method described hereinabove, that is, one layer of liquid gelled insulator is layered on top of another to form an insulating coating;
Identical numbers refer to identical parts, such as the coil former or mandrel 4, the insulation applicator 5 and the gelling station 9. The inner or outer insulation coatings 27a and 34 of the coil shown in FIG. 5 are of substantially uniform thickness throughout and are formed similarly to the previously described embodiments. The following description is limited to methods of forming the graded thickness insulation coatings, such as coatings 27b and 27c.

With reference to FIG. 6, which shows the coil forming operation at the gelling station, the conductor winding layer 29a is coated with the insulation coating 2.
7a, and the insulation coating 27b is the conductor winding layer 29.
a, from which, in this embodiment, provision is provided to cause a relative axial displacement between the insulation applicator 5 and the coil structure when applying the liquid insulation. More specifically, during the conductor winding operation, the applicator 5 is advanced coaxially so that during each revolution of the coil former 4 it covers the entire gelled layer applied in the previous step and also at least the conductor winding. line layer 29
A liquid layer of insulation (which immediately gels in gelling station 9) is applied by applicator 5 to cover one exposed winding layer of a. This procedure is illustrated in FIG. 7, for example lines 27b ₁ and 27
b ₂ represents various layers of liquid insulation applied individually and gelled, although a continuous operation is preferred. Although in this embodiment the width of the successively applied layers is shown to increase gradually (the reason for this is that moving the applicator 5 from left to right as shown in FIGS. 6 and 7) If the applicator 5 is first applied to the liquid insulation in order to cover the entire width of the underlying conductor winding layer and then moved to the right, the width of the layer will gradually decrease.

To form a winding layer 29b on the insulating sheathing 27b formed in this way, the conductor 7 is wound from the thin end of the sheath to the thick end of the sheath, and then the thickness is An insulating coating 27c having a changed value is molded. However, in that case the relative axial movement of the applicator 5 and the coil structure is reversed in order to form a coating 27c with an opposite taper to the already formed coating 27b.

Next, the conductor winding layer 29c is formed at a predetermined location on the gelled coating 27c, and then the winding layer 29c is formed on the gelled coating 27c.
An insulating coating 34 is formed on c, preferably by the same applicator 5 as described above, but with the axial movement stopped and the liquid insulating material applied in several layers one on top of the other,
All of that layer spans the entire width of the coil as it rotates.

It will be appreciated that the present invention allows alternating formation of insulating coatings, such as coatings 27a-c and 34, and conductor winding layers, such as winding layers 29a-c, in a substantially continuous operation. Furthermore, the volume of insulation in the coil formed as described above is only about half the volume of insulation in a similarly rated coil formed by conventional methods as shown in FIG. The insulating layer between the winding layers is of uniform thickness in the measured areas with the greatest electrical stress.

Now considering the next embodiment of the invention, FIG. 8 shows a coil structure mounted on a mandrel or coil former having end flanges 60 and 62, which, like FIG. Body winding layer 44
a, 44b, 44c, insulating base coating or base material 4
2a, an insulating outer coating 50, and e.g.
The insulation coating 4 is relatively thick at one end of 8 or 76 and relatively thin at the other end, e.g. 70 or 78, respectively.
2b and 42c.

The coil structure of FIG. 8 differs from the method of FIG. 5 in the manner in which the insulation coating is formed, or rather in the type of applicator used to apply the coating. In this regard, according to FIGS. 9-15, FIG. 9 shows a base coating 42a applied onto the mandrel 4 through a nozzle 54 of rectangular cross-section (FIG. 12), from which liquid insulating material 42a is applied.
2. Preferably, a crosslinked viscous resin is extruded onto the surface of the mandrel 4 while rotating the mandrel 4 in the direction of arrow 10. In this embodiment, the extruded insulating material will have the required thickness after one complete revolution of the mandrel and will be thick enough to form the coating 42a, and the extruded insulation material will be thick enough to form the coating 42a after one complete revolution of the mandrel. is cut at the nozzle, so that the tips and ends of the viscous liquid layer thus applied join together in a butt joint to form a continuous coating 42a. Of course, once again the viscosity of the resin extruded from nozzle 54 is selected to minimize undesirable flow of the resin until gelling at the gelling station, shown as ultraviolet emitter 58.

