JPH0410203B2 - - Google Patents
Info
- Publication number
- JPH0410203B2 JPH0410203B2 JP11038383A JP11038383A JPH0410203B2 JP H0410203 B2 JPH0410203 B2 JP H0410203B2 JP 11038383 A JP11038383 A JP 11038383A JP 11038383 A JP11038383 A JP 11038383A JP H0410203 B2 JPH0410203 B2 JP H0410203B2
- Authority
- JP
- Japan
- Prior art keywords
- coil
- lead wire
- molded
- lead
- resin
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
Links
- WABPQHHGFIMREM-UHFFFAOYSA-N lead(0) Chemical compound [Pb] WABPQHHGFIMREM-UHFFFAOYSA-N 0.000 claims description 28
- 239000012212 insulator Substances 0.000 claims description 20
- 229920005989 resin Polymers 0.000 claims description 17
- 239000011347 resin Substances 0.000 claims description 17
- 238000004519 manufacturing process Methods 0.000 claims description 15
- 238000000465 moulding Methods 0.000 claims description 13
- 238000004804 winding Methods 0.000 claims description 10
- 238000007493 shaping process Methods 0.000 claims 1
- 238000009413 insulation Methods 0.000 description 10
- 238000000034 method Methods 0.000 description 7
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 5
- 238000010586 diagram Methods 0.000 description 5
- 230000002093 peripheral effect Effects 0.000 description 5
- 238000005266 casting Methods 0.000 description 4
- 239000000463 material Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000011162 core material Substances 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 239000012778 molding material Substances 0.000 description 2
- 230000035515 penetration Effects 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000011521 glass Substances 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/127—Encapsulating or impregnating
Landscapes
- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Coils Of Transformers For General Uses (AREA)
- Insulating Of Coils (AREA)
Description
【発明の詳細な説明】
この発明は、モールドコイルの製造方法に関す
る。さらに詳しくは、特殊な金型を要せず簡便に
高電圧用のモールドコイルが製造できるモールド
コイルの製造方法に関する。DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a molded coil. More specifically, the present invention relates to a method for manufacturing a molded coil that can easily manufacture a molded coil for high voltage without requiring a special mold.
従来から、筒状絶縁体を芯材としこの外周にコ
イル層を形成しエポキシ系樹脂やウレタン系樹脂
等の絶縁性樹脂で一体に注形したモールドコイル
が知られており、ことにこのモールドコイルを組
合せた変圧器が電力用変圧器の分野などで汎用さ
れている。これらの代表的なモールドコイルを第
１図及び第２図に示す。図において、１はレヤー
巻の素コイル、２は筒状絶縁体、３は同一縁面方
向に導出されるリード線、４はモールド樹脂をそ
れぞれ示す。また、第３図は第２図の素コイルの
巻線構成を示す概略図である。 Conventionally, molded coils have been known in which a cylindrical insulator is used as a core material, a coil layer is formed around the outer periphery, and the molded coil is integrally cast with insulating resin such as epoxy resin or urethane resin. Transformers that combine these are widely used in the field of power transformers. These typical molded coils are shown in FIGS. 1 and 2. In the figure, 1 is a layered coil, 2 is a cylindrical insulator, 3 is a lead wire led out in the direction of the same edge, and 4 is a molded resin. Moreover, FIG. 3 is a schematic diagram showing the winding configuration of the elementary coil of FIG. 2.
ところで、比較的低電圧の用途に用いられるモ
ールドコイルは第１図に示したようなコイル構成
のものでも各レアー間の電位差が低いので絶縁性
に何ら支障はないが、高電圧すなわちコイルの端
子電圧が高くなると、レアー間の電位差が高くな
り巻始めと巻終りとの間のみならず全体の巻線間
の電位差ことに厚み方向の電位差が大となり、絶
縁設計上の支障が生じ好ましくない。 By the way, molded coils used for relatively low voltage applications, even those with the coil configuration shown in Figure 1, have a low potential difference between each layer, so there is no problem with insulation. When the voltage increases, the potential difference between the layers increases, and the potential difference not only between the start and end of the winding but also between the entire windings and the potential difference in the thickness direction becomes large, which is undesirable because it causes problems in insulation design.
