WO2011136144A1 - Bobbin for electrical equipment and method for producing same - Google Patents
Bobbin for electrical equipment and method for producing same Download PDFInfo
- Publication number
- WO2011136144A1 WO2011136144A1 PCT/JP2011/059937 JP2011059937W WO2011136144A1 WO 2011136144 A1 WO2011136144 A1 WO 2011136144A1 JP 2011059937 W JP2011059937 W JP 2011059937W WO 2011136144 A1 WO2011136144 A1 WO 2011136144A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- bobbin
- body portion
- flange
- flange portion
- insulating film
- Prior art date
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F5/00—Coils
- H01F5/02—Coils wound on non-magnetic supports, e.g. formers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F7/00—Magnets
- H01F7/06—Electromagnets; Actuators including electromagnets
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/46—Fastening of windings on the stator or rotor structure
- H02K3/52—Fastening salient pole windings or connections thereto
- H02K3/521—Fastening salient pole windings or connections thereto applicable to stators only
- H02K3/522—Fastening salient pole windings or connections thereto applicable to stators only for generally annular cores with salient poles
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
- H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
- H01F27/325—Coil bobbins
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2203/00—Specific aspects not provided for in the other groups of this subclass relating to the windings
- H02K2203/12—Machines characterised by the bobbins for supporting the windings
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- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K2213/00—Specific aspects, not otherwise provided for and not covered by codes H02K2201/00 - H02K2211/00
- H02K2213/03—Machines characterised by numerical values, ranges, mathematical expressions or similar information
Definitions
- the present invention relates to a bobbin for an electric device used for an electric device such as an electric motor, a generator, a transformer, and an inverter, and a manufacturing method thereof.
- bobbins for electrical equipment used for electric motors, generators, transformers, inverters, etc. are provided on each of a cylindrical body having a round shape or a square shape, and both axial ends of the body.
- the trunk portion and the collar portion are usually made of synthetic resin, and are integrally formed by injection molding as shown in Patent Document 1, for example.
- the thickness of the body part is usually as thick as 2 to 3 mm. It is.
- Patent Document 2 discloses a configuration in which the body portion is thinned.
- the body part of the bobbin for electric equipment disclosed in Patent Document 2 is composed of a first holding member made of synthetic resin and a second holding member of a thin film body which is a nonmagnetic material.
- the body is composed of two members, the first holding member and the second holding member, it is necessary to ensure the bonding strength between the two members. If the joining of these two members is insufficient, the first holding member is likely to be detached from the second holding member when an electric wire is wound around the body portion or when a bobbin for an electric device is mounted on the stator core. There's a problem. Further, since the thick first holding member forms a part of the body portion, there is a problem that it is difficult to improve the line area ratio and the thermal conductivity.
- an object of the present invention is to provide a bobbin for an electric device having a high line area ratio of electric wires, excellent heat dissipation, and high joint strength of members, and a manufacturing method thereof.
- the bobbin for an electric device includes a body portion, a flange portion, and an engagement hole.
- drum is formed in the cylinder shape with the insulating film.
- the flanges are provided at both end portions in the axial direction of the body part, the body parts are fitted on the inner peripheral side, are formed of a material different from that of the body part, and project annularly from the body part radially outward.
- the engagement holes are respectively provided at both end portions in the axial direction of the body portion, penetrate the body portion in the thickness direction, and the inner peripheral side of the collar portion facing the body portion enters.
- the method for manufacturing a bobbin for an electric device includes a step of forming a body portion and a step of forming a collar portion.
- an insulating material having a thickness of 0.05 mm to 0.5 mm is formed into a cylindrical body portion.
- the collar portion it is formed at both end portions in the axial direction of the barrel portion molded into a cylindrical shape with an outer diameter larger than that of the barrel portion. At this time, the collar portion is formed integrally with the trunk portion.
- the body and the buttock are formed of different materials.
- drum is formed with the insulating film. Therefore, it is easy to reduce the thickness of the trunk portion. Therefore, the number of turns of the electric wire per unit cross-sectional area, that is, the line area ratio of the electric wire can be increased. Further, the heat generated in the electric wire is transmitted to, for example, a stator core through an insulating film having a small thickness. Therefore, the heat dissipation of an electric wire can be improved.
- the collar part has entered the engagement hole of the trunk part. Therefore, the collar part and the trunk part are in a state of being engaged with each other in the engagement hole. Therefore, the joint strength between the trunk part and the collar part can be increased, and the dropping of the collar part from the trunk part can be reduced.
- a bobbin for an electric device of the present invention it is possible to manufacture an electric device bobbin having a high wire area ratio, excellent heat dissipation, and high bonding strength.
- Sectional drawing which shows the state which fitted the bobbin for electrical devices by 1st Embodiment to the stator core
- the schematic which looked at the state which fitted the bobbin for electric devices by 1st Embodiment to the stator core from the center side of the stator core Sectional view along line III-III in Fig. 1 Sectional view along line IV-IV in FIG. Sectional drawing which expands and shows the principal part of the bobbin for electric devices by 1st Embodiment shown in FIG.
- the figure equivalent to FIG. 1 which shows the state before fitting the bobbin for electrical devices by 1st Embodiment to a stator core.
- the schematic perspective view which shows the bobbin for electric devices by 1st Embodiment.
- FIG. 11 which shows the bobbin for electric devices by 3rd Embodiment.
- FIG. 16 which shows the bobbin for electric devices by 4th Embodiment.
- Sectional view along line XIX-XIX in FIG. Schematic which shows the manufacturing process of the bobbin for electric devices by 5th Embodiment
- FIG. 21 which shows the bobbin for electric devices by 7th Embodiment.
- the figure equivalent to FIG. 21 which shows the bobbin for electric devices by 8th Embodiment.
- the figure corresponding to FIG. 5 which shows the bobbin for electric devices by 9th Embodiment. Schematic which shows the bobbin for electric devices by 10th Embodiment.
- the bobbin for electric equipment according to the first embodiment is applied to a rotating electric machine used as a motor and a generator in a hybrid vehicle or an electric vehicle.
- the bobbin for electrical equipment is not limited to the rotating electrical machine of this vehicle, but may be applied to other electrical equipment such as a transformer or an inverter.
- 1 to 4 show a part of the inner rotor type rotating electrical machine 11 in an enlarged manner.
- the rotating electrical machine 11 includes a stator 12 and a rotor 13 as shown in FIG.
- the rotor 13 is provided on the inner peripheral side of the stator 12 with a predetermined gap therebetween.
- the rotor 13 has a rotor core 14 and a permanent magnet (not shown).
- the permanent magnet is embedded in the rotor core 14.
- the rotor core 14 is formed in a cylindrical shape, and a shaft (not shown) is provided on the inner peripheral side.
- the stator 12 has a stator core 15 and a coil 16.
- the stator core 15 has a yoke portion 17 and a plurality of teeth portions 18.
- the yoke portion 17 is formed in a cylindrical shape.
- the teeth part 18 protrudes from the inner peripheral end of the yoke part 17 toward the central axis.
- FIG. 1 shows only one tooth portion 18 among the plurality of tooth portions 18.
- the yoke portion 17 may employ various shapes of outer walls such as an ellipse and a polygon instead of a complete cylindrical outer wall.
- the teeth portion 18 is formed in a substantially rectangular parallelepiped shape as shown in FIGS.
- the teeth 18 are arranged at equal intervals in the circumferential direction of the stator core 15. As a result, a slot 15a is formed between the adjacent tooth portions 18 in the stator core 15 as shown in FIGS.
- the coil 16 is formed by winding an electric wire such as a copper wire around the outer peripheral side of the body portion 22 of the bobbin 21 for electrical equipment.
- an electric wire such as a copper wire around the outer peripheral side of the body portion 22 of the bobbin 21 for electrical equipment.
- the electric equipment bobbin 21 provided with the coil 16 is fitted into the tooth portion 18 from the inner peripheral side of the stator core 15.
- the coil 16 around which the electric wire is wound is provided on the tooth portion 18 with the body portion 22 of the bobbin 21 for electric equipment interposed therebetween.
- An arrow F shown in FIG. 6 is a direction in which the electric equipment bobbin 21 is fitted.
- the electrical equipment bobbin 21 has a body part 22, a first flange part 23, a second flange part 24, and an engaged part 25 as shown in FIGS.
- drum 22 is formed in the cylinder shape.
- the body portion 22 is formed in a rectangular tube shape.
- the trunk portion 22 is not limited to a rectangular tube shape, and can be arbitrarily set according to the shape of the tooth portion 18 such as a cylindrical shape or an elliptical cylindrical shape.
- the body 22 has an upper side wall 22a, a lower side wall 22b, a right side wall 22c, and a left side wall 22d.
- the upper side wall 22a, the lower side wall 22b, the right side wall 22c, and the left side wall 22d form a space 21a inside.
- the space 21 a substantially matches the shape of the tooth portion 18 and is set slightly larger than the tooth portion 18.
- the upper side wall 22a and the lower side wall 22b are positioned at axial ends of the stator core 15 when the electric equipment bobbin 21 is fitted to the tooth portion 18 as shown in FIGS. Further, the right side wall 22 c and the left side wall 22 d are located in the slot 15 a of the stator core 15 when the electric equipment bobbin 21 is fitted to the tooth portion 18.
- the body 22 including the upper side wall 22a, the lower side wall 22b, the right side wall 22c, and the left side wall 22d is formed of an insulating material such as an insulating film.
- This insulating film is a film having a known insulating property such as a film made of a general-purpose insulating material or a film made of a laminated insulating material.
- the insulating film include plastic films such as aramid paper such as Nomex (registered trademark) manufactured by Du Pont of the United States, polyphenylene sulfide film, polyimide film, polyether ether ketone film, and polyethylene terephthalate film.
- a laminated film obtained by laminating aramid paper and a plastic film is excellent in heat resistance, insulation, mechanical properties, and the like. Therefore, a laminated film obtained by laminating aramid paper and a plastic film can be suitably used as an insulating film that forms the body portion 22 of the bobbin 21 for an electric device.
