WO2020071532A1

WO2020071532A1 - Method for manufacturing coil component, method for manufacturing electric machine, coil component, and electric machine

Info

Publication number: WO2020071532A1
Application number: PCT/JP2019/039282
Authority: WO
Inventors: 啓生大藤; 興起仲; 橋本　昭; 行庸唐田; 和明廣田; 辰郎日野; 隆之鬼橋
Original assignee: 三菱電機株式会社
Priority date: 2018-10-04
Filing date: 2019-10-04
Publication date: 2020-04-09
Also published as: JPWO2020071532A1

Abstract

A method for manufacturing a coil component, provided with an injection step for injecting a molten metal into a mold. The mold has a first mold and a second mold capable of moving relative to each other in a specific axial intersection direction. The coil component has a first coil wire part, a second coil wire part, and a third coil wire part. When the coil component is viewed along the axial intersection direction, the region of the first coil wire part is outside of the region of the second coil wire part. From among the surfaces formed on each of the first coil wire part and the second coil wire part, the surfaces facing the first mold side are molded by the first mold. From among the surfaces formed on each of the first coil wire part and the second coil wire part, the surfaces facing the second mold side are molded by the second mold.

Description

Method for manufacturing coil component, method for manufacturing electric machine, coil component, and electric machine

The present invention relates to a method for manufacturing a coil component for manufacturing a coil component constituting a coil, a method for manufacturing an electric machine, a coil component, and an electric machine.

Conventionally, coils used in electric motors are formed by winding a conductive wire around a core to which an insulator is attached or a core to which an insulating paint is applied. For example, a rectangular wire that is difficult to wind around a core is inserted into a slot of the core in a state where the wire is formed in a coil shape by performing a bending process in advance (for example, see Patent Document 1).

JP 2017-038474 A

(4) In the conventional method described in Patent Document 1, a plurality of bending steps are required to form a conductive wire into a coil shape. For this reason, there is a possibility that the shape of the coil component may change after being formed in a coil shape due to the residual stress in the bent portion.

The present invention has been made in order to solve the above-described problems, and has a method for manufacturing a coil component, a method for manufacturing an electric machine, a coil component, and an electric machine capable of manufacturing a coil component with high shape accuracy. What you get.

The method for manufacturing a coil component according to the present invention includes an injection step of injecting a molten metal into a mold, and after the injection step, a mold removal step of removing a molded product obtained by curing the molten metal in the mold from the mold. The mold has a first mold and a second mold that are relatively movable in a direction intersecting a specific axis, and the mold has a first coil wire portion and a first coil wire portion. , A second coil wire portion, and a linear third coil wire portion connecting the respective ends of the first coil wire portion and the second coil wire portion. Each of the second coil wire portions intersects in the axis intersecting direction, and the third coil wire portion is disposed along the axis intersecting direction. When the coil component is viewed along the axis intersecting direction, The area of the one coil wire part is out of the area of the second coil wire part, and the first coil wire part and the Of the surfaces formed on each of the coil wire portions, the surface facing the first mold side is formed by the first mold, and the surface formed on each of the first coil wire portion and the second coil wire portion is formed. The surface facing the second mold is molded by the second mold.
In addition, the coil component according to the present invention includes a first coil wire portion, a second coil wire portion, and a straight third wire connecting end portions of the first coil wire portion and the second coil wire portion. A first coil wire portion and a second coil wire portion are disposed apart from each other in an axis crossing direction along the third coil wire portion, and the first coil wire portion and the second coil wire portion are arranged along the axis crossing direction. When the wire portion and the second coil wire portion are viewed, the region of the first coil wire portion is out of the region of the second coil wire portion.

According to the method for manufacturing a coil component, the method for manufacturing an electric machine, the coil component, and the electric machine according to the present invention, a coil component with high shape accuracy can be manufactured.

FIG. 3 is a perspective view illustrating an example of a coil component manufactured using the method for manufacturing a coil component according to the first embodiment of the present invention. FIG. 2 is a perspective view illustrating an example of a mold used for manufacturing the coil component of FIG. 1. FIG. 3 is a sectional perspective view showing the mold of FIG. 2. FIG. 3 is a sectional perspective view showing a state in which the mold of FIG. 2 is closed. 2 is a flowchart illustrating a procedure for manufacturing the coil component of FIG. 1. FIG. 5 is a sectional view showing a state where the mold of FIG. 4 is opened. FIG. 7 is a cross-sectional view illustrating a state where a molded product is extruded from the state of FIG. 6. It is a perspective view which shows the state of FIG. FIG. 9 is a perspective view showing a molded product taken out of the state of FIG. 8. FIG. 10 is a perspective view showing a state where an unnecessary portion is separated from the molded product of FIG. 9. FIG. 10 is a perspective view showing a state in which burrs are formed on the molded product of FIG. 9. FIG. 10 is a cross-sectional view showing a mold used in the method for manufacturing a coil component according to the second embodiment of the present invention. FIG. 13 is a cross-sectional view showing a state in which a plunger of the type shown in FIG. 12 is advanced. FIG. 14 is a cross-sectional view illustrating a state in which the mold is opened after the plunger is retracted from the state of FIG. 13. FIG. 15 is a cross-sectional view illustrating a state in which a molded product has been extruded by an extrusion pin from the state of FIG. It is a perspective view which shows the state of FIG. FIG. 13 is a perspective view showing a mold used in the method for manufacturing a coil component according to the third embodiment of the present invention. FIG. 18 is a perspective view showing a state where the mold of FIG. 17 is opened after molding. FIG. 19 is a perspective view showing a state in which a molded product is extruded by an extrusion pin from the state of FIG. 18. FIG. 20 is a perspective view showing a molded product taken out of the mold in the state of FIG. 19. FIG. 21 is a perspective view showing a state where an unnecessary portion is separated from the molded product of FIG. 20. FIG. 9 is a perspective view showing an example of another coil component manufactured by the method for manufacturing a coil component according to the first to third embodiments of the present invention. FIG. 14 is a perspective view showing a mold used in the method for manufacturing a coil component according to the fourth embodiment of the present invention. It is a perspective view showing other examples of a coil part manufactured by a manufacturing method of a coil part of Embodiment 4 of the present invention. FIG. 25 is a perspective view showing a coil component as a modification of the coil component of FIG. 24. FIG. 26 is a top view showing the coil component as viewed along arrow XXVI in FIG. 25. FIG. 26 is a bottom view showing the coil component as viewed along arrow XXVII of FIG. 25. FIG. 26 is a perspective view showing a mold when the coil component of FIG. 25 is manufactured. FIG. 29 is a perspective view showing a state when the mold of FIG. 28 is viewed from another direction. FIG. 29 is a perspective view showing a state where the coil component is detached from the fixed mold of FIG. 28. FIG. 29 is a perspective view showing a state where the coil component is detached from the movable mold of FIG. 28. FIG. 13 is a perspective view showing another example of the coil component manufactured by the method for manufacturing a coil component according to the first to third embodiments of the present invention. It is the schematic which shows the manufacturing method of the coil component of Embodiment 5 of this invention. FIG. 15 is a partial cross-sectional view showing a rotating electric machine as an electric machine according to a sixth embodiment. FIG. 15 is a perspective view showing a rotating electric machine according to a sixth embodiment. FIG. 21 is a perspective view showing a stator core of a rotary electric machine according to Embodiment 6. FIG. 15 is a partially broken enlarged view showing a stator of a rotating electric machine according to a sixth embodiment. FIG. 15 is a perspective view showing a linear motor as an electric machine according to a seventh embodiment. FIG. 19 is a schematic partial cross-sectional view showing a transformer as an electric machine according to an eighth embodiment. FIG. 40 is a perspective view showing a main part of the transformer excluding the tank, the iron core spacer and the coil spacer of FIG. 39. FIG. 41 is a perspective view showing a state when a main part of the transformer of FIG. 40 is viewed from a different direction.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

Embodiment 1 FIG.
FIG. 1 is a perspective view showing a coil component manufactured using the method for manufacturing a coil component according to the first embodiment of the present invention. The coil component 10 is a coil element that constitutes a coil used in an electric machine such as a motor or a generator. In this example, a coil element constituting an armature coil of the electric motor is a coil component 10. The coil component 10 is made of a conductive metal.

The coil component 10 has a plurality of straight portions 12 and a plurality of corner portions 11 individually formed between the ends of the plurality of straight portions 12. In this example, the shape of the coil component 10 is a hexagonal ring by the six straight portions 12 and the six corner portions 11. Further, in this example, the cross-sectional shape of the linear portion 12 is rectangular. Note that the cross-sectional shape of the linear portion 12 may be circular, square, or the like. The coil component 10 is manufactured by casting using a mold.