As shown in FIG. 8, a conductor, e.g., an enameled wire, is wound from left to right on the gelled insulating coating 42a to form a winding layer 44a, and then a winding layer 44a is formed thereon in the same manner as described for the coating 42a, as shown in FIG. The insulation coating 42b is formed as shown in FIG. However, now using a nozzle 64 having a generally triangular or trapezoidal opening 66 (see FIG. 13), this nozzle imparts the desired tapered or wedge-shaped cross-sectional shape to the insulating material 42. This provides a gradient in the thickness of the coating 42b such that the coating 42b is relatively thick at one end 68 and relatively thin at the other end 70.

The isometric view of FIG. 15 shows that the insulating material 42
4 and shows in detail how it is extruded onto the conductor winding layer 44a. Of course, the single layer of the insulating coating 42b is also immediately gelled by emitting radiation from the radiation source 58 (FIG. 10) while rotating the mandrel 4.

By continuously rotating the mandrel 4, the conductor winding layer 44b is wound from right to left on the gelled insulating coating 42b with a gradient thickness, as shown in FIG. Nozzle 72 for applying 42c
(Fig. 11) is placed in position. This nozzle 72 has a generally triangular or trapezoidal opening 74 (FIG. 14) just like nozzle 64, but relatively
Transposed 180 degrees, when coating 42c is similarly applied, coating 42c has a relatively thick end or edge 76, where the electrical stress between winding layers 44b and 44c is greatest and the relative It has a thinner end or edge 78 at the edge 78 and is arranged so that the electrical stress in this area is reduced. The winding layer 44c is continuously wound on the gelled coating 42c from left to right as shown in FIG.

For illustrative purposes, winding layer 44c completes the electrical winding, and this layer is insulated or coated 50, although additional conductor winding layers or graded insulation coatings may be applied if desired. covered, this covering 50
is applied in the same manner as base coating 42a, ie, by extrusion through a rectangular nozzle 54 shown in FIG. Of course, each insulation coating has an ultraviolet radiation device 58
Gel it using the gelling station shown in .

Another method of grading the insulation is shown in FIGS. 16 and 17, in which the entire insulation coating is applied by extrusion through a nozzle 54 having a rectangular opening, and coating 4
2b and 42c are beveled cutting edges 82 for trimming the extruded viscous material 42 at a suitable angle or by removing excess viscous material, as shown at 84, into a shape with a desired triangular or trapezoidal cross section. The bevel is created by a scraper or blade 80 placed at an appropriate angle.

18, 19 and 20 show an improvement very similar to FIGS. 16 and 17, with the difference that the blades 80 and therefore the gelling station 58 are located at the periphery of the coil structure with respect to the direction of rotation of the mandrel 4. It is a point quite far away from the nozzle 54. FIG. 20 includes only two layers of winding layers 44a and 44b instead of the three layers shown in FIG. In order to do this, it is covered with an insulating coating 92 having a tapered cross section matching the slope of the winding layer 44b.

Advantages of the Invention The advantages obtained by the present invention are to provide a method for manufacturing a cellulose-free electrical winding structure by continuous operation, to reduce costs by continuous operation, and to eliminate shrinkage cavities by adjusting the thickness of liquid resin coating. , improving the space factor of the coil, eliminating the work of gluing and drying the coil, and eliminating the problem of oil impregnation.

[Brief explanation of the drawing]

1 is a partial cross-sectional view of an electric coil according to the prior art; FIG. 2 is an isometric schematic diagram illustrating the method of manufacturing an electric coil according to a preferred embodiment of the present invention; FIG. 3 is a cross-sectional view taken along the line -- of FIG. FIG. 4 is an isometric view of a near-completed coil, FIG. 5 is a partial cross-sectional view of an electrical coil with varying insulating layer thickness according to the present invention, and FIG. 7 is an enlarged partial cross-sectional view showing in detail how the variation of the insulation layer thickness is effected in the method according to FIG. 6; FIG. a partial sectional view similar to FIG. 5 showing an electric coil with an insulating layer of varying thickness manufactured by the method shown in FIGS. 9 to 15 or 16 to 20; 9, 10 and 11 are partial end views showing the successive steps of applying an insulating layer in manufacturing the coil of FIG.
Figures 2, 13 and 14 are numbers 9, 10 and 1, respectively.
Figure 1 is a sectional view taken along lines XII-XII, - and -, and Figure 15 shows how to manufacture the coil shown in Figure 8 by varying the thickness of the liquid insulating layer on the conductor winding layer. Isometric and partial cross-sectional views; FIG. 16 is a cross-sectional view showing somewhat different methods of forming insulating layers of varying thickness; FIG. 17 is a cross-sectional view of FIG.
18 is a cross-sectional view showing an improved method of the method shown in FIG. 16, and FIG. 19 is a cross-sectional view of the method shown in FIG.
The line cross-sectional view and FIG. 20 are similar to FIG. 19, but the first diagram shows the coil in the next coil manufacturing process.
8 is a sectional view taken along the line -- in FIG. 8. In the figure, 2a, 2b... cardboard tube, 3a, 3
b, 3c... Conductor winding layer, 4... Mandrel, 5
... Applicator, 6 ... Winding portion, 7 ... Conductor, 9 ... Gelling station, 10 ... Rotation direction, 13 ... Insulating base material, 15 ... Conductor strip layer,
17, 21, 25...Insulating coating, 17', 21',
25'...Overlapping portion, 19...Conductor winding, 23,
29a, 29b, 29c, 44... conductor winding layer,
25...Coating layer, 27a, 42a...Base coating, 27b, 34, 42b, 42c...Insulating coating, 35...Strip piece, 44a, 44b, 44c...
...Conductor winding layer, 50...Insulating outer coating, 54,
64, 72... Nozzle, 58... Radiation emitting device, 60, 62... End flange, 66... Opening, 68, 76... Coil end, 78... Edge, 80... Blade, 82... ...cutting edge, 84...
removed part.