- a laminated film in which an aramid paper and a polyphenylene sulfide film are laminated, and a laminated film in which an aramid paper and a polyimide film are laminated are more preferable as an insulating film for forming the body portion 22 of the bobbin 21 for an electric device. Further, as shown in FIG.
- the thickness T 1 of the insulating film forming the body portion 22 is set to 0.05 ⁇ 0.5 mm.
- the thickness T 1 of the insulating film forming the body portion 22 is preferably 0.1 ⁇ 0.4 mm, more preferably 0.2 ⁇ 0.3 mm.
- the thickness T 1 of the insulating film forming the body portion 22, the strength is insufficient with less than 0.05 mm. For this reason, when an electric wire is wound around the bobbin 21 for an electric device, problems such as deformation of the body portion 22 are likely to occur.
- the thickness T 1 of the insulating film forming the body portion 22 exceeds 0.5 mm, the thickness of the body portion 22 becomes excessive.
- the body portion 22 is integrally connected to the first flange portion 23 and the second flange portion 24.
- the electrical equipment bobbin 21 includes a plurality of engagement holes 22e.
- the engagement holes 22e are provided at both end portions in the axial direction of the body portion 22, respectively. As shown in FIGS. 5 and 7, the engagement hole 22 e penetrates the insulating film forming the body portion 22 in the thickness direction, that is, in the radial direction.
- the engagement hole 22e has a circular cross-sectional shape, for example.
- the surface of the insulating film forming the barrel 22 is subjected to surface treatment.
- the surface of the insulating film forming the body is subjected to, for example, plasma treatment, corona treatment, chemical treatment, or the like. These processes may be only one type or a combination of a plurality of processes.
- the surface of the insulating film is modified in properties such as hydrophilicity. Therefore, for example, the adhesion of the surface of the insulating film is improved as the wettability is improved.
- the body portion 22 forming the insulating film, the first flange portion 23, and the second flange portion 24 are more firmly bonded.
- plasma treatment is particularly preferable in order to enhance effects such as ease of treatment and wettability. In this specification, plasma processing will be described as an example.
- the 1st collar part 23 and the 2nd collar part 24 regulate the movement of the coil 16 provided in the trunk
- the coil 16 provided in the trunk portion 22 is displaced in the radial direction of the stator core 15. Therefore, the first flange portion 23 and the second flange portion 24 are in contact with the coil 16 at the end portion in the axial direction of the body portion 22 and restrict the movement of the coil 16.
- Both the first collar part 23 and the second collar part 24 are formed in an annular shape that protrudes radially outward from the body part 22. That is, as for the 1st collar part 23, the edge part of the inner peripheral side has opposed the trunk
- the first flange portion 23 is provided at one end portion in the axial direction of the trunk portion 22. Specifically, the first flange portion 23 is located on the side of the stator core 15 that faces the yoke portion 17 when the electric equipment bobbin 21 is fitted to the tooth portion 18.
- the first flange 23 has a plurality of engaged portions 25 on the inner peripheral side. The engaged portion 25 enters the engagement hole 22e formed by the body portion 22 when the first flange portion 23 is attached to the body portion 22.
- the engaged portion 25 is formed in a columnar shape corresponding to the engaging hole 22e.
- the engaged portion 25 can be changed in shape according to the shape of the engagement hole 22e. For example, when the cross section of the engagement hole 22e is a square shape, the engaged portion 25 is formed in a quadrangular prism shape.
- the second collar part 24 has an inner peripheral edge facing the body part 22 in the same manner as the first collar part 23.
- the second flange 24 is provided at the other end in the axial direction of the body 22, that is, at the end opposite to the first flange 23.
- the second flange portion 24 is located on the center side of the stator core 15 when the electric device bobbin 21 is fitted to the tooth portion 18.
- the second flange portion 24 is set so that the total length in the circumferential direction of the stator core 15 is smaller than that of the first flange portion 23. This is because the second flange portion 24 is located closer to the center side of the stator core 15 than the first flange portion 23.
- the electric equipment bobbin 21 is fitted to the teeth portion 18 formed radially with respect to the center of the stator core 15. Therefore, the interval between the bobbins 21 for electric equipment adjacent in the circumferential direction of the stator core 15 is smaller toward the center side of the stator core 15, that is, the second flange portion 24 side.
- the second collar part 24 is set to have a smaller overall length in the circumferential direction of the stator core 15 than the first collar part 23 so that the second collar parts 24 of the adjacent bobbins 21 for electrical equipment do not contact each other. Yes.
- the second collar part 24 Similar to the first collar part 23, the second collar part 24 has a plurality of engaged parts 25 on the inner peripheral side. The engaged portion 25 enters the engagement hole 22 e formed by the body portion 22 when the second flange portion 24 is attached to the body portion 22.
- the shape of the engaged portion 25 of the second flange 24 is the same as that of the first flange 23.
- the surface of the second flange portion 24 on the rotor 13 side may be curved concentrically with the outer wall of the rotor 13. Further, the surface of the first flange portion 23 on the side of the yoke portion 17 may be curved concentrically with the inner wall of the yoke portion 17. In particular, since the surface of the first flange portion 23 on the side of the yoke portion 17 and the inner wall of the yoke portion 17 have an approximate curvature, the end portion on the yoke portion 17 side of the bobbin 21 for electric equipment is formed by the inner wall of the yoke portion 17. The position is determined.
- the 1st collar part 23, the 2nd collar part 24, and the to-be-engaged part 25 are formed with the synthetic resin.
- the synthetic resin for example, polyphenylene sulfide resin (PPS resin), acrylonitrile-butadiene-styrene copolymer resin, polyimide resin, polyethylene terephthalate resin, polyacetal resin, and the like are preferable.
- the first flange portion 23, the second flange portion 24, and the engaged portion 25 are formed integrally with the body portion 22 by, for example, insert molding.
- the thickness of the 1st collar part 23 and the 2nd collar part 24 is arbitrary.
- the first flange portion 23 and the second flange portion 24 is set the the second thickness T 2 as shown in FIG. 14 to 2 ⁇ 3 mm.
- the thickness T 2 of the first flange portion 23 and the second flange portion 24 is preferably set as small as possible within a range capable of forming.
- the engaged portion 25 is filled in the engagement hole 22e of the body portion 22 simultaneously with the formation of the first flange portion 23 and the second flange portion 24. Thereby, the engaged portion 25 is formed integrally with the first flange portion 23 and the second flange portion 24, respectively. In this way, the engaged portions of the first flange portion 23 and the second flange portion 24 are filled by filling the engaged portion 25 into the engagement hole 22e simultaneously with the formation of the first flange portion 23 and the second flange portion 24. 25 enters the engagement hole 22e and is engaged. As a result, the first flange portion 23 and the second flange portion 24 and the body portion 22 can be firmly connected.
- the electrical equipment bobbin 21 includes a filling member 26 as shown in FIG.
- the filling member 26 is formed between the body portion 22, the first flange portion 23, and the second flange portion 24 on the inner peripheral side of the barrel portion 22, the inner periphery side of the first flange portion 23, and the inner periphery side of the second flange portion 24. Fill the gap between them.
- the filling member 26 is desirably formed of a material having excellent thermal conductivity.
- the filling member 26 is desirably a material whose fluidity increases as the temperature rises, such as a thermoplastic resin or grease.
- An insert molding die 31 shown in FIG. 12 includes a base portion 32, a lower die 33, and an upper die 34.
- the lower mold 33 is provided above the base portion 32.
- the upper mold 34 is provided above the lower mold 33.
- the base portion 32 holds the lower die 33 and the upper die 34.
- the base part 32 has a block part 35 for determining the position of the body part 22 of the bobbin 21 for electric equipment.
- the block portion 35 has a quadrangular prism shape that is substantially the same shape as the tooth portion 18 of the stator core 15.
- the base portion 32 has a plurality of protruding pins 36 that protrude upward. The protruding pin 36 is for removing the bobbin 21 for electric equipment formed from the lower mold 33.
- the lower mold 33 is composed of a pair of block-shaped movable lower molds 37.
- the pair of movable lower molds 37 is provided above the base part 32 and moves along the upper surface of the base part 32 to open the mold.
- An arrow Y shown in FIG. 12 indicates the direction in which the mold opens.
- the movable lower die 37 has a notch 38 ′ corresponding to the shape of almost half of the electric equipment bobbin 21.
- the pair of movable lower dies 37 are combined to form a cavity 38 that houses the bobbin 21 for an electric device.
- a nozzle 39 that connects the movable lower mold 37 and the cavity 38 is provided above the movable lower mold 37.
- the nozzle 39 supplies, for example, molten resin such as PPS to the cavity 38.
- the first brim part 23 and the second brim part 24 are formed by the resin supplied from the nozzle 39.
- the upper die 34 has a spool runner 40 penetrating vertically.
- the molten resin is supplied to the nozzle 39 of the lower mold 33 via the spool runner 40 of the upper mold 34.
- a storage portion 41 connected to the spool runner 40 is formed at the upper end of the upper die 34.
- the molten resin supplied from the outside is stored in the storage unit 41.
- the plasma treatment is performed using a discharge generated by applying a direct current or alternating current high voltage between the electrodes.
- the discharge generated by the application of a high voltage is a corona discharge at atmospheric pressure or a glow discharge in vacuum.
- the insulating film forming the body portion 22 is subjected to plasma treatment by being exposed to the electric discharge generated thereby.
- the plasma treatment is preferably a vacuum treatment with a wide selection range of treatment gases.
- helium, neon, argon, nitrogen, oxygen, carbon dioxide gas, air, water vapor, or the like is used alone or in a mixed state as a treatment gas. Of these, argon and carbon dioxide are preferable from the viewpoint of discharge starting efficiency.
- the treatment pressure in the plasma treatment is in a pressure range of 0.1 Pa to 1330 Pa, and more preferably in a range of 1 Pa to 266 Pa.
- the 13 has a process chamber 52 that can be sealed.