材料 As for the properties of the material of the coil component 10, the higher the conductivity, the better, and the better the fluidity, the better. Therefore, for example, copper for casting, aluminum for casting, etc. are used as the material of the coil component 10. When a copper-based material is used as the material for the coil component 10, it is desirable to use a material having a conductivity of 60% to 85% with respect to soft copper as the material for the coil component 10. Specifically, it is desirable to use CAC101, CAC103, and the like as the material of the coil component 10. When an aluminum-based material is used as the material for the coil component 10, a material having a conductivity of 20% to 40% with respect to soft copper is preferably used as the material for the coil component 10. Specifically, it is desirable to use ADC1, ADC3, ADC5, ADC6, ADC10, ADC10Z, ADC12, ADC12Z, ADC14, and the like as the material of the coil component 10.

Therefore, by using copper for casting or aluminum for casting as the material of the coil component 10, the fluidity of the material of the coil component 10 at the time of casting can be improved. Therefore, even if the coil component 10 has a complicated shape, the coil component 10 can be easily manufactured. Further, the electric resistance of the coil component 10 can be reduced. Therefore, by using the coil component 10 for the coil included in the electric machine, the electric resistance of the coil can be suppressed, and the efficiency of the electric machine can be increased. Examples of the electric machine in which the coil component 10 is used include a rotating electric machine used as an electric motor, a generator, and the like.

FIG. 2 is a perspective view showing a mold used in the method of manufacturing the coil component 10 of FIG. FIG. 3 is a sectional perspective view showing the mold of FIG. In this example, the mold 1 used for manufacturing the coil component 10 is a mold. In this example, the coil component 10 is manufactured by die casting. Therefore, mold 1 is a die-cast type. The mold 1 has a fixed mold 20 as a first mold and a movable mold 30 as a second mold.

The fixed mold 20 has a fixed side mating surface 21 which is a flat surface. The fixed mold 20 is provided with an air vent 22 and a fixed-side recess 23. The air vent 22 is a through hole extending from the fixed side mating surface 21 to the outer surface of the fixed mold 20. The fixed-side recess 23 is a recess located at the boundary between the upper surface of the fixed mold 20 and the fixed-side mating surface 21.

The movable die 30 has a movable side mating surface 31 which is a flat surface facing the fixed side mating surface 21 of the fixed die 20. In addition, the movable die 30 is moved relative to the fixed die 20 between an operating position where the movable side mating surface 31 contacts the fixed side mating surface 21 and an open position where the movable side mating surface 31 is separated from the fixed side mating surface 21. It is movable. The movable die 30 is movable with respect to the fixed die 20 in a specific axis crossing direction intersecting each of the fixed side mating surface 21 and the movable side mating surface 31. That is, the mold 1 has the fixed mold 20 and the movable mold 30 that are relatively movable in the axis crossing direction. The mold 1 closes when the movable mold 30 reaches the operating position. The mold 1 is opened when the movable mold 30 reaches the open position.

The movable mold 30 is provided with a cavity 32, a movable side concave portion 33 and an injection path 34.

The cavity 32 is a groove formed on the movable side mating surface 31. The cavity 32 is open to the fixed mold 20 side. In this example, the shape of the cavity 32 is a hexagonal ring.

The movable concave portion 33 is a concave portion located at the boundary between the upper surface of the movable mold 30 and the movable side mating surface 31. The injection path 34 is a groove formed in the movable side mating surface 31. Therefore, similarly to the cavity 32, the injection path 34 is also opened to the fixed mold 20 side. The movable-side concave portion 33 is connected to the cavity 32 via an injection path 34.

FIG. 4 is a cross-sectional perspective view showing a state in which the mold 1 of FIG. 3 is closed. The open portions of the cavity 32 and the injection path 34 are closed by the fixed side mating surface 21 when the mold 1 is closed. When the mold 1 is closed, the gate 1A formed by the fixed recess 23 and the movable recess 33 is formed in the mold 1. The gate 1A formed in the mold 1 is open upward.

押出 An extruding member 36 having a plurality of pins 35 is attached to the movable mold 30. The plurality of pins 35 pass through the movable mold 30. Each of the pins 35 projects into the space in the cavity 32 or retreats from the space in the cavity 32 when the pushing member 36 moves with respect to the movable mold 30.

Next, a method for manufacturing the coil component 10 will be described. FIG. 5 is a flowchart showing a procedure for manufacturing the coil component 10 of FIG. When manufacturing the coil component 10, first, in step S1 as a melting process, a molten metal is produced by melting a metal that is a material of the coil component 10. Examples of the metal used as the material of the coil component 10 include aluminum, copper, and alloys containing these metals. As described above, various metals can be used as the metal as the material of the coil component 10. For this reason, the kind of metal used as the material of the coil component 10 can be properly used according to the capacity or cost of the electric machine.

後 Thereafter, in step S2 as an injection step, molten metal is injected into the mold 1 from the gate 1A with the mold 1 closed. Thereby, the molten metal is filled into the cavity 32 of the mold 1 through the injection path 34. At this time, excess molten metal overflows from the cavity 32 into the injection path 34 and the air vent 22.

後 Thereafter, in step S3 as a cooling step, the mold 1 is cooled. Thus, in the mold 1, the molten metal is cured to form the molded product 2. The molded product 2 extends not only to the cavity 32 but also to the injection path 34 and the air vent 22.

後 Thereafter, the molded article 2 is removed from the mold 1 in step S4 as a mold removing step. When removing the molded product 2 from the mold 1, the movable mold 30 is first moved to the open position to open the mold 1. FIG. 6 is a sectional perspective view showing a state where the mold 1 of FIG. 4 is opened. When the mold 1 is opened in a state where the molded article 2 has been molded in the mold 1, the molded article 2 comes off the fixed mold 20 integrally with the movable mold 30.

Then, the extruding member 36 is moved with respect to the movable mold 30 in a direction in which each pin 35 projects into the cavity 32. Thus, the molded product 2 is pushed out of the cavity 32 by each pin 35. FIG. 7 is a cross-sectional perspective view showing a state where the molded product 2 is pushed out by the plurality of pins 35 of FIG. FIG. 8 is a perspective view showing the mold 1 and the molded product 2 of FIG. The molded product 2 is detached from the movable mold 30 by being pushed out by the plurality of pins 35. Thus, the molded product 2 comes off the mold 1.

FIG. 9 is a perspective view showing the molded product 2 removed from the mold 1 of FIG. The molded product 2 removed from the mold 1 includes not only the coil component 10 but also a plurality of projections 2A molded by the injection path 34 and the air vent 22, respectively. Each projection 2A is an unnecessary part for the coil component 10.

Therefore, after the molded product 2 is removed from the mold 1, in step S5 as a removing step, each of the protrusions 2A, which are unnecessary portions, is removed from the molded product 2. FIG. 10 is a perspective view showing a state in which each protrusion 2A is removed from the molded product 2 of FIG. When each projection 2A is removed from the molded product 2, the coil component 10 is obtained. That is, a part of the molded product 2 becomes the coil component 10. Each projection 2A is removed from the molded product 2 by, for example, a cutter.

後 Thereafter, in step S6 as an insulating process, the coil component 10 is subjected to insulating processing. Examples of the insulating processing include plating using an insulating material, painting using an insulating material, and the like. Thus, the coil component 10 is manufactured.

In the method of manufacturing the coil component 10, a part of the molded product 2 formed by curing the molten metal in the mold 1 is the coil component 10. For this reason, the coil component 10 can be manufactured without performing bending. Thereby, generation of residual stress in the coil component 10 can be suppressed. Therefore, a change in the shape of the coil component 10 due to the residual stress can be reduced, and the coil component 10 with high shape accuracy can be manufactured. In addition, a large number of molded products 2 can be manufactured using the mold 1. For this reason, the productivity of the coil component 10 can be improved. Furthermore, if there is a metal which is a material of the coil component 10, the coil component 10 can be manufactured without obtaining a conductive wire.

Here, when the mold 1 is closed, a gap may be partially formed between the movable side mating surface 31 and the fixed side mating surface 21. In this case, in step S2 as an injection step, a part of the molten metal filled in the cavity 32 easily flows into the gap between the movable side mating surface 31 and the fixed side mating surface 21. Therefore, when the molten metal is cooled in a state where the molten metal is partially interposed in the gap between the movable side mating surface 31 and the fixed side mating surface 21, the molten metal is removed from the mold 1 in step S4 as a mold releasing step. A plate-shaped burr is formed on the molded product 2.