この様な場合、第４図及び第５図に示されるよ
うに小型の素コイル１′を用いてコイルの高さ方
向に複数個積み重ねそれらを直列に結線して、巻
回層が複数に分割構成された素コイルを構成させ
ることが考えられている。かようなコイルは、巻
回層が分割されているためにレアー間ことに厚み
方向の電位差が長さに対応して減少されており、
絶縁設計上好ましいものである。 In such cases, as shown in Figures 4 and 5, multiple small coils 1' are stacked in the height direction of the coil and connected in series, so that the winding layer is divided into multiple layers. It has been considered to construct an elemental coil. In such a coil, since the winding layers are divided, the potential difference between the layers, particularly in the thickness direction, is reduced in proportion to the length.
This is preferable in terms of insulation design.
しかしながら、上記分割方式のコイルにおいて
二本のリード線を第１図のモールドコイルと同様
に同一縁面方向に導出する場合（変圧器の内側コ
イルなどでは外部配線の都合上、同一縁面方向と
するのが好ましい）、内周側のリード線は第４図
に示すようにコイル下部から上部に導出する必要
があり、この際導出されるリード線を各素コイル
１′に対して必要な絶縁寸法ｂを離隔して配置し、
このリード線の導出部分をモールドされるように
大き目のモールド金型で樹脂モールドする必要が
ある。すなわち、素コイルの厚みａに対応するモ
ールド金型をそのまま使用することはできず、絶
縁寸法ｂが増加した厚みａ＋ｂに対応する専用の
モールド金型を用いる必要がありコイルの厚さ方
向寸法が全体に大きくなるという不都合があつ
た。なお、コイル下部からのリード線の導出をコ
イルの外周側から行なう場合にも同様な不都合が
あつた。 However, when the two lead wires of the above-mentioned split-type coil are led out in the same edge direction as in the molded coil shown in Figure 1 (in the case of the inner coil of a transformer, etc., due to the external wiring, the two lead wires are led out in the same edge direction) (preferably), the lead wire on the inner circumferential side must be led out from the bottom of the coil to the top as shown in Figure 4, and in this case, the lead wire must be provided with the necessary insulation for each element coil 1'. spaced apart by dimension b,
It is necessary to mold resin using a large mold so that the lead-out portion of the lead wire can be molded. In other words, the mold corresponding to the thickness a of the bare coil cannot be used as is, and it is necessary to use a special mold corresponding to the thickness a+b with the increased insulation dimension b. There was an inconvenience that it became larger overall. Incidentally, a similar problem occurs when the lead wire is led out from the lower part of the coil from the outer circumferential side of the coil.
この発明はかような従来の問題点に鑑みなされ
たものであり、特殊なモールド金型を用いること
なく簡便に素コイル分割型のモールドコイルが得
られる製造方法を提供することを一つの目的とす
るものである。 This invention was made in view of such conventional problems, and one purpose is to provide a manufacturing method that can easily obtain a molded coil of the elemental coil split type without using a special molding die. It is something to do.
かくしてこの発明によれば、レヤー巻の素コイ
ルを筒状絶縁体の外周に複数個積み重ね、これら
を直列接続して巻回層が高さ方向に複数に分割構
成された素コイルを形成し、このコイルの二本の
リード線を同一縁面方向に導出すると共に樹脂モ
ールドを行なつてモールドコイルを製造するに際
し、前記筒状絶縁体に近接して導出される内周側
のリード線が、筒状絶縁体から貫ぬいてその内側
に導いた状態で該絶縁体の内壁面に沿つて他方の
リード線が導出されたコイル縁面方向に導出され
るよう構成し、かつ内壁面に沿うリード線導出部
分を覆う注形用板を装着して該リード線導出部分
をさらに樹脂モールドすることを特徴とするモー
ルドコイルの製造方法が提供される。 Thus, according to the present invention, a plurality of layer-wound elemental coils are stacked on the outer periphery of a cylindrical insulator, and these are connected in series to form an elemental coil in which the wound layer is divided into a plurality of layers in the height direction, When manufacturing a molded coil by leading out two lead wires of the coil in the direction of the same edge surface and performing resin molding, the lead wire on the inner peripheral side led out close to the cylindrical insulator is The lead wire is configured such that it penetrates through the cylindrical insulator and is guided inside the insulator, and the other lead wire is led out along the inner wall surface of the insulator in the direction of the edge surface of the coil, and the lead wire runs along the inner wall surface. A method for manufacturing a molded coil is provided, which comprises: attaching a casting plate that covers the wire lead-out portion, and further molding the lead wire lead-out portion with resin.