- the processing chamber 52 accommodates a processing roller 53 therein.
- the electrode 54 surrounds the processing roller 53 by forming a slight gap.
- the processing roller 53 is grounded.
- the electrode 54 is connected to a high frequency power supply 55.
- the processing chamber 52 is decompressed by opening a valve 56 connected to a vacuum pump (not shown).
- the processing chamber 52 is supplied with processing gas by opening a valve 57 connected to a gas supply source (not shown).
- the processing chamber 52 is provided with a pressure gauge 58 for detecting the internal pressure.
- the insulating film 42 wound in a roll shape is drawn out from the supply unit 59.
- the drawn insulating film 42 is wound around the processing roller 53 while being guided by a plurality of guide rollers 60 in the processing chamber 52.
- the insulating film 42 passes through the processing portion between the insulating film 42 and the plasma processing.
- the insulating film 42 that has been subjected to the plasma treatment is wound around the winding portion 61 while being guided by the guide roller 60.
- the insulating film 42 is subjected to plasma treatment on one side or both sides.
- the surface subjected to the plasma processing is disposed on the outer peripheral side of the body portion 22.
- the insulating film 42 constituting the body portion 22 is subjected to a surface treatment process.
- the surface treatment process is, for example, plasma treatment using the above-described plasma treatment machine 51.
- the plasma-treated film-like insulating film 42 is cut into a shape in which the body portion 22 is developed, that is, a rectangular shape.
- the length P of the long side of the insulating film 42 after cutting is the length in the horizontal direction of the upper side wall 22a, the length in the vertical direction of the left side wall 22d, the length in the horizontal direction of the lower side wall 22b, and the vertical length of the right side wall 22c.
- the length Q of the short side after cutting corresponds to the length in the front-rear direction of the body portion 22 and the length in the front-rear direction of the upper side wall 22a.
- the thickness of the insulating film 42 is set to 0.05 to 0.5 mm.
- the insulating film 42 is formed with holes corresponding to the engagement holes 22e at both ends of the long side when the body 22 is formed into a developed shape or before and after the forming.
- the engaging hole 22e may be formed after the insulating film 42 is formed into a predetermined shape, or the insulating film 42 may be formed after the engaging hole 22e is formed in advance. Further, the insulating film 42 and the engagement hole 22e may be formed simultaneously by a punching press using a mold.
- the formed insulating film 42 is formed into a shape corresponding to the body 22 as shown in FIG.
- the insulating film 42 is formed in a rectangular tube shape.
- the insulating film 42 bent into a rectangular tube shape has an adhesive margin portion located on the upper side wall 22a or the lower side wall 22b.
- an adhesive or the like may be applied to the glue margin, and the insulating film 42 may be temporarily fixed before insert molding. As a result, the molded insulating film 42 is less likely to lose its shape during insert molding.
- the process of forming the insulating film 42, forming the engagement hole 22e, and forming the body shape corresponds to a body shaping process.
- the insulating film 42 formed into a cylindrical shape is blocked in a state where the lower mold 33 is opened, that is, the movable lower mold 37 is separated from each other. It is inserted into the part 35.
- the process of fitting the insulating film 42 into the block part 35 of the lower mold 33 corresponds to a trunk part arranging step.
- the insulating film 42 formed into a cylindrical shape is slightly separated from the base portion 32 when fitted into the block portion 35.
- the strength of the end portion in the axial direction of the body portion 22 is increased.
- the movable lower mold 37 is combined to form a cavity 38 as shown in FIG. Thereby, the cylindrical insulating film 42 is accommodated in the cavity 38. This process corresponds to a lower mold fixing process.
- the upper die 34 is attached to the upper surface of the lower die 33 as shown in FIG. Then, the molten resin is injected into the storage portion 41 of the upper mold 34.
- the resin injected into the storage unit 41 is supplied to the cavity 38 via the spool runner 40 and the nozzle 39.
- insert molding is performed using the insulating film 42 formed into a cylindrical shape, that is, the barrel portion 22 as an insert, and the barrel portion 22 is integrated with the first flange portion 23, the second flange portion 24, and the engaged portion 25. To be molded.
- the first flange portion 23, the second flange portion 24, and the engaged portion 25 are formed integrally with the barrel portion 22 using the barrel portion 22 as an insert.
- This process corresponds to a buttocks molding process.
- the engaged portion 25 formed by resin injection enters the engaging hole 22e of the body portion 22. Therefore, the engaged portion 25 integrally protruding from the first flange portion 23 and the second flange portion 24 is in a state of being engaged with the engagement hole 22e.
- the surface of the body portion 22 is improved in wettability and adhesiveness by applying a surface treatment such as plasma treatment to the insulating film in advance. Therefore, the molten resin forming the first flange portion 23 and the second flange portion 24 is ensured to have fluidity along the insulating film 42. As a result, the resin forming the first flange portion 23 and the second flange portion 24 adheres to the body portion 22 in a sufficient range. Thereby, the trunk
- the upper die 34 is removed from the lower die 33.
- the movable lower mold 37 of the lower mold 33 opens the mold.
- the protruding pin 36 of the base portion 32 protrudes from the base portion 32, whereby the electric equipment bobbin 21 is removed from the base portion 32.
- the surface treatment process such as the plasma treatment is performed before the trunk shaping process is described, but after the trunk shaping process is performed, the hip molding process is performed.
- a surface treatment step may be performed before.
- the surface treatment may be performed on the insulating film 42 after the insulating film 42 is formed into a predetermined size.
- FIG. 11 In the electric equipment bobbin 21 shown in FIG. 11 obtained by the above-described processing, an electric wire is wound around the outer periphery of the trunk portion 22. Thereby, as for the bobbin 21 for electric equipments, the coil 16 is provided in the outer periphery of the trunk
- the electric machine bobbin 21 provided with the coil 16 and filled with the filling member 26 is fitted into the tooth portion 18 of the stator core 15 from the inner peripheral side of the stator core 15 as indicated by an arrow F in FIG. Thereby, the coil 16 is in a state of being concentratedly wound around the teeth portion 18 with the bobbin 21 for electric equipment interposed therebetween.
- the tooth portion 18 is accommodated inside the right side wall 22c and the left side wall 22d of the body portion 22.
- the upper side wall 22 a and the lower side wall 22 b of the body part 22 are located outside the full length of the tooth part 18 in the axial direction of the stator core 15.
- the space between the body portion 22 and the tooth portion 18 is filled with a filling member 26.
- the stator core 15 is attached with an electric equipment bobbin 21 in which the coils 16 are provided in all the teeth portions 18.
- the line product ratio of the electric wire will be described with reference to FIG.
- the body portion 102, the first flange portion 103, and the second flange portion 104 are integrally formed of the same resin and seamlessly by, for example, injection molding.
- drum 22 of 1st Embodiment is thin compared with the conventional trunk
- the coil 16 using the electric machine bobbin 21 of the first embodiment has a higher magnetic flux density than the conventional one. Therefore, the electrical equipment bobbin 21 of the first embodiment can improve the rotational efficiency of the rotating electrical machine 11 from the viewpoint of magnetic flux density.
- the body portion 22 of the bobbin 21 for electric equipment fitted to the teeth portion 18 of the stator core 15 has the thickness of the right side wall 22c and the left side wall 22d of 0.05-0. It is composed of a 5 mm insulating film. Therefore, the thickness of the right side wall 22c and the left side wall 22d of the trunk portion 22 is thinner than a bobbin formed by conventional insert molding. Therefore, more electric wires can be wound around the body portion 22 of the bobbin 21 for electric equipment, and the line area ratio of the electric wires can be increased. Further, since the body portion 22 becomes thin, heat generated from the electric wire is easily transmitted to the stator core 15 via the thin body portion 22. Therefore, the heat generated in the electric wire can be quickly diffused, and the heat dissipation can be improved. By increasing the heat dissipation, the rotating electrical machine 11 can achieve higher output and higher efficiency.
- the bobbin 21 for an electric device according to the first embodiment has an engagement hole 22e at the end of the body portion 22 in the axial direction.
- the to-be-engaged part 25 has approached into the engagement hole 22e, respectively.
- drum 22 and the 2nd collar part 24 are joined by high intensity
- the first collar part 23 and the second collar part 24 are insert-molded with the body part 22 as an insert. Therefore, even when the body part 22, the first collar part 23, and the second collar part 24 are formed of different materials, manufacturing can be facilitated. At the same time, the first collar 23 and the second collar 24 are sufficiently thickened by insert molding. Therefore, the strength of the first collar part 23 and the second collar part 24 can be increased. Further, the body portion 22 is integrally joined to the first flange portion 23 and the second flange portion 24. Therefore, even when these are formed of different materials, the bobbin 21 for electrical equipment can be easily attached to components such as the stator core 15.
- a filling member 26 is provided on the inner peripheral side of the body portion 22.
- the filling member 26 fills a step between the trunk portion 22 and the first and second collar portions 23 and 24.
- a surface treatment for improving wettability is performed on the surface of the insulating material before performing the trunk shaping process or after performing the trunk shaping process and before performing the hip molding process. ing.
- the molten resin which forms the 1st collar part 23 and the 2nd collar part 24 becomes easy to flow along the insulating material which forms the trunk
- high adhesiveness is ensured with the resin which forms the 1st collar part 23 and the 2nd collar part 24, and the insulating material which forms the trunk
- the principal part of the bobbin 21 for electric equipment by 2nd Embodiment is shown in FIG.
- the 1st collar part 23 and the 2nd collar part 24 have a substantially symmetrical structure. Therefore, in FIG. 15, the periphery of the first collar part 23 is illustrated, and illustration and description of the second collar part 24 are omitted.
- the 1st collar part 23 has a pair of clamping piece 23a, as shown in FIG.
- the pair of sandwiching pieces 23 a is provided at a position sandwiching the body portion 22 in the thickness direction of the body portion 22.
- the sandwiching piece 23 a is integrally formed with the same resin as that of the first flange 23 simultaneously with the first flange 23.