FIG. 11 is a perspective view showing a state in which burrs 90 are formed on the molded product 2 of FIG. On the coil component 10 included in the molded product 2, a molding position forming surface 100 molded by the fixed-side mating surface 21 is formed. The burrs 90 are formed on the inner periphery and the outer periphery of the molding position forming surface 100, respectively. The burrs 90 formed on the inner periphery of the mold position forming surface 100 project from the mold position forming surface 100 to the inside of the coil component 10. The burrs 90 formed on the outer periphery of the molding position forming surface 100 project from the molding position forming surface 100 to the outside of the coil component 10. The burr 90 is an unnecessary part for the coil component 10.

Therefore, in step S5 as a removing step, the burr 90 may be shaved and removed from the molded product 2. By doing so, the accuracy of the shape of the coil component 10 can be further improved. Further, by shaving not only the burr 90 but also the surface of the molded product 2, the shape of the coil component 10 can be determined with higher accuracy.

表面 The surface of the part where the burr 90 is formed in the molded product 2 is a casting surface. The surface roughness of the casting surface is generally about Rz80. On the other hand, when the surface of the molded product 2 is shaved in the removing step, the surface roughness of the surface of the coil component 10 becomes, for example, about Rz10. Thus, by shaving the surface of the molded product 2 in the removing step, the surface roughness of the surface of the coil component 10 can be reduced.

Also, by inclining both side surfaces of the groove constituting the cavity 32 with respect to the movable side mating surface 31, the groove width of the cavity 32 is continuously increased from the bottom of the cavity 32 toward the opening of the cavity 32. Is also good. That is, the gradient of both sides of the cavity 32 with respect to the movable side mating surface 31 may be set as the draft. In this case, the width of each linear portion 12 of the coil component 10 included in the molded product 2 also increases continuously from the bottom side of the cavity 32 toward the open side of the cavity 32 in accordance with the groove width of the cavity 32. . By doing so, the molded article 2 can be easily removed from the cavity 32 in the mold removing step. Therefore, it is possible to prevent the molded article 2 from being caught on the mold 1 and to prevent the molded article 2 from dropping, and to prevent a problem that the operation of the manufacturing equipment is stopped. Further, in this case, in the coil component 10, the width of each linear portion 12 changes in the thickness direction of the coil component 10. Thereby, for example, when the coil including the coil component 10 is arranged in the slot of the core of the electric machine, a gap can be generated between the side surface of the coil component 10 and the inner surface of the slot. Therefore, the cooling air can be easily passed through the gap between the side surface of the coil component 10 and the inner surface of the slot, and the cooling efficiency of the electric machine can be improved.

In the above example, the die 1 used in the method for manufacturing the coil component 10 is a die-cast type. However, the mold 1 used in the method for manufacturing the coil component 10 is not limited to this. For example, the mold 1 used in the method for manufacturing the coil component 10 may be a sand mold or a plaster mold.

Embodiment 2 FIG.
Next, a method for manufacturing a coil component according to the second embodiment of the present invention will be described.

FIG. 12 is a sectional perspective view showing a mold 1 used in the method for manufacturing a coil component according to the second embodiment of the present invention. The mold 1 according to the second embodiment differs from the mold 1 according to the first embodiment in that a fixed gate 20 is provided with a gate 1A and a runner 24. The mold 1 according to the second embodiment is different from the mold 1 according to the first embodiment in that the movable mold 30 is provided with an air vent 37. Further, the mold 1 according to the second embodiment is different from the mold 1 according to the first embodiment in that the plunger 25 is attached to the fixed mold 20. Other configurations are the same as those of the first embodiment.

型 As shown in FIG. 12, in the mold 1 of the second embodiment, the gate 1A is provided on the upper surface of the fixed mold 20. A runner 24 connecting the gate 1A and the cavity 32 is provided below the gate 1A. A plunger 25 is inserted into the runner 24. The plunger 25 can move forward and backward along the runner 24. The plunger 25 pushes the molten metal filled in the runner 24 into the cavity 32 by moving forward along the runner 24.

Next, a method for manufacturing a coil component according to the second embodiment will be described with reference to FIGS. In the second embodiment, when manufacturing the coil component 10, a molten metal is prepared as in the first embodiment, and then the molten metal is injected into the mold 1 in an injection step.

When pouring the molten metal into the mold 1, first, the molten metal is poured from the gate 1A into the runner 24 with the mold 1 in FIG. 12 closed.
Next, the plunger 25 is moved forward to fill the cavity 32 of the movable mold 30 with the molten metal from the runner 24.
FIG. 13 is a sectional perspective view showing a state in which the plunger 25 has moved forward in the mold 1 of FIG. The plunger 25 moves forward in the direction indicated by the arrow A in FIG. 13 and pushes the molten metal in the runner 24 into the cavity 32 of the movable mold 30. Thereby, the cavity 32 is filled with the molten metal. At this time, excess molten metal overflows from inside the cavity 32 into the air vent 37.

Then, in the cooling step, the mold 1 is cooled, and the molten metal in the mold 1 is hardened. Thus, a molded product 2 is formed in the mold 1. The molded product 2 extends not only to the cavity 32 but also to the runner 24 and the air vent 37.

Next, in the mold removing step, the molded product is removed from the mold 1. When removing the molded product from the mold 1, the plunger 25 is first retracted. Next, the movable mold 30 is moved to the open position to open the mold 1. FIG. 14 is a sectional perspective view showing a state where the mold 1 of FIG. 13 is opened. When the mold 1 is opened in a state where the molded article 2 has been molded in the mold 1, the molded article 2 comes off the fixed mold 20 integrally with the movable mold 30.

後 Thereafter, the extruding member 36 is moved with respect to the movable mold 30, and the molded product 2 is extruded by the plurality of pins 35. FIG. 15 is a cross-sectional perspective view showing a state where the molded product 2 is pushed out by the plurality of pins 35 of FIG. FIG. 16 is a perspective view showing the mold 1 and the molded product 2 of FIG. The molded product 2 is detached from the movable mold 30 by being pushed out by the plurality of pins 35. Thus, the molded product 2 comes off the mold 1.

Similarly to the molded product 2 of the first embodiment, the molded product 2 removed from the mold 1 includes not only the coil component 10 but also a plurality of protrusions 2A molded by the runner 24 and the air vent 37, respectively. Have been. Therefore, after the molded article 2 is removed from the mold 1, the projections 2A, which are unnecessary portions, are removed from the molded article 2 in the removing step. When each projection 2A is removed from the molded product 2, the coil component 10 is obtained. That is, a part of the molded product 2 becomes the coil component 10. Each projection 2A is removed from the molded product 2 by, for example, a cutter. Subsequent steps are the same as in the first embodiment.

Embodiment 3 FIG.
Next, a method for manufacturing a coil component according to the third embodiment of the present invention will be described.
The mold 1 used in the method for manufacturing a coil component according to the third embodiment is different from the first embodiment in that a movable mold 30 is provided with a plurality of cavities 32 filled with molten metal. Other configurations are the same as those of the first embodiment.

FIG. 17 is a perspective view showing a mold 1 used in the method for manufacturing a coil component according to the third embodiment of the present invention. As shown in FIG. 17, the mold 1 of the third embodiment has a shape in which a plurality of the molds 1 of the first embodiment are connected.

In this example, the movable side mating surface 31 of the movable mold 30 is provided with one gate 1A into which molten metal is injected and a plurality of cavities 32. An injection path 34 is provided in each of the plurality of cavities 32. Each injection path 34 is connected to each other via a runner 38. The molten metal injected from the gate 1A is filled into each cavity 32 via the runner 38. In this example, the shapes of the plurality of cavities 32 are all the same.

Next, a method for manufacturing a coil component according to the third embodiment will be described with reference to FIGS.

でも Also in the third embodiment, a molten metal is prepared in the same manner as in the first embodiment. Thereafter, the mold 1 is closed from the state in which the mold 1 in FIG. 17 is opened, and molten metal is injected from the gate 1A in an injection step. As a result, the molten metal is filled into each cavity 32 of the mold 1 via the injection path 34 and the runner 38. At this time, excess molten metal overflows from the cavity 32 into the injection path 34 and the air vent 22.

Next, in the cooling step, the mold 1 is cooled. Thus, in the mold 1, the molten metal is cured to form the molded product 2. The molded product 2 extends not only to each cavity 32 but also to the injection path 34, the runner 38 and the air vent 22.