以下、図面と共にこの発明を詳説する。第６図
及び第７図は、この発明の製造方法によつて得ら
れるモールドコイルを例示する図であり、第８図
はこの発明の製造方法の例示説明図である。 Hereinafter, this invention will be explained in detail with reference to the drawings. 6 and 7 are diagrams illustrating a molded coil obtained by the manufacturing method of the present invention, and FIG. 8 is an illustration explanatory diagram of the manufacturing method of the present invention.
この発明の製造方法において、まずレヤー巻の
素コイル１′が筒状絶縁体２の外周に複数個積み
重ねられる。レヤー巻の素コイルとしては当該分
野で知られた種々のものが使用でき、所望のコイ
ル幅、コイル高さなどに対応して大きさや個数が
適宜選択される。また、筒状絶縁体もガラス基材
入エポキシ樹脂等からなる当該分野で知られた
種々のものが使用できる。 In the manufacturing method of the present invention, first, a plurality of layer-wound element coils 1' are stacked on the outer periphery of the cylindrical insulator 2. Various layered coils known in the art can be used, and the size and number of coils are appropriately selected depending on the desired coil width, coil height, etc. Furthermore, various types of cylindrical insulators known in the art, such as epoxy resin containing a glass base material, can be used.
積み重ねられた各素コイル１′は次いで直列に
接続され巻回層がコイルの高さ方向に複数に分割
構成された一つの素コイルが形成される。かかる
素コイルを樹脂でモールドするに際し、まず最下
段の巻回層から延出する内周側のリード線３ａ
は、筒状絶縁体２に穿設された小孔７を通してコ
イルの内芯空間側に貫ぬかれ、外周側のリード線
３ｂと同じ方向にかつ筒状絶縁体の内壁面に沿つ
て直線状に導出される。このような状態で素コイ
ルへの樹脂モールドを行ない、さらに筒状絶縁体
２の内壁面に沿う内周側リード線３ａの導出部分
を、第８図に示すごとく該導出部分を覆う注形用
板６を装着しこの間にモールド樹脂を流し込んで
筒状絶縁体と一体にモールドすることにより、第
６図及び第７図に示すごときモールドコイルが得
られる。なお、素コイルのモールドとリード線導
出部分のモールドとは同一工程で行なつてもよ
い。 The stacked elemental coils 1' are then connected in series to form one elemental coil in which the winding layer is divided into a plurality of layers in the height direction of the coil. When molding such an elementary coil with resin, first the inner lead wire 3a extending from the lowest winding layer is
is penetrated into the inner core space side of the coil through a small hole 7 drilled in the cylindrical insulator 2, and linearly extends in the same direction as the lead wire 3b on the outer peripheral side and along the inner wall surface of the cylindrical insulator. is derived. In this state, the coil is resin-molded, and the lead wire 3a extending along the inner wall surface of the cylindrical insulator 2 is molded with a molding material that covers the lead wire 3a as shown in FIG. A molded coil as shown in FIGS. 6 and 7 can be obtained by attaching the plate 6 and pouring a molding resin therebetween and molding it integrally with the cylindrical insulator. Note that the molding of the elementary coil and the molding of the lead wire lead-out portion may be performed in the same process.