- One of the pair of sandwiching pieces 23 a is located on the inner side in the radial direction of the body portion 22.
- the other of the sandwiching pieces 23 a is located outside in the radial direction of the body portion 22.
- both ends of the engagement hole 22e are opposed to the pair of sandwiching pieces 23a in the radial direction of the body portion 22. That is, one end of the engagement hole 22e is opposed to the inner circumferential side sandwiching piece 23a, and the other end is opposed to the outer circumferential side sandwiching piece 23a.
- the engaged portion 25 protruding from the first flange 23 connects the pair of sandwich pieces 23 a in the radial direction of the body portion 22. That is, the engaged portion 25 penetrates the engagement hole 22 e and connects the pair of sandwiching pieces 23 a to each other in the radial direction of the trunk portion 22. Both ends of the engaged portion 25 are formed integrally with the sandwiching piece 23a.
- the molten resin that becomes the first flange portion 23 forms the pinching piece 23a, and part of the resin enters the engagement hole 22e to form the engaged portion 25. To do. Thereby, the 1st collar part 23 forms the pinching piece 23a and the to-be-engaged part 25 integrally with resin.
- the body portion 22 is fixed to the first flange portion 23 at a plurality of positions in the circumferential direction by the integral clip piece 23a and the engaged portion 25. Accordingly, the bonding strength between the body portion 22 and the first flange portion 23 can be further increased.
- the 2nd collar part 24 is the structure similar to the 1st collar part 23. FIG. Therefore, the second flange 24 can be firmly joined to the body 22 in the same manner as the first flange 23.
- FIGS. 16 and 17 an electric equipment bobbin 71 according to a third embodiment is shown in FIGS. 16 and 17.
- the bobbin 71 for electric equipment shown in FIG. 16 and FIG. 17 is provided with a connecting portion 72 for reinforcement.
- the connecting portion 72 is a side wall that connects the first flange portion 23 and the second flange portion 24.
- the connecting portion 72 is provided integrally with the first flange portion 23 and the second flange portion 24.
- the connecting portion 72 is provided on each of the upper side, which is the outer peripheral side of the upper side wall 22a, and the lower side, which is the outer peripheral side of the lower side wall 22b.
- the bobbin 71 for electrical equipment is insert-molded with the body portion 22 as an insert as in the first embodiment.
- the connecting portion 72 is formed integrally with the first flange portion 23 and the second flange portion 24 during the insert molding.
- the thickness of the connecting portion 72 is arbitrarily set within a range that can be formed by insert molding.
- the thickness of the connecting portion 72 is set to 1 to 3 mm, for example.
- the connecting portion 72 is provided between the first flange portion 23 and the second flange portion 24.
- the connecting portion 72 has a thickness larger than that of the trunk portion 22. For this reason, the strength of the body portion 22 against compression in the axial direction increases. Thereby, the deformation
- the connection part 72 is provided in the outer side of the upper side wall 22a and the lower side wall 22b, respectively.
- drum 22 the right side wall 22c and the left side wall 22d are formed with the insulating film. Therefore, even if the connecting portion 72 is provided, the number of turns of the electric wire constituting the coil 16 is not affected. Therefore, the line area ratio of the electric wire can be increased while increasing the strength.
- FIGS. 18 and 19 show an electric equipment bobbin 81 according to the fourth embodiment.
- the bobbin 81 for electric equipment shown in FIGS. 18 and 19 is provided with a connecting portion 82 for reinforcement.
- the connecting portion 82 is a side wall that connects the first flange portion 23 and the second flange portion 24.
- the connecting portion 82 is provided integrally with the first flange portion 23 and the second flange portion 24.
- the connecting portions 82 are respectively provided on the lower side, which is the inner peripheral side of the upper side wall 22a, and the upper side, which is the inner peripheral side of the lower side wall 22b.
- the bobbin 81 for electric equipment is insert-molded by using the body portion 22 as an insert as in the first embodiment.
- the connecting portion 82 is formed integrally with the first flange portion 23 and the second flange portion 24 during the insert molding.
- the thickness of the connecting portion 62 is arbitrarily set within a range that can be formed by insert molding.
- the thickness of the connecting portion 82 is set to 1 to 3 mm, for example.
- the fourth embodiment can also increase the strength of the bobbin 81 for electric equipment while increasing the line area ratio of the electric wires.
- FIG. 20 (Fifth embodiment) An electric equipment bobbin 91 according to the fifth embodiment is shown in FIG.
- the bobbin 91 for electrical equipment according to the fifth embodiment is press-molded instead of the insert molding in the above-described plurality of embodiments.
- both end portions in the axial direction are bent outward.
- drum 22 has the flange part 22f in the both ends of an axial direction.
- the engagement hole 22e is disposed in the flange portion 22f.
- the 1st collar part 23 and the 2nd collar part 24 are both 2 layer structures.
- the first collar 23 has two first collar parts 23b and an adhesive member 92.
- the first flange portion 23b is formed by dividing the thickness of the first flange portion 23 into two equal parts.
- the adhesive member 92 bonds the first flange part 23b and the body part 22 together.
- the adhesive member 92 is formed in a frame shape having the same shape as the first flange 23, for example.
- the adhesive member 92 is formed of an adhesive sheet having adhesiveness on both sides.
- the first flange portion 23 is formed by laminating the first flange portion 23b, the adhesive member 92, the flange portion 22f of the body portion 22, the adhesive member 92, and the first flange portion piece 23b. It is provided integrally with the body portion 22. At this time, the engagement hole 22e is disposed between the two first flange portions 23b.
- the second collar part 24 has two second collar parts 24 b and an adhesive member 92.
- the second flange part 24 b is formed by dividing the thickness of the second flange part 24 into two equal parts.
- the bonding member 92 bonds the second flange part 24b and the body part 22 together.
- the adhesive member 92 is formed of an adhesive sheet having adhesiveness on both sides, and is formed in a frame shape having the same shape as the second flange portion 24.
- the second flange portion 24 is formed by laminating the second flange portion piece 24b, the adhesive member 92, the flange portion 22f of the body portion 22, the adhesive member 92, and the second flange portion piece 24b, It is provided integrally with the body portion 22.
- the engagement hole 22e is disposed between the two second flange pieces 24b.
- the two first flange parts 23b correspond to sandwiching pieces.
- the two second flange parts 24b correspond to sandwiching pieces.
- the surface of the insulating film 42 constituting the body portion 22 is subjected to surface treatment such as plasma treatment.
- the step of performing the surface treatment corresponds to the surface treatment step.
- the details of the surface treatment are as described in the first embodiment, and a description thereof will be omitted.
- the insulating film 42 is formed into a rectangular shape in which the body portion 22 is developed as shown in FIG.
- the insulating film 42 may form a cut portion 42a on the long side as shown in FIG. By forming the cut portion 42a, it becomes easy to bend in a later step.
- the timing for performing the surface treatment is not limited as in the first embodiment.
- the formed insulating film 42 is bent into a rectangular tube shape as shown in FIG. Further, the formed insulating film 42 is bent at both ends in the axial direction to the outer peripheral side. Thereby, the flange part 22f is formed.
- This process corresponds to a trunk shaping process.
- the body part 22 formed in the body part shaping process shifts to the hip part forming process.
- the flange portion 22f of the body portion 22 is provided with a first flange portion 23b, a second flange portion piece 24b, and an adhesive member 92. Laminated in order. Thereafter, the laminated members are formed into the first collar part 23 and the second collar part 24 by press molding.
- the first flange 23 is in the order of the first flange part 23b, the adhesive member 92, the flange part 22f of the trunk part 22, the adhesive member 92, and the first flange part 23b from the axial end of the body part 22. After being laminated, it is press-molded. Thereby, the adhesive member 92 adheres each member.
- the second flange 24 includes the second flange 24b, the adhesive member 92, the flange 22f of the barrel 22, the adhesive member 92, and the second flange 24b from the end of the barrel 22 in the axial direction. After being laminated in this order, it is press-molded. Thereby, the adhesive member 92 adheres each member.
- the obtained electrical equipment bobbin 91 is fitted into the teeth portion 18 of the stator core 15 shown in FIG. 1 in the same manner as the electrical equipment bobbin 21 of the first embodiment. Thereby, the insulating film of the trunk
- the thickness of the body portion 22 is reduced as in the first embodiment. Therefore, more electric wires than the coil 16 are wound around the bobbin 91 for electric equipment. Therefore, high output and high efficiency of the rotating electrical machine can be achieved. Moreover, in 5th Embodiment, it replaces with insert molding and the 1st collar part 23 and the 2nd collar part 24 can be integrally formed in the trunk
- the engagement hole 22g has a square cross section.
- the engagement hole 22h has a triangular cross section.
- a part of the engagement hole 22 i is opened at the outer edge of the insulating film 42.
- the bobbin 21 for an electric device does not include a filling member on the inner peripheral side of the trunk portion 22.
- the filling member 26 may be omitted as shown in the ninth embodiment.
- the bobbin 21 for an electric device may divide the body portion 22, the first flange portion 23, and the second flange portion 24 into two. Thereby, the bobbin 21 for electric equipment can pinch
- FIG. The electric equipment bobbin 21 may be divided into two or more, and the division position is not limited to the above and can be arbitrarily set.
- the present invention is not limited to the embodiment described above and shown in the drawings, and the following modifications and expansions are possible.
- drum 22 demonstrated the example which comprises the upper side wall 22a, the lower side wall 22b, the right side wall 22c, and the left side wall 22d with the insulating film.
- the body 22 has at least the right side wall 22c and the left side wall 22d made of an insulating film.
- the upper side wall 22 a and the lower side wall 22 b may be formed integrally with the first flange portion 23 and the second flange portion 24 with the same material as the first flange portion 23 and the second flange portion 24.
- connection part 72 in the third embodiment and the connection part 82 in the fourth embodiment have been described as being formed in a wall shape.
- the shape of the connecting portion 72 and the connecting portion 82 can be arbitrarily set, for example, formed in a plurality of columnar shapes.