後 Thereafter, the molded article is removed from the mold 1 in the mold removing step. When removing the molded product from the mold 1, the movable mold 30 is first moved to the open position and the mold 1 is opened. FIG. 18 is a cross-sectional perspective view showing a state in which the mold 1 is opened while the movable mold 30 and the molded product 2 in FIG. 17 are integrated. When the mold 1 is opened in a state where the molded article 2 has been molded in the mold 1, the molded article 2 comes off the fixed mold 20 integrally with the movable mold 30.

Thereafter, the extruded member 36 (not shown) is moved with respect to the movable mold 30 and the molded product 2 is extruded by the plurality of pins 35. FIG. 19 is a sectional perspective view showing a state where the molded product 2 is pushed out by the plurality of pins 35. The molded product 2 is detached from the movable mold 30 by being pushed out by the plurality of pins 35. Thus, the molded product 2 comes off the mold 1.

FIG. 20 is a perspective view showing the molded product 2 removed from the mold 1 in FIG. The molded product 2 removed from the mold 1 includes not only the coil component 10 but also a plurality of protrusions 2A molded by the injection path 34, the runner 38, and the air vent 22, respectively. Each projection 2A is an unnecessary part for the coil component 10.

Therefore, after removing the molded product 2 from the mold 1, in the removing step, the respective projections 2A, which are unnecessary portions, are removed from the molded product 2. FIG. 21 is a perspective view showing a state in which each protrusion 2A has been removed from the molded product 2 of FIG. When each projection 2A is removed from the molded product 2, a plurality of coil components 10 are obtained. That is, a part of the molded product 2 becomes a plurality of coil components 10. Each projection 2A is removed from the molded product 2 by, for example, a cutter. Subsequent steps are the same as in the first embodiment.

In the third embodiment, six cavities 32 are provided in the mold 1. However, the configuration of the mold 1 is not limited to this. For example, the number of cavities 32 provided in the mold 1 may be less than six, or may be seven or more.

In the first to third embodiments, the shape of the coil component 10 is an annular shape with no steps. However, the shape of the coil component 10 is not limited to this. For example, the shape of the coil component 10 may be a shape like the coil component 10A shown in FIG.

In the example of FIG. 22, the coil component 10A positions two portions having three linear portions 12A and two corner portions 11A formed between the linear portions 12A in the axial direction at the two end portions 16. Are shifted and connected. Even with the coil component 10A having such a shape, the coil component 10A can be manufactured by one molding.

In the above example, all of the cavities 32 have the same shape. However, the shapes of the plurality of cavities 32 may be different from each other. In this case, a molded product 2 including a plurality of coil components 10 molded according to the shape of each cavity 32 is obtained. By doing so, the coil components 10 having different shapes can be manufactured at the same time.

Embodiment 4 FIG.
Next, a method for manufacturing a coil component according to the fourth embodiment of the present invention will be described. The coil manufacturing method according to the fourth embodiment is different from the first to third embodiments in that the entire molded product 2 is the coil component 10B. The mold 1 used in the method for manufacturing a coil component according to the fourth embodiment differs from the first embodiment in that the movable mold 30 moves up and down with respect to the fixed mold 20 to open and close the mold 1. Is different.

FIG. 23 is a perspective view showing a mold 1 used in the method for manufacturing a coil component according to the fourth embodiment. In the mold 1 shown in FIG. 23, for example, a coil component 10B having a shape different from an annular shape can be formed.

The coil component 10B is provided on a plurality of linear portions 12B arranged continuously, a plurality of corner portions 11B formed between ends of the plurality of linear portions 12B, and two linear portions 12B arranged on both ends. And two terminal portions 18 provided. The coil component 10B has a δ shape as a whole when viewed along the axial direction. In this example, in the coil component 10B, one linear portion 12B overlaps with another linear portion 12B at an interval. Other configurations and manufacturing methods are the same as in the first embodiment.

By adding a slide die that moves in the horizontal direction to the die 1 as shown in FIG. 23, a spiral coil component 10C as shown in FIG. 24 can be formed. Also, the coil component 10C can be molded by using a sand mold.

The helical coil component 10C includes a plurality of linear portions 12C arranged continuously, a plurality of corner portions 11C formed between ends of the plurality of linear portions 12C, and two linear portions arranged at both ends. 12C. The two straight portions 12C connected via each corner 11C are orthogonal to each other.

平面 A plane facing the outside of the coil component 10C is formed as a coil outer peripheral surface 121 on each of the linear portions 12C. Each of the corners 11C has a ridge 122 formed along the axis of the coil component 10C. The ridge line 122 is a boundary line formed by intersecting the respective coil outer peripheral surfaces 121 of two linear portions 12C adjacent to each other via the corner portion 11C.

As described above, the corner 11C is provided with the ridgeline 122 formed by intersecting the respective coil outer peripheral surfaces 121 of the two straight portions 12C. For this reason, the corner 11C of the coil component 10C can be prevented from being rounded. Thereby, the space in which the coil component 10C is arranged can be effectively used.

In addition, a spiral space may be formed as a cavity between the fixed mold 20 and the movable mold 30 when the mold 1 is closed.

FIG. 25 is a perspective view showing a coil component 10D as a modification of the coil component 10C in FIG. FIG. 26 is a top view showing the coil component 10D when viewed along the arrow XXVI in FIG. FIG. 27 is a bottom view showing the coil component 10D as viewed along arrow XXVII in FIG. The coil component 10D is a spiral coil component having the coil axis P. The coil component 10D has a plurality of first coil wire portions 101, a plurality of second coil wire portions 102, a plurality of third coil wire portions 103, and a plurality of fourth coil wire portions 104. The coil component 10D is formed in a spiral shape by continuously connecting the first coil wire portion 101, the second coil wire portion 102, the third coil wire portion 103, and the fourth coil wire portion 104.

Each third coil wire portion 103 is a straight coil wire portion along a specific axis crossing direction Q intersecting the coil axis P. In the example of FIG. 25, the direction orthogonal to the coil axis P is the axis crossing direction Q. The plurality of third coil wire portions 103 are arranged at intervals in the direction along the coil axis P.

Each fourth coil wire portion 104 is arranged at a position distant from each third coil wire portion 103 in a direction orthogonal to each of the coil axis P and the axis cross direction Q. Each fourth coil wire portion 104 is a straight coil wire portion along the axis cross direction Q. That is, each fourth coil wire portion 104 is arranged in parallel with each third coil wire portion 103. Further, the plurality of fourth coil wire portions 104 are arranged at intervals in the direction along the coil axis P.

Each of the third coil wire portions 103 and the fourth coil wire portions 104 is formed with a coil inner circumferential surface facing the inside of the coil component 10D and a coil outer circumferential surface facing the outside of the coil component 10D. I have.

The plurality of first coil wire portions 101 are arranged at intervals in the direction along the coil axis P. Each of the first coil wire portions 101 is a coil wire portion that intersects the coil axis P and the axis crossing direction Q, respectively. In this example, a linear coil wire portion orthogonal to each of the coil axis P and the axis cross direction Q is the first coil wire portion 101. When the coil component 10D is viewed along the axis crossing direction Q, the plurality of first coil wire portions 101 are inclined in the same direction with respect to the coil axis P as shown in FIGS.

Each second coil wire portion 102 is arranged at a position away from each first coil wire portion 101 in the axis crossing direction Q. That is, the plurality of first coil wire portions 101 and the plurality of second coil wire portions 102 are arranged apart from each other in the axis cross direction Q. Further, the plurality of second coil wire portions 102 are arranged at intervals in the direction along the coil axis P.

Each of the second coil wire portions 102 is a coil wire portion that intersects with each of the coil axis P and the axis cross direction Q. In this example, a linear coil wire portion orthogonal to each of the coil axis P and the axis cross direction Q is the second coil wire portion 102. When the coil component 10D is viewed along the axis crossing direction Q, as shown in FIGS. 26 and 27, the plurality of second coil wire portions 102 Inclined to

Each third coil wire portion 103 connects one end of each of the first coil wire portion 101 and the second coil wire portion 102. When the coil component 10D is viewed along the axis crossing direction Q, as shown in FIGS. 26 and 27, each of the third coil wire portions 103 is composed of a first coil wire portion 101 and a second coil wire portion 102 adjacent to each other. Are connected to each other at one end.