上記注形用板としては、通常型材として使用し
うるものであれば使用できブリキや鉄板のごとき
金属製の板を用いる場合にはモールドした後、離
型することが必要であるが、所望の絶縁強度を有
する材質からなるものであれば離型する必要はな
い。 As the above-mentioned casting plate, any material that can be used as a normal molding material can be used. If a metal plate such as tin or iron plate is used, it is necessary to release the mold after molding. If it is made of a material that has dielectric strength, it is not necessary to release it from the mold.
一方、上記リード線導出部分を被覆固定する断
面略三ケ月状の樹脂層５は少なくとも使用時の鉄
心など貫入を阻害しない程度の樹脂層であつて、
被覆リード線と上記鉄心との間の絶縁性を充分に
保つ程度の被覆厚みを有するように注形用板の大
きさで適宜設定すればよい。かかるリード線被覆
樹脂層は使用時の鉄心の貫入固定の点からも好都
合である。 On the other hand, the resin layer 5 having an approximately crescent-shaped cross section that covers and fixes the lead wire lead-out portion is at least a resin layer that does not impede penetration of the iron core during use,
The size of the casting plate may be appropriately set so that the thickness of the coating is sufficient to maintain sufficient insulation between the covered lead wire and the iron core. Such a lead wire coating resin layer is also advantageous in terms of penetration and fixation of the iron core during use.
なお素コイルの樹脂モールドは、通常の方法に
従い、筒状絶縁体に対応する外周側筒状金型及び
上、下部金型をセツトし、その注に樹脂を充填硬
化されることにより行なわれる。 The resin molding of the coil is carried out by setting an outer cylindrical mold corresponding to the cylindrical insulator, upper and lower molds, and filling the mold with resin and hardening it, according to the usual method.
このようにして得られたモールドコイルは、内
周側のリード線が他方のリード線と同一縁面方向
に導出されておりことに変圧器用の内側モールド
コイルとして外部配線上有利であり、さらに内周
側リード線と素コイルとの間には比較的厚い絶縁
層である筒状絶縁体と注形樹脂が介在する構成で
あるため充分な絶縁性が保たれている。従つて、
分割構成した素コイルの効果とも合送つて絶縁性
が優れたものでありとくに高電圧（数千〜数万
Ｖ）が印加される用途に使用されるモールドコイ
ルとして有用なものである。 The molded coil obtained in this way has the lead wire on the inner circumference drawn out in the same direction as the other lead wire, and is advantageous for external wiring as an inner molded coil for a transformer. Sufficient insulation is maintained because the cylindrical insulator, which is a relatively thick insulating layer, and the molded resin are interposed between the circumferential lead wire and the element coil. Therefore,
Combined with the effect of the divided element coil, it has excellent insulation properties, and is particularly useful as a molded coil used in applications where high voltage (several thousand to tens of thousands of volts) is applied.
このようにこの発明の製造法によれば、絶縁性
に優れたモールドコイルを簡便に得ることができ
る。しかもその注型には専用の金型や特殊な金型
を用いることなく、低電圧用のモールドコイル製
造用金型をそのまま使用することができかつ絶縁
層増加によるコイル本体の大型化が実質的に防止
されている。従つて、種々の用途ことに高電圧の
印加される電力用モールドコイルの製造方法とし
て有用なものである。 As described above, according to the manufacturing method of the present invention, a molded coil with excellent insulation properties can be easily obtained. Furthermore, the molding process does not require a dedicated mold or special mold, and the mold for producing low-voltage molded coils can be used as is, and the increase in the size of the coil body due to the increase in insulation layers can be effectively achieved. is prevented. Therefore, the present invention is useful as a method for manufacturing power molded coils to which high voltage is applied for various purposes.
なお、この発明で得られるモールドコイルはそ
れ自身従来とは異なる構成からなり有用なもので
ある。従つて他の観点によればこの発明は、第７
図で示されるごとく、巻回層が分割構成されたモ
ールドコイルであつて、内周側リード線の貫通導
出構造に特徴づけられる電力用モールドコイルを
も提供するものである。 Incidentally, the molded coil obtained by the present invention has a configuration different from the conventional one and is useful. Therefore, according to another aspect, this invention
As shown in the figure, the present invention also provides a power molded coil in which the winding layer is divided into parts, and which is characterized by a structure in which the inner peripheral lead wire is led through.