- the adhesive member 92 in the fifth embodiment has been described by taking an adhesive sheet as an example.
- the adhesive member 92 is not limited to an adhesive sheet, and may be an adhesive having general fluidity.
- the surface treatment in the plurality of embodiments has been described by taking the plasma treatment as an example, but is not limited thereto, and may be a corona treatment or a chemical treatment.
- the embodiment described above is merely an example, and the material and thickness of the insulating film are determined as appropriate depending on the use of the bobbin for each electric device, and other materials, shapes, positions of connecting portions, etc. can be changed as appropriate. it can.
- the bobbin for electric equipment can be applied not only to electric equipment such as a transformer and an inverter but also to an outer rotor type rotating electrical machine.
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Abstract
Disclosed is a bobbin for electrical equipment, provided with a body portion, jaw portions, and engagement holes. The body portion is composed of an insulation film, and has a cylindrical shape. The jaw portions are respectively provided on both axial ends of the body portion, and the body portion is fitted in the inner peripheral portions of the jaw portions. The jaw portions are composed of a material different from the material of the body portion, and are annularly projected from the body portion toward the outside in the radial direction. The engagement holes are respectively provided on both axial ends of the body portion, and penetrate through the body portion in the thickness direction. The inner peripheral-side portion of each jaw portion, which is opposite to the body portion, is inserted in each engagement hole.
Description
本発明は、電気モータ、発電機、変圧器およびインバータなどの電気機器に用いられる電気機器用ボビンおよびその製造方法に関する。
The present invention relates to a bobbin for an electric device used for an electric device such as an electric motor, a generator, a transformer, and an inverter, and a manufacturing method thereof.
一般に、電気モータ、発電機、変圧器およびインバータなどに用いられる電気機器用ボビンは、丸型または角型の筒状をなす胴部と、胴部の軸方向両端部のそれぞれに設けられた鍔部とを備えている。胴部および鍔部は、通常合成樹脂製であり、例えば特許文献1に示すように射出成形によって一体に成形されている。このように胴部および鍔部を射出成形により一体に成形された電気機器用ボビンは、胴部の厚さが通常2~3mmと厚いため、電線の密度、いわゆる線積率を高めることは困難である。
In general, bobbins for electrical equipment used for electric motors, generators, transformers, inverters, etc. are provided on each of a cylindrical body having a round shape or a square shape, and both axial ends of the body. Department. The trunk portion and the collar portion are usually made of synthetic resin, and are integrally formed by injection molding as shown in Patent Document 1, for example. In such a bobbin for an electric device in which the body part and the collar part are integrally formed by injection molding, the thickness of the body part is usually as thick as 2 to 3 mm. It is.
胴部を薄くした構成としては、例えば特許文献2に開示されているものがある。特許文献2に開示されている電気機器用ボビンの胴部は、合成樹脂製の第1の保持部材と、非磁性体である薄膜体の第2保持部材とから構成されている。
For example, Patent Document 2 discloses a configuration in which the body portion is thinned. The body part of the bobbin for electric equipment disclosed in Patent Document 2 is composed of a first holding member made of synthetic resin and a second holding member of a thin film body which is a nonmagnetic material.
しかしながら、胴部を第1の保持部材と第2の保持部材との2つの部材から構成する場合、2つの部材の接合強度を確保する必要がある。これら2つの部材の接合が不十分であると、胴部に電線を巻くとき、あるいは電気機器用ボビンを固定子鉄心に装着するときなどに、第1保持部材は第2保持部材から外れやすいという問題がある。また、厚い第1の保持部材が胴部の一部を形成しているため、線積率の向上や熱伝導性の向上も難しいという問題がある。
However, when the body is composed of two members, the first holding member and the second holding member, it is necessary to ensure the bonding strength between the two members. If the joining of these two members is insufficient, the first holding member is likely to be detached from the second holding member when an electric wire is wound around the body portion or when a bobbin for an electric device is mounted on the stator core. There's a problem. Further, since the thick first holding member forms a part of the body portion, there is a problem that it is difficult to improve the line area ratio and the thermal conductivity.
そこで、本発明の目的は、電線の線積率が高く、放熱性に優れ、かつ部材の接合強度が高い電気機器用ボビンおよびその製造方法を提供することにある。
Therefore, an object of the present invention is to provide a bobbin for an electric device having a high line area ratio of electric wires, excellent heat dissipation, and high joint strength of members, and a manufacturing method thereof.
上記した目的を達成するために、本発明の電気機器用ボビンは、胴部、鍔部および係合孔を備える。胴部は、絶縁フィルムで筒状に形成されている。鍔部は、胴部の軸方向の両端部にそれぞれ設けられ、内周側に胴部が嵌め込まれ、胴部と異なる材料で形成され、胴部から径方向外側へ環状に突出している。係合孔は、胴部の軸方向の両端部にそれぞれ設けられ、胴部を厚さ方向に貫き、胴部と対向する鍔部の内周側が進入する。
In order to achieve the above-described object, the bobbin for an electric device according to the present invention includes a body portion, a flange portion, and an engagement hole. The trunk | drum is formed in the cylinder shape with the insulating film. The flanges are provided at both end portions in the axial direction of the body part, the body parts are fitted on the inner peripheral side, are formed of a material different from that of the body part, and project annularly from the body part radially outward. The engagement holes are respectively provided at both end portions in the axial direction of the body portion, penetrate the body portion in the thickness direction, and the inner peripheral side of the collar portion facing the body portion enters.
また、本発明の電気機器用ボビンの製造方法は、胴部を成形する工程、および鍔部を成形する工程を含んでいる。胴部を成形する工程では、厚さが0.05mm~0.5mmの絶縁材料は筒状の胴部に成形される。鍔部を成形する工程では、筒状に成形した胴部の軸方向の両端部に胴部よりも大きな外径で形成される。このとき、鍔部は、胴部と一体に形成される。
Further, the method for manufacturing a bobbin for an electric device according to the present invention includes a step of forming a body portion and a step of forming a collar portion. In the step of forming the body portion, an insulating material having a thickness of 0.05 mm to 0.5 mm is formed into a cylindrical body portion. In the step of forming the collar portion, it is formed at both end portions in the axial direction of the barrel portion molded into a cylindrical shape with an outer diameter larger than that of the barrel portion. At this time, the collar portion is formed integrally with the trunk portion.
本発明の電気機器用ボビンによれば、胴部と鍔部とが異なる材料で形成されている。また、胴部は、絶縁フィルムで形成されている。そのため、胴部の厚さの低減は容易である。したがって、単位断面積当たりの電線の巻数、すなわち電線の線積率を高めることができる。また、電線で発生した熱は、厚さの小さな絶縁フィルムを経由して、例えば固定子鉄心などに伝わる。したがって、電線の放熱性を高めることができる。さらに、鍔部は、胴部の係合孔に進入している。そのため、鍔部と胴部とは、係合孔において噛み合った状態となる。したがって、胴部と鍔部との接合強度を高めることができ、胴部からの鍔部の脱落を低減することができる。
According to the bobbin for electric equipment of the present invention, the body and the buttock are formed of different materials. Moreover, the trunk | drum is formed with the insulating film. Therefore, it is easy to reduce the thickness of the trunk portion. Therefore, the number of turns of the electric wire per unit cross-sectional area, that is, the line area ratio of the electric wire can be increased. Further, the heat generated in the electric wire is transmitted to, for example, a stator core through an insulating film having a small thickness. Therefore, the heat dissipation of an electric wire can be improved. Furthermore, the collar part has entered the engagement hole of the trunk part. Therefore, the collar part and the trunk part are in a state of being engaged with each other in the engagement hole. Therefore, the joint strength between the trunk part and the collar part can be increased, and the dropping of the collar part from the trunk part can be reduced.
本発明の電気機器用ボビンの製造方法によれば、電線の線積率が高く、放熱性に優れ、かつ接合強度が高い電気機器用ボビンを製造することができる。
According to the method for manufacturing a bobbin for an electric device of the present invention, it is possible to manufacture an electric device bobbin having a high wire area ratio, excellent heat dissipation, and high bonding strength.
以下、電気機器用ボビンの複数の実施形態を図面に基づいて説明する。なお、複数の実施形態において、同一の構成部位には同一の符号を付し、説明を省略する。
(第1実施形態)
まず、第1実施形態について、図1~図14を参照して説明する。図面には、前後、左右および上下の各方向を矢印で示している。本明細書中では、便宜上、回転電機の軸方向を上下方向として説明する。 Hereinafter, a plurality of embodiments of an electric equipment bobbin will be described with reference to the drawings. Note that, in a plurality of embodiments, the same components are denoted by the same reference numerals, and description thereof is omitted.
(First embodiment)
First, a first embodiment will be described with reference to FIGS. In the drawings, the front, rear, left and right and up and down directions are indicated by arrows. In the present specification, for the sake of convenience, the axial direction of the rotating electrical machine will be described as the vertical direction.
(第1実施形態)
まず、第1実施形態について、図1~図14を参照して説明する。図面には、前後、左右および上下の各方向を矢印で示している。本明細書中では、便宜上、回転電機の軸方向を上下方向として説明する。 Hereinafter, a plurality of embodiments of an electric equipment bobbin will be described with reference to the drawings. Note that, in a plurality of embodiments, the same components are denoted by the same reference numerals, and description thereof is omitted.
(First embodiment)
First, a first embodiment will be described with reference to FIGS. In the drawings, the front, rear, left and right and up and down directions are indicated by arrows. In the present specification, for the sake of convenience, the axial direction of the rotating electrical machine will be described as the vertical direction.