Each fourth coil wire portion 104 connects the other end portions of the first coil wire portion 101 and the second coil wire portion 102 to each other. When the coil component 10D is viewed along the axis crossing direction Q, as shown in FIGS. 26 and 27, each of the fourth coil wire portions 104 is composed of the first coil wire portion 101 and the second coil wire portion 102 adjacent to each other. Are connected to each other.

When the coil component 10D is viewed along the axis crossing direction Q, the first coil wire portions 101 and the second coil wire portions 102 are alternately arranged in a direction along the coil axis P. When the coil component 10D is viewed along the axis crossing direction Q, as shown in FIGS. 26 and 27, the region of each first coil wire portion 101 deviates from the region of each second coil wire portion 102. I have.

As shown in FIG. 25, each first coil wire portion 101 has a first coil inner surface 101a as an inner circumferential surface of the coil facing the inside of the coil component 10D, and a coil outer circumferential surface facing the outside of the coil component 10D. And the first coil outer surface 101b. Each second coil wire portion 102 has a second coil inner surface 102a as an inner circumferential surface of the coil facing the inside of the coil component 10D, and a second coil outer surface 102b as a coil outer circumferential surface facing the outside of the coil component 10D. Are formed.

In the first coil wire portion 101 and the second coil wire portion 102 connected to each other via the third coil wire portion 103, when the coil component 10D is viewed along the axis cross direction Q, it is shown in FIGS. 26 and 27. As described above, the side 101c of the first coil wire portion 101 on the side of the second coil wire portion 102 and the side 102c of the second coil wire portion 102 on the side of the first coil wire portion 101 are located at the position of the third coil wire portion 103. Cross each other.

In the first coil wire portion 101 and the second coil wire portion 102 connected to each other via the fourth coil wire portion 104, when the coil component 10D is viewed along the axis cross direction Q, it is shown in FIGS. 26 and 27. As described above, the side 101d of the first coil wire portion 101 on the side of the second coil wire portion 102 and the side 102d of the second coil wire portion 102 on the side of the first coil wire portion 101 are located at the position of the fourth coil wire portion 104. Cross each other.

In the example of FIG. 25, each of the first coil wire portions 101, each of the second coil wire portions 102, each of the third coil wire portions 103, and each of the fourth coil wire portions 104 are a plurality of linear portions. In the example of FIG. 25, a corner is formed between each end of each of the first coil wire portions 101, each of the second coil wire portions 102, each of the third coil wire portions 103, and each of the fourth coil wire portions 104. Have been. At each corner, a boundary line at which the respective coil outer peripheral surfaces of two linear portions adjacent to each other via the corner intersect is formed as a ridge line.

FIG. 28 is a perspective view showing the mold 1 when manufacturing the coil component 10D of FIG. FIG. 29 is a perspective view showing a state when the mold 1 of FIG. 28 is viewed from another direction. FIG. 30 is a perspective view showing a state where the coil component 10D is detached from the fixed mold 20 of FIG. FIG. 31 is a perspective view showing a state where the coil component 10D is detached from the movable mold 30 in FIG.

The fixed mold 20 and the movable mold 30 are relatively movable in the axis cross direction Q. In the example of FIG. 28, the movable mold 30 moves vertically with respect to the fixed mold 20, so that the fixed mold 20 and the movable mold 30 move relatively. The mold 1 closes when the fixed mold 20 and the movable mold 30 come into contact with each other. The mold 1 is opened when the fixed mold 20 and the movable mold 30 are separated from each other.

The fixed mold 20 has a first mold body 201 and a plurality of first teeth 202 provided on the first mold body 201.

１The first mold body 201 has a first mold recess in which a plurality of first teeth 202 are arranged. Further, a fixed side mating surface 205 facing the movable mold 30 is formed on the first mold body 201 as a first mating surface. The fixed side mating surface 205 is formed around the first mold recess.

The plurality of first teeth 202 are arranged at intervals in the direction along the coil axis P. Further, the plurality of first teeth 202 are respectively arranged along an axis intersecting direction Q intersecting the coil axis P.

The movable mold 30 has a second mold body 301 and a plurality of second teeth 302 provided on the second mold body 301.

では In the example of FIG. 28, the second die body 301 is a plate-like member. A plurality of second teeth 302 project from the second mold body 301 toward the fixed mold 20. A movable side mating surface 305 facing the fixed mold 20 is formed on the second mold body 301 as a second mating surface. The movable side mating surface 305 is formed around a region where the plurality of second teeth 302 are provided.

The plurality of second teeth 302 are arranged at intervals in the direction along the coil axis P. Further, the plurality of second teeth 302 are respectively arranged along the axis cross direction Q.

Each of the fixed-side mating surface 205 and the movable-side mating surface 305 is a surface that intersects in the axis intersecting direction Q. In the example of FIG. 28, the fixed side mating surface 205 and the movable side mating surface 305 are orthogonal to the axis crossing direction Q.

When the mold 1 is closed, the plurality of first teeth 202 and the plurality of second teeth 302 are alternately meshed. When the mold 1 is closed, the fixed side mating surface 205 and the movable side mating surface 305 are in contact with each other. Further, when the mold 1 is closed, spaces are formed as cavities between each first tooth 202 and the second mold body 301 and between each second tooth 302 and the first mold body 201. I have. The shape of the cavity formed in the mold 1 is a spiral shape in which the shape along the outer peripheral surface of the first tooth 202 and the shape along the outer peripheral surface of the second tooth 302 are alternately continuous.

As shown in FIG. 28, the outer peripheral surface of each first tooth 202 includes a first parallel surface 203 along the axis crossing direction Q and a first crossing surface 204 intersecting with the axis crossing direction Q. . The first parallel surface 203 is formed at an end on the same side of the plurality of first teeth 202. The first intersection plane 204 is formed toward the movable mold 30.

As shown in FIG. 29, the outer peripheral surface of each second tooth 302 includes a second parallel surface 303 along the axis crossing direction Q and a second crossing surface 304 intersecting with the axis crossing direction Q. . The second parallel surface 303 is formed at an end on the same side of the plurality of second teeth 302. The end of the second tooth 302 on which the second parallel surface 303 is formed is an end opposite to the end of the first tooth 202 on which the first parallel surface 203 is formed. The second intersection plane 304 is formed toward the fixed mold 20.

The coil component 10D is manufactured by the same steps as those in the first embodiment. Therefore, the method for manufacturing the coil component 10D includes the steps S1 to S6 in the first embodiment. In step S2 as an injection step, a spiral cavity formed in the mold 1 with the mold 1 closed is filled with molten metal. In step S4 as a mold removing step, the spiral molded article 2 is molded as the coil component 10D by opening the mold 1.

When the coil component 10D comes off from the mold 1 in step S4 as a mold release process, the fixed mold 20 moves with respect to the coil component 10D in the first mold release direction Q1 in FIG. 30, and the second mold release in FIG. The movable mold 30 moves with respect to the coil component 10D in the direction Q2. Here, the first die-cutting direction Q1 and the second die-cutting direction Q2 are opposite directions apart from each other on a straight line along the axis crossing direction Q.

Each first coil wire portion 101 is molded between the first crossing surface 204 of the first tooth 202 and the second mold body 301. Each second coil wire portion 102 is molded between the second intersecting surface 304 of the second tooth 302 and the first mold body 201.

Of the surfaces formed on each of the first coil wire portion 101 and each of the second coil wire portions 102, the surface facing the fixed die 20 side, that is, the first coil inner surface 101a and the second coil outer surface 102b are fixed die 20 molded. Specifically, the first coil inner surface 101a is molded by the first crossing surface 204 of the first tooth 202, and the second coil outer surface 102b is molded by the first mold body 201.

Also, of the surfaces formed on each of the first coil wire portion 101 and each of the second coil wire portions 102, the surface facing the movable die 30 side, that is, the first coil outer surface 101b and the second coil inner surface 102a are: Molded by the movable mold 30. Specifically, the second coil inner surface 102a is molded by the second intersecting surface 304 of the second tooth 302, and the first coil outer surface 101b is molded by the second mold body 301.

Furthermore, each third coil wire portion 103 is molded between the second parallel surface 303 of the second tooth 302 and the inner surface of the first mold recess of the first mold body 201. Each fourth coil wire portion 104 is molded between the first parallel surface 203 of the first tooth 202 and the inner surface of the first mold recess of the first mold body 201.

In step S4 as the mold release step, the fixed mold 20 moves in the first mold-releasing direction Q1 with respect to the coil component 10D without the fixed mold 20 hanging on the coil component 10D. Further, in the mold releasing step, the movable die 30 moves in the second die-releasing direction Q2 with respect to the coil component 10D without the movable die 30 hanging on the coil component 10D.