第１図は従来のモールドコイルを例示する斜視
図、第２図は第１図の部分断面図、第３図は第２
図の素コイルの巻線構成を示す概略図、第４図は
従来の他のモールドコイルを例示する第２図相当
図、第５図は第４図のモールドコイルの巻線構成
を示す第３図相当図、第６図はこの発明のモール
ドコイルの製造方法によつて得られるモールドコ
イルを例示する斜視図、第７図は第２図及び第４
図に対応する第６図の部分断面図、第８図はこの
発明の製造方法の一工程を示す説明斜視図であ
る。
１，１′……素コイル、２……筒状絶縁体、３
……リード線、３ａ……内周側リード線、３ｂ…
…外周側リード線、４……モールド樹脂、５……
樹脂層、６……注形用板、７……小孔。
Fig. 1 is a perspective view illustrating a conventional molded coil, Fig. 2 is a partial sectional view of Fig. 1, and Fig. 3 is a partial cross-sectional view of Fig. 2.
4 is a schematic diagram showing the winding configuration of the bare coil shown in FIG. 4. FIG. 4 is a diagram corresponding to FIG. 2 illustrating another conventional molded coil. FIG. FIG. 6 is a perspective view illustrating a molded coil obtained by the molded coil manufacturing method of the present invention, and FIG.
FIG. 6 is a partial sectional view corresponding to the drawing, and FIG. 8 is an explanatory perspective view showing one step of the manufacturing method of the present invention. 1, 1'...Elementary coil, 2...Cylindrical insulator, 3
...Lead wire, 3a...Inner peripheral side lead wire, 3b...
...Outer peripheral side lead wire, 4...Mold resin, 5...
Resin layer, 6...Plate for casting, 7...Small hole.
Claims (1)
数個積み重ね、これらを直列接続して巻回層が高
さ方向に複数に分割構成された素コイルを形成
し、このコイルの二本のリード線を同一縁面方向
に導出すると共に樹脂モールドを行なつてモール
ドコイルを製造するに際し、前記筒状絶縁体に近
接して導出される内周側のリード線が、筒状絶縁
体から貫ぬいてその内側に導いた状態で該絶縁体
の内壁面に沿つて他方のリード線が導出されたコ
イル縁面方向に導出されるよう構成し、かつ内壁
面に沿うリード線導出部分を覆う注形用板を装着
して該リード線導出部分をさらに樹脂モールドす
ることを特徴とするモールドコイルの製造方法。1 A plurality of layer-wound elemental coils are stacked on the outer periphery of a cylindrical insulator, and these are connected in series to form an elemental coil in which the winding layer is divided into a plurality of layers in the height direction. When manufacturing a molded coil by leading the lead wires in the direction of the same edge surface and performing resin molding, the lead wires on the inner circumferential side that are led out close to the cylindrical insulator penetrate through the cylindrical insulator. The other lead wire is drawn out along the inner wall surface of the insulator in the direction of the edge surface of the coil, and the lead wire is covered along the inner wall surface. A method for producing a molded coil, comprising: attaching a shaping plate and further molding the lead wire lead-out portion with resin.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP11038383A JPS601822A (en) | 1983-06-20 | 1983-06-20 | Manufacture of molded coil |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP11038383A JPS601822A (en) | 1983-06-20 | 1983-06-20 | Manufacture of molded coil |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPS601822A JPS601822A (en) | 1985-01-08 |
| JPH0410203B2 true JPH0410203B2 (en) | 1992-02-24 |
Family
ID=14534413
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP11038383A Granted JPS601822A (en) | 1983-06-20 | 1983-06-20 | Manufacture of molded coil |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPS601822A (en) |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US8911652B2 (en) * | 2011-09-06 | 2014-12-16 | Automatic Switch Company | System and method of sealing coil leads during encapsulation |
-
1983
- 1983-06-20 JP JP11038383A patent/JPS601822A/en active Granted
Also Published As
| Publication number | Publication date |
|---|---|
| JPS601822A (en) | 1985-01-08 |
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