第1実施形態による電気機器用ボビンは、ハイブリッド自動車または電気自動車などにモータおよび発電機として用いられる回転電機に適用される。電気機器用ボビンは、この車両の回転電機に限らず、変圧器あるいはインバータなどの他の電気機器に適用してもよい。
図1~図4は、インナーロータ型の回転電機11の一部を拡大して示している。回転電機11は、図1に示すように固定子12および回転子13を備えている。回転子13は、固定子12の内周側に所定の隙間を挟んで設けられている。回転子13は、回転子鉄心14および図示しない永久磁石を有している。永久磁石は、回転子鉄心14に埋め込まれている。回転子鉄心14は、円筒形状に形成され、内周側には図示しないシャフトが設けられる。 The bobbin for electric equipment according to the first embodiment is applied to a rotating electric machine used as a motor and a generator in a hybrid vehicle or an electric vehicle. The bobbin for electrical equipment is not limited to the rotating electrical machine of this vehicle, but may be applied to other electrical equipment such as a transformer or an inverter.
1 to 4 show a part of the inner rotor type rotatingelectrical machine 11 in an enlarged manner. The rotating electrical machine 11 includes a stator 12 and a rotor 13 as shown in FIG. The rotor 13 is provided on the inner peripheral side of the stator 12 with a predetermined gap therebetween. The rotor 13 has a rotor core 14 and a permanent magnet (not shown). The permanent magnet is embedded in the rotor core 14. The rotor core 14 is formed in a cylindrical shape, and a shaft (not shown) is provided on the inner peripheral side.
図1~図4は、インナーロータ型の回転電機11の一部を拡大して示している。回転電機11は、図1に示すように固定子12および回転子13を備えている。回転子13は、固定子12の内周側に所定の隙間を挟んで設けられている。回転子13は、回転子鉄心14および図示しない永久磁石を有している。永久磁石は、回転子鉄心14に埋め込まれている。回転子鉄心14は、円筒形状に形成され、内周側には図示しないシャフトが設けられる。 The bobbin for electric equipment according to the first embodiment is applied to a rotating electric machine used as a motor and a generator in a hybrid vehicle or an electric vehicle. The bobbin for electrical equipment is not limited to the rotating electrical machine of this vehicle, but may be applied to other electrical equipment such as a transformer or an inverter.
1 to 4 show a part of the inner rotor type rotating
固定子12は、固定子鉄心15およびコイル16を有している。固定子鉄心15は、ヨーク部17および複数のティース部18を有している。ヨーク部17は、円筒状に形成されている。ティース部18は、ヨーク部17の内周側の端部から中心軸側へ突出する。図1は、複数のティース部18のうち1つのティース部18のみを示している。ヨーク部17は、完全な円筒状の外壁に代えて、楕円形や多角形などのさまざまな形状の外壁を採用してもよい。ティース部18は、図2~図4に示すように概ね直方体形状に形成されている。ティース部18は、固定子鉄心15の周方向へ等間隔に配置されている。これにより、固定子鉄心15において隣り合うティース部18の相互間には、図1、図5および図6に示すようにスロット15aが形成される。
The stator 12 has a stator core 15 and a coil 16. The stator core 15 has a yoke portion 17 and a plurality of teeth portions 18. The yoke portion 17 is formed in a cylindrical shape. The teeth part 18 protrudes from the inner peripheral end of the yoke part 17 toward the central axis. FIG. 1 shows only one tooth portion 18 among the plurality of tooth portions 18. The yoke portion 17 may employ various shapes of outer walls such as an ellipse and a polygon instead of a complete cylindrical outer wall. The teeth portion 18 is formed in a substantially rectangular parallelepiped shape as shown in FIGS. The teeth 18 are arranged at equal intervals in the circumferential direction of the stator core 15. As a result, a slot 15a is formed between the adjacent tooth portions 18 in the stator core 15 as shown in FIGS.
コイル16は、電気機器用ボビン21の胴部22の外周側に銅線などの電線を巻くことで形成されている。第1実施形態の場合、図6に示すようにコイル16が設けられた電気機器用ボビン21は、固定子鉄心15の内周側からティース部18に嵌め込まれる。これにより、電線が巻かれたコイル16は、電気機器用ボビン21の胴部22を挟んでティース部18に設けられる。図6に示す矢印Fは、電気機器用ボビン21を嵌め込む方向である。
The coil 16 is formed by winding an electric wire such as a copper wire around the outer peripheral side of the body portion 22 of the bobbin 21 for electrical equipment. In the case of the first embodiment, as shown in FIG. 6, the electric equipment bobbin 21 provided with the coil 16 is fitted into the tooth portion 18 from the inner peripheral side of the stator core 15. As a result, the coil 16 around which the electric wire is wound is provided on the tooth portion 18 with the body portion 22 of the bobbin 21 for electric equipment interposed therebetween. An arrow F shown in FIG. 6 is a direction in which the electric equipment bobbin 21 is fitted.
電気機器用ボビン21は、図1~図11に示すように胴部22、第一鍔部23、第二鍔部24および被係合部25を有している。胴部22は、筒状に形成されている。第1実施形態の場合、胴部22は、角筒状に形成されている。胴部22は、角筒状に限らず、円筒状や楕円筒状など、ティース部18の形状に合わせて任意に設定することができる。胴部22は、図7~図11に示すように上側壁22a、下側壁22b、右側壁22cおよび左側壁22dを有している。上側壁22a、下側壁22b、右側壁22cおよび左側壁22dは、内側に空間21aを形成している。この空間21aは、ティース部18の形状とほぼ一致し、ティース部18よりもわずかに大きく設定されている。上側壁22aおよび下側壁22bは、図2~図4に示すようにティース部18に電気機器用ボビン21を嵌めたとき、それぞれ固定子鉄心15の軸方向の端部に位置する。また、右側壁22cおよび左側壁22dは、ティース部18に電気機器用ボビン21を嵌めたとき、固定子鉄心15のスロット15a内に位置する。
The electrical equipment bobbin 21 has a body part 22, a first flange part 23, a second flange part 24, and an engaged part 25 as shown in FIGS. The trunk | drum 22 is formed in the cylinder shape. In the case of the first embodiment, the body portion 22 is formed in a rectangular tube shape. The trunk portion 22 is not limited to a rectangular tube shape, and can be arbitrarily set according to the shape of the tooth portion 18 such as a cylindrical shape or an elliptical cylindrical shape. As shown in FIGS. 7 to 11, the body 22 has an upper side wall 22a, a lower side wall 22b, a right side wall 22c, and a left side wall 22d. The upper side wall 22a, the lower side wall 22b, the right side wall 22c, and the left side wall 22d form a space 21a inside. The space 21 a substantially matches the shape of the tooth portion 18 and is set slightly larger than the tooth portion 18. The upper side wall 22a and the lower side wall 22b are positioned at axial ends of the stator core 15 when the electric equipment bobbin 21 is fitted to the tooth portion 18 as shown in FIGS. Further, the right side wall 22 c and the left side wall 22 d are located in the slot 15 a of the stator core 15 when the electric equipment bobbin 21 is fitted to the tooth portion 18.
ここで、上側壁22a、下側壁22b、右側壁22cおよび左側壁22dからなる胴部22は、例えば絶縁フィルムなどの絶縁材料で形成されている。この絶縁フィルムは、例えば汎用絶縁材からなるフィルムや積層絶縁材からなるフィルムなど、公知の絶縁性を有するフィルムである。絶縁フィルムとしては、例えば米国デュポン(Du Pont)社製のノーメックス(登録商標)などのアラミド紙、ポリフェニレンサルファイドフィルム、ポリイミドフィルム、ポリエーテルエーテルケトンフィルム、ポリエチレンテレフタレートフィルムなどのプラスチックフィルムが挙げられる。特に、アラミド紙とプラスチックフィルムとを積層した積層フィルムは、耐熱性、絶縁性、機械的特性などに優れている。そのため、アラミド紙とプラスチックフィルムとを積層した積層フィルムは、電気機器用ボビン21の胴部22を形成する絶縁フィルムとして好適に使用することができる。特にアラミド紙とポリフェニレンサルファイドフィルムとを積層した積層フィルム、およびアラミド紙とポリイミドフィルムとを積層した積層フィルムは、電気機器用ボビン21の胴部22を形成する絶縁フィルムとしてより好ましい。また、図14(a)に示すように、胴部22を形成する絶縁フィルムの厚さT1は、0.05~0.5mmに設定している。この胴部22を形成する絶縁フィルムの厚さT1は、好ましくは0.1~0.4mmであり、より好ましくは0.2~0.3mmである。胴部22を形成する絶縁フィルムの厚さT1は、0.05mm未満であると強度が不足する。そのため、電気機器用ボビン21に電線を巻いたとき、胴部22の変形を招くなどの不具合を生じやすくなる。一方、胴部22を形成する絶縁フィルムの厚さT1は、0.5mmを超えると、胴部22の厚さが過大となる。そのため、電線の巻数が減るため線積率が低下するとともに、熱伝導性の低下によって放熱性も低下する。胴部22は、第一鍔部23および第二鍔部24と一体に接続されている。
Here, the body 22 including the upper side wall 22a, the lower side wall 22b, the right side wall 22c, and the left side wall 22d is formed of an insulating material such as an insulating film. This insulating film is a film having a known insulating property such as a film made of a general-purpose insulating material or a film made of a laminated insulating material. Examples of the insulating film include plastic films such as aramid paper such as Nomex (registered trademark) manufactured by Du Pont of the United States, polyphenylene sulfide film, polyimide film, polyether ether ketone film, and polyethylene terephthalate film. In particular, a laminated film obtained by laminating aramid paper and a plastic film is excellent in heat resistance, insulation, mechanical properties, and the like. Therefore, a laminated film obtained by laminating aramid paper and a plastic film can be suitably used as an insulating film that forms the body portion 22 of the bobbin 21 for an electric device. In particular, a laminated film in which an aramid paper and a polyphenylene sulfide film are laminated, and a laminated film in which an aramid paper and a polyimide film are laminated are more preferable as an insulating film for forming the body portion 22 of the bobbin 21 for an electric device. Further, as shown in FIG. 14 (a), the thickness T 1 of the insulating film forming the body portion 22 is set to 0.05 ~ 0.5 mm. The thickness T 1 of the insulating film forming the body portion 22 is preferably 0.1 ~ 0.4 mm, more preferably 0.2 ~ 0.3 mm. The thickness T 1 of the insulating film forming the body portion 22, the strength is insufficient with less than 0.05 mm. For this reason, when an electric wire is wound around the bobbin 21 for an electric device, problems such as deformation of the body portion 22 are likely to occur. On the other hand, the thickness T 1 of the insulating film forming the body portion 22 exceeds 0.5 mm, the thickness of the body portion 22 becomes excessive. Therefore, since the number of turns of the electric wire is reduced, the line area ratio is lowered, and the heat dissipation is also lowered due to the decrease in thermal conductivity. The body portion 22 is integrally connected to the first flange portion 23 and the second flange portion 24.