In the method of manufacturing the coil component 10D, when the coil component 10D is viewed along the axis crossing direction Q, the region of the first coil wire portion 101 is out of the region of the second coil wire portion 102. Therefore, each of the fixed mold 20 and the movable mold 30 can be moved along the axis crossing direction Q with respect to the coil component 10D. Thereby, the coil component 10D can be removed from each of the fixed mold 20 and the movable mold 30 without the coil component 10D interfering with each of the fixed mold 20 and the movable mold 30. Therefore, even if the shape of the coil component 10D is a complicated shape such as a spiral shape, the coil component 10D can be manufactured without performing a bending process on a conductive wire. Thereby, the shape accuracy of the coil component 10D can be improved. Further, the entire molded product 2 can be used as the coil component 10D, and the productivity of the coil component 10D can be improved.

稜 A ridge formed by intersecting the outer peripheral surfaces of the coils is provided at a corner of the coil component 10D. Therefore, similarly to Embodiment 4, the space in which coil component 10D is arranged can be effectively used.

コイル The coil component 10D is made of copper for casting or aluminum for casting. For this reason, even if the shape of the coil component 10D is a complicated shape, the coil component 10D can be easily manufactured.

Note that a connection type mold having a shape in which a plurality of molds 1 shown in FIG. 28 are connected may be used for manufacturing a coil component. In this case, the closed mold has a plurality of cavities connected to one gate via a runner. In this case, the molten metal injected from the gate is filled into each cavity via the runner. Further, in this case, the molded product molded by the connection type mold includes a plurality of coil components 10D molded according to the shape of each cavity. Thereby, in step S5 as a removing step, unnecessary portions in the molded product molded by the connection type mold are removed, and a plurality of coil components 10D are obtained. In this way, a plurality of coil components 10D can be manufactured at the same time, and the productivity of the coil components 10D can be further improved.

In the case where the connection type mold is used for manufacturing the coil component, the shapes of the plurality of cavities formed in the mold may be different from each other. In this manner, a plurality of coil components 10D having different shapes can be manufactured at the same time, and the productivity of the coil components 10D can be further improved.

In the mold 1 shown in FIG. 28, the first mold body 201 has a first mold recess, and the second mold body 301 is a plate-like member. However, the first mold body 201 may be a plate-shaped member, and the second mold body 301 may be formed with a second mold recess. In this case, a plurality of second teeth 302 project from the first mold body 201 toward the movable mold 30. In this case, a plurality of second teeth 302 are arranged in the second mold recess of the second mold body 301. Also in this case, a spiral cavity can be formed in the closed mold 1, and the spiral coil component 10D can be molded.

Also, the first mold recess may be formed in the first mold body 201 and the second mold recess may be formed in the second mold body 301. In this case, a part of each of the plurality of first teeth 202 arranged in the first mold recess projects from the first mold recess. In this case, a part of each of the plurality of second teeth 302 arranged in the second mold recess projects from the second mold recess. Further, in this case, the fixed side mating surface 205 is formed around the first mold concave portion, and the movable side mating surface 305 is formed around the second mold concave portion. When the mold 1 is closed, the portion of each second tooth 302 projecting from the second mold recess is inserted into the first mold recess, and the portion of each first tooth 202 projecting from the first mold recess is inserted into the second mold recess. Inserted into the recess. Also in this case, a spiral cavity can be formed in the closed mold 1, and the spiral coil component 10D can be molded.

When the first mold recess is formed in the first mold body 201 and the second mold recess is formed in the second mold body 301, each of the third coil wire portions 103 and each of the fourth coil wire portions of the coil component 10D are provided. Traces of the split surface of the mold 1 are formed on each of the molds 104. When the mold 1 is closed, a split surface of the mold 1 is formed at the boundary between the first mold body 201 and the second mold body 301. The split surface of the mold 1 is formed at a position corresponding to each of the third coil wire portions 103 and each of the fourth coil wire portions 104 of the coil component 10D. Accordingly, in this case, traces are formed on each of the third coil wire portions 103 and each of the fourth coil wire portions 104 according to the shape of the boundary between the first mold body 201 and the second mold body 301. By doing so, the ease of removing the coil component 10D with respect to each of the fixed mold 20 and the movable mold 30 can be made equal, and the coil component 10D can be removed from each of the fixed mold 20 and the movable mold 30 in the mold removing step. It can be easily removed.

コイル Also, it is possible to mold the coil component 10 as shown in FIG. 32 using the mold 1 used in the coil component manufacturing method according to the first to third embodiments. The coil component 10 has six straight portions 12 and six corner portions 11 formed individually between the ends of the six straight portions 12, and has a hexagonal annular shape. Ridge lines 122 are formed at the six corners 11 of the coil component 10.

Embodiment 5 FIG.
Next, a method for manufacturing a coil component according to the fifth embodiment will be described. FIG. 33 is a schematic diagram showing a manufacturing apparatus for performing the method for manufacturing a coil component according to the fifth embodiment of the present invention.

As shown in FIG. 33, in the method for manufacturing a coil component of the fifth embodiment, a mold 1 and a hot-chamber die-casting apparatus 80 for supplying molten metal to the mold 1 are used.

The mold 1 is provided with a gate 1A at the lower part of the fixed mold 20 for injecting molten metal from the side. The hot chamber type die casting apparatus 80 includes a pot 81 in which molten metal is stored, a pipe 82 arranged in the pot 81, a nozzle 83 provided at a tip of the pipe 82, and a nozzle 83 provided in the pipe 82. And a plunger 84 pushed out of the plunger. The pipe 82 is provided with a gate 82A.

Next, a method for manufacturing a coil component according to the fifth embodiment will be described.

First, as shown in FIG. 33, the nozzle 83 of the hot chamber type die casting device 80 is attached to the gate 1A of the fixed mold 20.
Next, the pot 81 is filled with molten metal. The molten metal stored in the pot 81 is automatically poured into the pipe 82 via the gate 82A of the pipe 82. The molten metal in the pipe 82 reaches near the nozzle 83.
Next, in the pouring step, the plunger 84 is lowered, and the molten metal in the pipe 82 is discharged from the nozzle 83. The molten metal discharged from the nozzle 83 is injected into the gate 1A of the fixed mold 20. The molten metal injected into the gate 1A is filled into the cavity 32 of the movable mold 30.
The subsequent procedure is the same as in the first to third embodiments.

As described above, according to the method for manufacturing a coil component of the fifth embodiment, the molten metal can be automatically supplied into the pipe 82 by using the hot chamber die casting apparatus 80. Thereby, the molding of the coil component 10 can be performed quickly and continuously.

Embodiment 6 FIG.
FIG. 34 is a partial cross-sectional view showing a rotating electric machine as an electric machine according to a sixth embodiment. FIG. 35 is a perspective view showing a rotating electric machine according to the sixth embodiment. The rotating electric machine 110 includes an annular stator 111 that generates a rotating magnetic field, a rotor 112 rotatably provided inside the stator 111 via a gap, and a housing 113 that supports the stator 111 and the rotor 112. And

The stator 111 has an annular stator core 111a through which magnetic flux passes, and a stator coil 111b provided on the stator core 111a. Between the stator core 111a and the stator coil 111b, insulating paper (not shown) for electrically insulating the stator core 111a and the stator coil 111b is provided. When power is supplied to the stator coil 111b, the stator coil 111b generates a magnetic field.

The rotor 112 is supported by a housing 113 via a bearing 114 so as to be rotatable inside the stator 111. The rotor 112 has a rotor core 112b through which magnetic flux passes, a rotor shaft 112a fixed to the rotor core 112b, and a plurality of permanent magnets 112c embedded in the rotor core 112b. The rotor shaft 112a rotates integrally with the rotor core 112b by energizing the stator coil 111b. Thus, the rotor shaft 112a transmits the torque to the outside.

The rotor 112 is not limited to a permanent magnet type rotor, and a plurality of rotor conductors which are not insulated are housed in slots of a rotor core, and both ends of each rotor conductor are short-circuited by a short-circuit ring. Alternatively, a winding type rotor in which an insulated wire or an insulated conductor is attached to a slot of the rotor core may be used.

Next, the stator 111 will be specifically described. For convenience of description, the longitudinal direction of the rotor shaft 112a is defined as an axial direction, the radial direction of the rotor shaft 112a is defined as a radial direction, and the rotational direction about the axis of the rotor shaft 112a is defined as a circumferential direction.