Claims (1)

[Claims] 1. A winding support material, a liquid resin application device, and a resin gelling device are provided, and a relative rotational movement is applied between the winding support material, the liquid resin application device, and the resin gelling device. , forming a first winding layer having at least one layer of conductor windings by winding the conductor on a winding support, and applying electrical insulation to a predetermined thickness on the first winding layer; A method of manufacturing a cellulose-free electrical winding structure by a substantially continuous operation comprising applying an electrically insulating film, wherein the step of providing an electrically insulating film comprises applying a liquid resin during each rotational movement of the relative rotational movement. Immediately after applying a thin film of liquid resin insulation from the equipment, the applied liquid resin insulation film gels in situ to a hardness sufficient to support the winding layer with each revolution. By selecting the applied thickness per revolution of the coating to accommodate the shrinkage that occurs as the liquid resin insulation film gels with each revolution to control and limit the maximum size of the shrinkage cavity. An electrical insulating layer is formed by multiple rotations, and a second winding layer consisting of at least one conductor winding layer is formed by winding a conductor on the gelled resin electrical insulator. A method of manufacturing a cellulose-free electrical winding structure in a substantially continuous operation characterized by: 2. The method of claim 1, wherein the step of winding the conductor on the winding support comprises spirally winding the conductor to form a multi-wound conductor. 3. The method according to claim 1, wherein the step of winding the conductor around the winding support material comprises winding the band-shaped conductor in a spiral manner to form one conductor winding layer. 4. The method of claim 1, wherein the step of forming the first winding layer and the second winding layer uses the same continuous conductor to form the winding layers of the same electrical winding. 5. The method of claim 1, wherein the winding layers of different electric windings are formed using continuous conductors in which the steps of forming the first winding layer and the second winding layer are different. 6. The step of preparing the winding support material is performed by applying a number of successive liquid resin insulation layers to the substrate and gelling each liquid resin insulation layer immediately before applying the next liquid resin insulation layer. 2. The method of claim 1, wherein the winding support is formed as part of a substantially continuous operation comprising forming the winding support during multiple rotations. 7. The method according to claim 1, wherein a predetermined number of conductor winding layers are formed by repeating the step of forming an insulated winding layer. 8 The process of successively applying films of liquid resin insulating material to form an electrical insulating layer for each rotation includes the process of coating the axial end of the already wound winding layer with liquid resin insulating material and the coated liquid. 8. The method according to claim 7, comprising a gelling step of immediately gelling the resin insulation material. 9. At least some of the steps of coating the axial ends of the winding layer further overlap with the previous gelled liquid resin insulation coating applied to the axial ends of the previously wound winding layer. The method described in item 7. 10. Inserting heat-fusible strips between at least some layers of conductor windings and subsequently removing them by applying heat to melt said heat-fusible strips to form coolant ducts. The method described in scope item 7. 11. The method of claim 1, comprising the steps of applying a liquid resin insulation to the axial ends of the winding layer and gelling the liquid resin insulation immediately. 12 The process of applying a thin film of liquid resin insulation to the winding layer coats the axial end of the winding layer with the liquid resin insulation, and gels the liquid resin insulation applied to the axial end of the winding layer. 2. The method of claim 1, comprising a gelling step. 13. The method of claim 1, wherein the winding support comprises a previously applied winding layer.