電気機器用ボビン21は、複数の係合孔22eを備えている。具体的には、係合孔22eは、胴部22において軸方向の両側の端部にそれぞれ設けられている。係合孔22eは、図5および図7に示すように胴部22を形成する絶縁フィルムを厚さ方向、すなわち径方向に貫いている。係合孔22eは、例えば断面形状が円形である。
The electrical equipment bobbin 21 includes a plurality of engagement holes 22e. Specifically, the engagement holes 22e are provided at both end portions in the axial direction of the body portion 22, respectively. As shown in FIGS. 5 and 7, the engagement hole 22 e penetrates the insulating film forming the body portion 22 in the thickness direction, that is, in the radial direction. The engagement hole 22e has a circular cross-sectional shape, for example.
胴部22を形成する絶縁フィルムは、表面に表面処理が施されている。具体的には、胴部を形成する絶縁フィルムの表面は、例えばプラズマ処理、コロナ処理または化学処理などが施されている。これらの処理は、一種のみ、または複数の処理を組み合わせてもよい。胴部22を形成する絶縁フィルムに表面処理を施すことにより、絶縁フィルムの表面は親水性などの性質が改質される。そのため、例えば絶縁フィルムの表面は、濡れ性の向上にともない、接着性が向上する。その結果、絶縁フィルムを形成する胴部22と第一鍔部23および第二鍔部24とは、より強固に接合する。表面処理としては、処理の簡便さや濡れ性向上などの効果を高めるために、特にプラズマ処理が好ましい。本明細書中では、プラズマ処理を例に説明する。
The surface of the insulating film forming the barrel 22 is subjected to surface treatment. Specifically, the surface of the insulating film forming the body is subjected to, for example, plasma treatment, corona treatment, chemical treatment, or the like. These processes may be only one type or a combination of a plurality of processes. By subjecting the insulating film forming the body portion 22 to surface treatment, the surface of the insulating film is modified in properties such as hydrophilicity. Therefore, for example, the adhesion of the surface of the insulating film is improved as the wettability is improved. As a result, the body portion 22 forming the insulating film, the first flange portion 23, and the second flange portion 24 are more firmly bonded. As the surface treatment, plasma treatment is particularly preferable in order to enhance effects such as ease of treatment and wettability. In this specification, plasma processing will be described as an example.
第一鍔部23および第二鍔部24は、胴部22に設けられたコイル16の移動を規制する。具体的には、胴部22に設けられたコイル16は、固定子鉄心15の径方向にずれを生じる。そこで、第一鍔部23および第二鍔部24は、胴部22の軸方向の端部においてコイル16と接し、コイル16の移動を規制する。
The 1st collar part 23 and the 2nd collar part 24 regulate the movement of the coil 16 provided in the trunk | drum 22. Specifically, the coil 16 provided in the trunk portion 22 is displaced in the radial direction of the stator core 15. Therefore, the first flange portion 23 and the second flange portion 24 are in contact with the coil 16 at the end portion in the axial direction of the body portion 22 and restrict the movement of the coil 16.
第一鍔部23および第二鍔部24は、いずれも胴部22から径方向外側へ突出する環状に形成されている。すなわち、第一鍔部23は、内周側の縁部が胴部22と対向している。第一鍔部23は、胴部22の軸方向において一方の端部に設けられている。具体的には、第一鍔部23は、ティース部18に電気機器用ボビン21を嵌めたとき、固定子鉄心15のヨーク部17と対向する側に位置する。第一鍔部23は、内周側に複数の被係合部25を有している。被係合部25は、第一鍔部23を胴部22に取り付けたとき、上述の胴部22が形成する係合孔22eに進入する。被係合部25は、係合孔22eに対応する円柱状に形成されている。被係合部25は、係合孔22eの形状に合わせて形状を変更可能である。例えば係合孔22eの断面を四角形状とするとき、被係合部25は四角柱状に形成される。
Both the first collar part 23 and the second collar part 24 are formed in an annular shape that protrudes radially outward from the body part 22. That is, as for the 1st collar part 23, the edge part of the inner peripheral side has opposed the trunk | drum 22. The first flange portion 23 is provided at one end portion in the axial direction of the trunk portion 22. Specifically, the first flange portion 23 is located on the side of the stator core 15 that faces the yoke portion 17 when the electric equipment bobbin 21 is fitted to the tooth portion 18. The first flange 23 has a plurality of engaged portions 25 on the inner peripheral side. The engaged portion 25 enters the engagement hole 22e formed by the body portion 22 when the first flange portion 23 is attached to the body portion 22. The engaged portion 25 is formed in a columnar shape corresponding to the engaging hole 22e. The engaged portion 25 can be changed in shape according to the shape of the engagement hole 22e. For example, when the cross section of the engagement hole 22e is a square shape, the engaged portion 25 is formed in a quadrangular prism shape.
第二鍔部24は、第一鍔部23と同様に内周側の縁部が胴部22と対向している。第二鍔部24は、胴部22の軸方向において他方の端部、すなわち第一鍔部23と反対側の端部に設けられている。具体的には、第二鍔部24は、ティース部18に電気機器用ボビン21を嵌めたときに、固定子鉄心15の中心側に位置する。第二鍔部24は、固定子鉄心15の周方向における全長が第一鍔部23よりも小さく設定されている。これは、第二鍔部24は、第一鍔部23よりも固定子鉄心15の中心側に位置しているからである。すなわち、電気機器用ボビン21は、固定子鉄心15の中心に対し放射状に形成されているティース部18に嵌められる。そのため、固定子鉄心15の周方向において隣り合う電気機器用ボビン21の間隔は、固定子鉄心15の中心側すなわち第二鍔部24側ほど小さい。これにより、隣り合う電気機器用ボビン21の第二鍔部24同士が接しないように、第二鍔部24は第一鍔部23よりも固定子鉄心15の周方向の全長が小さく設定されている。第二鍔部24は、第一鍔部23と同様に内周側に複数の被係合部25を有している。被係合部25は、第二鍔部24を胴部22に取り付けたとき、胴部22が形成する係合孔22eに進入する。第二鍔部24の被係合部25の形状は、第一鍔部23と同様である。
The second collar part 24 has an inner peripheral edge facing the body part 22 in the same manner as the first collar part 23. The second flange 24 is provided at the other end in the axial direction of the body 22, that is, at the end opposite to the first flange 23. Specifically, the second flange portion 24 is located on the center side of the stator core 15 when the electric device bobbin 21 is fitted to the tooth portion 18. The second flange portion 24 is set so that the total length in the circumferential direction of the stator core 15 is smaller than that of the first flange portion 23. This is because the second flange portion 24 is located closer to the center side of the stator core 15 than the first flange portion 23. That is, the electric equipment bobbin 21 is fitted to the teeth portion 18 formed radially with respect to the center of the stator core 15. Therefore, the interval between the bobbins 21 for electric equipment adjacent in the circumferential direction of the stator core 15 is smaller toward the center side of the stator core 15, that is, the second flange portion 24 side. Thereby, the second collar part 24 is set to have a smaller overall length in the circumferential direction of the stator core 15 than the first collar part 23 so that the second collar parts 24 of the adjacent bobbins 21 for electrical equipment do not contact each other. Yes. Similar to the first collar part 23, the second collar part 24 has a plurality of engaged parts 25 on the inner peripheral side. The engaged portion 25 enters the engagement hole 22 e formed by the body portion 22 when the second flange portion 24 is attached to the body portion 22. The shape of the engaged portion 25 of the second flange 24 is the same as that of the first flange 23.
第二鍔部24は、回転子13側の面が回転子13の外壁と同心円状に湾曲していてもよい。また、第一鍔部23は、ヨーク部17側の面がヨーク部17の内壁と同心円状に湾曲していてもよい。特に第一鍔部23のヨーク部17側の面とヨーク部17の内壁とが近似した曲率であることにより、電気機器用ボビン21のヨーク部17側の端部は、ヨーク部17の内壁によって位置が決定される。
The surface of the second flange portion 24 on the rotor 13 side may be curved concentrically with the outer wall of the rotor 13. Further, the surface of the first flange portion 23 on the side of the yoke portion 17 may be curved concentrically with the inner wall of the yoke portion 17. In particular, since the surface of the first flange portion 23 on the side of the yoke portion 17 and the inner wall of the yoke portion 17 have an approximate curvature, the end portion on the yoke portion 17 side of the bobbin 21 for electric equipment is formed by the inner wall of the yoke portion 17. The position is determined.