FIG. 36 is a perspective view showing a stator core 111a of the rotating electric machine according to the sixth embodiment. FIG. 37 is a partially broken enlarged view showing stator 111 of the rotary electric machine according to Embodiment 6. The stator core 111a has a plurality of magnetic pole pieces 1111 arranged in an annular shape. In the sixth embodiment, the stator core 111a is constituted by the 48 magnetic pole pieces 1111. Each pole piece 1111 is a laminated body in which a plurality of thin plates are laminated in the axial direction and integrated. The thin plate constituting the pole piece 1111 is formed by punching out a T-shape from an electromagnetic steel plate. The thickness of the electromagnetic steel sheet is set, for example, in the range of 0.1 mm to 1.0 mm.

The magnetic pole piece 1111 has a back yoke portion 1111a and a tooth portion 1111b protruding from the back yoke portion 1111a radially inward of the stator 111. The stator core 111a is inserted into the housing 113 by press fitting, shrink fitting, or the like in a state in which a plurality of magnetic pole pieces 1111 are arranged in an annular shape with the circumferential sides of the back yoke portion 1111a facing each other. Thus, the stator core 111a is held in the housing 113. A space as a slot 111c is formed between the adjacent tooth portions 1111b. Stator coil 111b is arranged in slot 111c.

In the sixth embodiment, for convenience of explanation, the number of poles of the rotor 112 is 8, the number of slots 111c in the stator core 111a is 48, and the stator coil 111b is a three-phase winding. That is, the slots 111c are formed in the stator core 111a at a rate of two per phase for each pole.

The housing 113 is formed in a cylindrical shape from an iron-based material. The housing 113 is formed with a bolt insertion hole 115 penetrating the mounting portion of the housing 113 in the axial direction.

In the sixth embodiment, iron is used as the material of the housing 113. However, the housing 113 may be made of a nonmagnetic material such as aluminum or stainless steel. In the sixth embodiment, an electromagnetic steel plate is used as the material of the pole piece 1111. However, other magnetic thin plates may be used. For example, SPCC may be used as the material of the pole piece 1111. Further, in the sixth embodiment, the teeth portion 1111b is arranged at the center in the circumferential direction of the arc-shaped back yoke portion 1111a. However, the teeth portion 1111b may be shifted from the central portion in the circumferential direction of the back yoke portion 1111a to the circumferential end portion.

The stator core 111a is obtained by fixing a plurality of magnetic pole pieces 1111 in an annular shape. In the sixth embodiment, 48 magnetic pole pieces 1111 are fixed in an annular shape. As a method of circularizing the plurality of pole pieces 1111, it is conceivable to fix the plurality of pole pieces 1111 arranged in a ring by welding, bonding, resin molding, or the like.

The stator coil 111b is obtained by connecting a plurality of coil components obtained by any of the manufacturing methods described in the first to fifth embodiments. The stator 111 is obtained by preparing the stator core 111a, inserting a plurality of coil components into the slot 111c, and connecting the plurality of coil components.

Before the stator core 111a is manufactured by arranging the plurality of magnetic pole pieces 1111 in an annular shape, the coil component is arranged on each magnetic pole piece 1111. Thereafter, the stator core 111a is manufactured by arranging the magnetic pole pieces 1111 in an annular shape. Thus, the stator 111 can be obtained.

The rotating electric machine 110 is obtained by disposing the rotor 112 inside the stator 111 fixed in the housing 113.

As described above, the rotating electric machine 110 is used as an electric machine including a coil component. The method for manufacturing rotating electric machine 110 includes the method for manufacturing a coil component according to any of the first to fifth embodiments. Therefore, in addition to the effects of any of the first to fifth embodiments, even if the shape of the stator coil 111b is complicated, the stator coil 111b can be easily manufactured. Accordingly, rotating electric machine 110 can be easily manufactured, and cost reduction of rotating electric machine 110 can be achieved.

Embodiment 7 FIG.
FIG. 38 is a perspective view showing a linear motor 120 as an electric machine according to the seventh embodiment. The linear motor 120 includes a stator 120a and a pair of movers 120b. In FIG. 38, only a part of each of the stator 120a and the mover 120b is illustrated for easy understanding of the configuration.

The stator 120a is arranged along a preset traveling direction A1. The stator 120a has a plurality of first magnets 123 and a plurality of second magnets 124. The first magnet 123 and the second magnet 124 are alternately arranged in the traveling direction A1. The direction of the magnetic pole of the first magnet 123 and the direction of the magnetic pole of the second magnet 124 are opposite to each other.

A pair of movers 120b are arranged on both sides in the width direction of the stator 120a. The width direction of the stator 120a is a direction orthogonal to the traveling direction A1. Each of the pair of movers 120b faces the stator 120a via a gap. The pair of movers 120b can move integrally with the stator 120a along the traveling direction A1.

Each of the pair of movers 120b has a core 125 along the traveling direction A1, and a plurality of windings 126 provided on the core 125. The core 125 is made of a magnetic material. As the core 125, for example, a laminated iron core made of an electromagnetic steel sheet is used. The lamination direction of the electromagnetic steel sheets of the core 125 is a thickness direction B1 orthogonal to both the traveling direction A1 and the width direction of the stator 120a.

The core 125 has a plurality of pole pieces 127 arranged linearly along the traveling direction A1. Each pole piece 127 has a core back 127a and a tooth 127b. The core back 127a is arranged outside the stator 120a in the width direction. The teeth 127b protrude from the core back 127a toward the stator 120a.

２Two core backs 127a adjacent to each other are in contact with each other. The plurality of teeth 127b are arranged at an interval from each other along the traveling direction A1. Each winding 126 includes a plurality of coil components obtained by any of the manufacturing methods described in the first to fifth embodiments. Each winding 126 is individually provided to each tooth 127b via an insulator (not shown) as an insulating member.

In the linear motor 120, a pair of movers 120b are arranged at positions symmetrical with respect to a plane passing through the axis of the stator 120a and orthogonal to the width direction of the stator 120a. That is, the pair of movers 120b are arranged at positions that are plane-symmetric with respect to the stator 120a.

一方 Comparing one of the pair of movers 120b with the other, the phases of the windings 126 provided on the two tooth portions 127b arranged at the same position in the traveling direction A1 are the same.

The winding 126 is obtained by connecting a plurality of coil components obtained by any of the manufacturing methods described in the first to fifth embodiments. The mover 120b is obtained by manufacturing the core 125 and then providing the windings 126 on the plurality of teeth 127b of the core 125.

Before the core 125 is manufactured by arranging the plurality of pole pieces 127 in a straight line, the windings 126 are arranged on the respective tooth portions 127b, and then the core 125 is manufactured by arranging the plurality of pole pieces 127 in a straight line. The movable element 120b can also be obtained.

The linear motor 120 is obtained by disposing a pair of movers 120b on both sides in the width direction of the stator 120a.

As described above, the linear motor 120 is used as an electric machine including a coil component. The method for manufacturing the linear motor 120 includes the method for manufacturing a coil component according to any of the first to fifth embodiments. Therefore, in addition to the effects of any of the first to fifth embodiments, the linear motor 120 can be easily manufactured. Thereby, the cost of the linear motor 120 can be reduced.

Embodiment 8 FIG.
FIG. 39 is a schematic partial sectional view showing a transformer as an electric machine according to the eighth embodiment. The transformer 130 according to the present embodiment has two iron cores 131, a coil 132 provided on the two iron cores 131, and a tank 133 that hermetically stores the two iron cores 131 and the coils 132. The inside of the tank 133 is filled with insulating oil 134. The insulating oil 134 is an oil that cools the iron core 131 and the coil 132 and maintains electrical insulation for the tank 133.

Each iron core 131 is configured by stacking a plurality of thin plates. The thin plate constituting the iron core 131 is obtained, for example, by punching a silicon steel plate. In FIG. 39, the lamination direction of the iron core 131 is defined as the x-axis direction. The coil 132 is formed by alternately stacking a plurality of coil layers 135 and a plurality of insulating spacers 136.

The coil layer 135 is formed of a spiral conductor. As the coil layer 135, for example, a strip-shaped copper plate formed in a spiral shape can be used. Further, as the insulating spacer 136, insulating paper called breath board, veneer plywood called reinforced wood, or the like can be used.

In the coil 132, a high-voltage side coil and a low-voltage side coil for causing the electric machine to function as a transformer are alternately stacked as a coil layer 135. The coil layer 135 includes a plurality of coil components obtained by any of the manufacturing methods described in the first to fifth embodiments. Coil 132 is obtained by connecting a plurality of coil components obtained by any of the manufacturing methods described in the first to fifth embodiments.

In the coil 132, the coil on the high voltage side and the coil on the low voltage side may be arranged concentrically. In FIG. 39, the lamination direction of the coil layer 135 in the coil 132 is the y-axis direction. The y-axis direction is orthogonal to the x-axis direction. In FIG. 39, a direction orthogonal to each of the x-axis direction and the y-axis direction is defined as a z-axis direction.

The two iron cores 131 are arranged side by side in the stacking direction of the thin plates of the iron cores 131, that is, in the x-axis direction. The two iron cores 131 are fixed to the tank 133 via a plurality of iron core spacers 137 by being tightened in the stacking direction of the thin plates of the iron cores 131 by bolts (not shown). The coil 132 is fixed to the tank 133 via a plurality of coil spacers 138 by being tightened by a bolt (not shown) in the laminating direction of the coil layers 135, that is, in the y-axis direction.

In the present embodiment, the plurality of first coil holding members 139, the plurality of second coil holding members 140, and the guides 141 are arranged between the two iron cores 131. The plurality of first coil holding members 139 are arranged on one side in the stacking direction of the coil layers 135, that is, in the y-axis direction when viewed from the coil 132. The plurality of second coil holding members 140 are arranged on the other side in the stacking direction of the coil layers 135, that is, the y-axis direction when viewed from the coil 132.

Inside the tank 133, a first opposing surface 133a and a second opposing surface 133b that are opposed to each other via the iron core 131 in the stacking direction of the coil layers 135, that is, the y-axis direction, are formed. Each first coil holding member 139 is a plate-shaped member arranged between the first facing surface 133a of the tank 133 and the coil 132. One end of the first coil holding member 139 is in contact with the coil 132. The other end of the first coil holding member 139 is in contact with the first facing surface 133a of the tank 133. Each second coil holding member 140 is a plate-shaped member arranged between the second facing surface 133b of the tank 133 and the coil 132. One end of the second coil holding member 140 is in contact with the coil 132. The other end of the second coil holding member 140 is separated from the second facing surface 133b of the tank 133.

Guide 141 is sandwiched between two iron cores 131. The guide 141 is fixed to each iron core 131. The second coil holding member 140 penetrates the guide 141. The second coil holding member 140 is movable in the y-axis direction with respect to the guide 141.

The tank 133 is provided with a pressing mechanism 142 that presses the plurality of second coil holding members 140 against the coil 132. The coil 132 is held between the first coil holding member 139 and the second coil holding member 140 by the pressing force of the pressing mechanism 142.

The pressing mechanism 142 has a screw 143 and a pressing plate 144. The pressing plate 144 is arranged inside the tank 133 in parallel with the second facing surface 133b. A screw hole 145 is provided in a wall of the tank 133 where the second facing surface 133b is formed. The screw 143 is inserted into the screw hole 145. The screw 143 is arranged coaxially with the guide 141. One end of the screw 143 is in contact with the pressing plate 144, and the other end of the screw 143 projects outside the tank 133.

FIG. 40 is a perspective view showing a main part of the transformer 130 excluding the tank 133, the iron core spacer 137, and the coil spacer 138 in FIG. FIG. 41 is a perspective view showing a state where a main part of transformer 130 of FIG. 40 is viewed from a different direction. In FIG. 41, the display of the pressing mechanism 142 is also omitted. In the present embodiment, two first coil holding members 139 are arranged in the z-axis direction. In the present embodiment, two second coil holding members 140 are arranged in the z-axis direction in accordance with the position of first coil holding member 139. In the present embodiment, two second coil holding members 140 are in contact with one pressing plate 144.

In the present embodiment, of the space in the tank 133, the space closer to the coil 132 than the pressing plate 144 is filled with the insulating oil 134. In the present embodiment, as shown in FIG. 39, the outer peripheral portion of the pressing plate 144 is air-tightly fixed to the inner surface of the tank 133. Thereby, the insulating oil 134 does not leak from between the outer peripheral portion of the pressing plate 144 and the inner surface of the tank 133. Therefore, of the space in the tank 133, the space on the second opposing surface 133b side with respect to the pressing plate 144 is filled with the atmosphere.

剛性 The rigidity of the pressing plate 144 is smaller than the rigidity of each of the tank 133 and the screw 143. The pressing plate 144 is elastically deformable. When the screw 143 is tightened, the pressing plate 144 bends toward the coil 132 while being elastically deformed. Thereby, the second coil holding member 140 is pressed against the coil 132 by the pressing plate 144. That is, the pressing mechanism 142 presses the plurality of second coil holding members 140 against the coil 132 via the pressing plate 144 by tightening the screw 143. The coil 132 is compressed between the first coil holding members 139 and the second coil holding members 140 in the direction in which the coils 132 are stacked.

Thus, the transformer 130 is used as an electric machine including a coil component. Further, the method of manufacturing transformer 130 includes the method of manufacturing a coil component according to any of the first to fifth embodiments. Therefore, in addition to the effects of any of the first to fifth embodiments, transformer 130 can be easily manufactured. Thereby, the cost of the transformer 130 can be reduced.

1 type, 1A gate, 2 molded product, 2A projection, 10, 10A to 10D coil part, 11, 11A to 11C corner, 12, 12A to 12C linear part, 16 end, 18 terminal, 20 fixed type ( 1st type), 21 ° fixed side mating surface, 22 ° air vent, 23 ° fixed side concave portion, 24 ° runner, 25 ° plunger, 30 ° movable type (second type), 31 ° movable side mating surface, 32 ° cavity, 33 ° movable side concave portion, 34 Injection path, 35-pin, 36-extrusion member, 37-air vent, 38-runner, 80-hot-chamber die-casting apparatus, 101 first coil wire section, 102 second coil wire section, 103 third coil wire section, 101a inner surface of first coil , 101b {first coil outer surface, 102a} second coil inner surface, 102b {second coil outer surface, 121} coil outer periphery , 122 ridgeline.

Claims

An injection step of injecting molten metal into the mold,
After the pouring step, a mold removing step of removing the molded product formed by curing the molten metal in the mold from the mold,
At least a part of the molded product is a coil component,
The mold has a first mold and a second mold that are relatively movable in a specific axis crossing direction,
The coil component includes a first coil wire portion, a second coil wire portion, and a straight third coil wire portion connecting the respective ends of the first coil wire portion and the second coil wire portion. And has
Each of the first coil wire portion and the second coil wire portion crosses in the axis crossing direction,
The third coil wire portion is disposed along the axis crossing direction,
When viewing the coil component along the axis crossing direction, the area of the first coil wire part is out of the area of the second coil wire part,
Of the surfaces formed on each of the first coil wire portion and the second coil wire portion, a surface facing the first mold side is molded by the first mold,
A method of manufacturing a coil component in which a surface facing the second mold side among surfaces formed on each of the first coil wire portion and the second coil wire portion is molded by the second mold.
The mold is provided with a plurality of cavities connected via a runner,
The method for manufacturing a coil component according to claim 1, wherein the molded product has a plurality of the coil components molded according to the shape of each cavity.
The method according to claim 2, wherein the shapes of the plurality of cavities are different from each other.
Each of the first coil wire portion, the second coil wire portion, and the third coil wire portion is included in the coil component as a plurality of straight portions,
Corners are formed between the ends of the plurality of straight portions,
In each of the plurality of straight portions, a coil outer peripheral surface facing the outside of the coil component is formed,
4. The corner according to claim 1, wherein a boundary line at which the coil outer peripheral surfaces of the two linear portions adjacent to each other via the corner intersect is formed as a ridge line. 13. The method for manufacturing a coil component according to the above section.
(5) A method for manufacturing an electric machine having the method for manufacturing a coil component according to any one of (1) to (4).
A first coil wire portion;
A second coil wire portion;
A straight third coil wire portion connecting the respective ends of the first coil wire portion and the second coil wire portion,
The first coil wire portion and the second coil wire portion are spaced apart from each other in an axis crossing direction along the third coil wire portion,
A coil component in which a region of the first coil wire portion is deviated from a region of the second coil wire portion when the first coil wire portion and the second coil wire portion are viewed along the axis crossing direction.
7. The coil component according to claim 6, wherein the third coil wire portion has a trace of a mold split surface.
8. The coil component according to claim 6, wherein the coil component is made of copper for casting or aluminum for casting.
An electric machine having the coil component according to any one of claims 6 to 8.