第一鍔部23、第二鍔部24および被係合部25は、合成樹脂で形成されている。ここで、合成樹脂としては、例えばポリフェニレンサルファイド樹脂(PPS樹脂)、アクリルニトリル-ブタジエン-スチレン共重合体樹脂、ポリイミド系樹脂、ポリエチレンテレフタレート系樹脂、ポリアセタール系樹脂などが好ましい。この第一鍔部23、第二鍔部24および被係合部25は、例えばインサート成形により胴部22と一体に形成されている。第一鍔部23および第二鍔部24の厚さは、任意である。第1実施形態の場合、第一鍔部23および第二鍔部24は、図14に示すようにその厚さT2を2~3mmに設定している。第一鍔部23および第二鍔部24の厚さT2は、成形が可能な範囲でできる限り小さく設定することが望ましい。このように第一鍔部23および第二鍔部24の厚さT2を低減することにより、電気機器用ボビン21の胴部22は軸方向の全長が拡大される。その結果、胴部22に巻かれる電線の巻数は増加し、電線の線積率が高められる。
The 1st collar part 23, the 2nd collar part 24, and the to-be-engaged part 25 are formed with the synthetic resin. Here, as the synthetic resin, for example, polyphenylene sulfide resin (PPS resin), acrylonitrile-butadiene-styrene copolymer resin, polyimide resin, polyethylene terephthalate resin, polyacetal resin, and the like are preferable. The first flange portion 23, the second flange portion 24, and the engaged portion 25 are formed integrally with the body portion 22 by, for example, insert molding. The thickness of the 1st collar part 23 and the 2nd collar part 24 is arbitrary. In the first embodiment, the first flange portion 23 and the second flange portion 24 is set the the second thickness T 2 as shown in FIG. 14 to 2 ~ 3 mm. The thickness T 2 of the first flange portion 23 and the second flange portion 24 is preferably set as small as possible within a range capable of forming. By thus reducing the thickness T 2 of the first flange portion 23 and the second flange portion 24, body portion 22 of the electric device for the bobbin 21 is the total length in the axial direction is enlarged. As a result, the number of turns of the electric wire wound around the trunk portion 22 increases, and the line area ratio of the electric wire is increased.
被係合部25は、第一鍔部23および第二鍔部24の形成と同時に胴部22の係合孔22eに充填される。これにより、被係合部25は、第一鍔部23および第二鍔部24とそれぞれ一体に形成される。このように第一鍔部23および第二鍔部24の形成と同時に被係合部25を係合孔22eに充填することにより、第一鍔部23および第二鍔部24の被係合部25は、係合孔22eに進入して噛み合った状態となる。その結果、第一鍔部23および第二鍔部24と、胴部22とは、強固に接続することができる。
The engaged portion 25 is filled in the engagement hole 22e of the body portion 22 simultaneously with the formation of the first flange portion 23 and the second flange portion 24. Thereby, the engaged portion 25 is formed integrally with the first flange portion 23 and the second flange portion 24, respectively. In this way, the engaged portions of the first flange portion 23 and the second flange portion 24 are filled by filling the engaged portion 25 into the engagement hole 22e simultaneously with the formation of the first flange portion 23 and the second flange portion 24. 25 enters the engagement hole 22e and is engaged. As a result, the first flange portion 23 and the second flange portion 24 and the body portion 22 can be firmly connected.
電気機器用ボビン21は、図5に示すように充填部材26を備えている。充填部材26は、胴部22の内周側、第一鍔部23の内周側および第二鍔部24の内周側において胴部22と第一鍔部23および第二鍔部24との間の段差を埋めている。この充填部材26は、熱伝導性に優れる材料で形成することが望ましい。充填部材26は、例えば熱可塑性樹脂やグリースなどのように温度が上昇するほど流動性が増すものが望ましい。
The electrical equipment bobbin 21 includes a filling member 26 as shown in FIG. The filling member 26 is formed between the body portion 22, the first flange portion 23, and the second flange portion 24 on the inner peripheral side of the barrel portion 22, the inner periphery side of the first flange portion 23, and the inner periphery side of the second flange portion 24. Fill the gap between them. The filling member 26 is desirably formed of a material having excellent thermal conductivity. The filling member 26 is desirably a material whose fluidity increases as the temperature rises, such as a thermoplastic resin or grease.
次に、上記の電気機器用ボビン21の成形に用いるインサート成形金型について図12を参照して説明する。
図12に示すインサート成形金型31は、土台部32、下型33および上型34を備えている。下型33は、土台部32の上方に設けられている。上型34は、下型33の上方に設けられている。土台部32は、下型33および上型34を保持する。土台部32は、電気機器用ボビン21の胴部22の位置を決定するためのブロック部35を有している。ブロック部35は、固定子鉄心15のティース部18とほぼ同じ形状の四角柱状である。土台部32は、上方に突出する複数の突出ピン36を有している。突出ピン36は、下型33から成形された電気機器用ボビン21を外すためのものである。 Next, an insert molding die used for molding thebobbin 21 for electric equipment will be described with reference to FIG.
An insert molding die 31 shown in FIG. 12 includes abase portion 32, a lower die 33, and an upper die 34. The lower mold 33 is provided above the base portion 32. The upper mold 34 is provided above the lower mold 33. The base portion 32 holds the lower die 33 and the upper die 34. The base part 32 has a block part 35 for determining the position of the body part 22 of the bobbin 21 for electric equipment. The block portion 35 has a quadrangular prism shape that is substantially the same shape as the tooth portion 18 of the stator core 15. The base portion 32 has a plurality of protruding pins 36 that protrude upward. The protruding pin 36 is for removing the bobbin 21 for electric equipment formed from the lower mold 33.
図12に示すインサート成形金型31は、土台部32、下型33および上型34を備えている。下型33は、土台部32の上方に設けられている。上型34は、下型33の上方に設けられている。土台部32は、下型33および上型34を保持する。土台部32は、電気機器用ボビン21の胴部22の位置を決定するためのブロック部35を有している。ブロック部35は、固定子鉄心15のティース部18とほぼ同じ形状の四角柱状である。土台部32は、上方に突出する複数の突出ピン36を有している。突出ピン36は、下型33から成形された電気機器用ボビン21を外すためのものである。 Next, an insert molding die used for molding the
An insert molding die 31 shown in FIG. 12 includes a
下型33は、一対のブロック状の可動下型37から構成されている。一対の可動下型37は、土台部32の上方に設けられ、土台部32の上面に沿って移動して型を開放する。図12に示す矢印Yは、型が開放する方向を示している。可動下型37は、電気機器用ボビン21のほぼ半分の形状に相当する切り欠き38’を有している。一対の可動下型37は、これらを合わせることにより、電気機器用ボビン21を収納するキャビティ38を形成する。可動下型37の上方には、可動下型37とキャビティ38とを接続するノズル39が設けられている。ノズル39は、例えば溶融したPPSなどの樹脂をキャビティ38へ供給する。第一鍔部23および第二鍔部24は、ノズル39から供給された樹脂によって形成される。
The lower mold 33 is composed of a pair of block-shaped movable lower molds 37. The pair of movable lower molds 37 is provided above the base part 32 and moves along the upper surface of the base part 32 to open the mold. An arrow Y shown in FIG. 12 indicates the direction in which the mold opens. The movable lower die 37 has a notch 38 ′ corresponding to the shape of almost half of the electric equipment bobbin 21. The pair of movable lower dies 37 are combined to form a cavity 38 that houses the bobbin 21 for an electric device. A nozzle 39 that connects the movable lower mold 37 and the cavity 38 is provided above the movable lower mold 37. The nozzle 39 supplies, for example, molten resin such as PPS to the cavity 38. The first brim part 23 and the second brim part 24 are formed by the resin supplied from the nozzle 39.
上型34は、上下に貫くスプールランナー40を有している。溶融した樹脂は、この上型34のスプールランナー40を経由して下型33のノズル39に供給される。上型34の上端には、スプールランナー40に接続する貯留部41が形成されている。外部から供給された溶融した樹脂は、この貯留部41に貯えられる。上型34と下型33とを合わせることにより、スプールランナー40の下端部はノズル39に接続する。
The upper die 34 has a spool runner 40 penetrating vertically. The molten resin is supplied to the nozzle 39 of the lower mold 33 via the spool runner 40 of the upper mold 34. A storage portion 41 connected to the spool runner 40 is formed at the upper end of the upper die 34. The molten resin supplied from the outside is stored in the storage unit 41. By combining the upper mold 34 and the lower mold 33, the lower end portion of the spool runner 40 is connected to the nozzle 39.
次に、プラズマ処理について図13を参照して説明する。
プラズマ処理は、電極間に直流または交流の高電圧を印加することによって生成する放電を利用して行われる。高電圧の印加によって生じる放電は、大気圧におけるコロナ放電あるいは真空におけるグロー放電などである。胴部22を形成する絶縁フィルムは、これらによって生じた放電に曝すことによりプラズマ処理される。プラズマ処理は、処理ガスの選択範囲が広い真空での処理が好ましい。また、プラズマ処理は、処理ガスとして、ヘリウム、ネオン、アルゴン、窒素、酸素、炭酸ガス、空気、水蒸気などが単独あるいは混合した状態で使用される。なかでもアルゴン、炭酸ガスは、放電開始効率の点から好ましい。プラズマ処理における処理圧力は、0.1Pa~1330Paの圧力範囲であり、さらに好ましくは、1Pa~266Paの範囲である。 Next, plasma processing will be described with reference to FIG.
The plasma treatment is performed using a discharge generated by applying a direct current or alternating current high voltage between the electrodes. The discharge generated by the application of a high voltage is a corona discharge at atmospheric pressure or a glow discharge in vacuum. The insulating film forming thebody portion 22 is subjected to plasma treatment by being exposed to the electric discharge generated thereby. The plasma treatment is preferably a vacuum treatment with a wide selection range of treatment gases. In the plasma treatment, helium, neon, argon, nitrogen, oxygen, carbon dioxide gas, air, water vapor, or the like is used alone or in a mixed state as a treatment gas. Of these, argon and carbon dioxide are preferable from the viewpoint of discharge starting efficiency. The treatment pressure in the plasma treatment is in a pressure range of 0.1 Pa to 1330 Pa, and more preferably in a range of 1 Pa to 266 Pa.
プラズマ処理は、電極間に直流または交流の高電圧を印加することによって生成する放電を利用して行われる。高電圧の印加によって生じる放電は、大気圧におけるコロナ放電あるいは真空におけるグロー放電などである。胴部22を形成する絶縁フィルムは、これらによって生じた放電に曝すことによりプラズマ処理される。プラズマ処理は、処理ガスの選択範囲が広い真空での処理が好ましい。また、プラズマ処理は、処理ガスとして、ヘリウム、ネオン、アルゴン、窒素、酸素、炭酸ガス、空気、水蒸気などが単独あるいは混合した状態で使用される。なかでもアルゴン、炭酸ガスは、放電開始効率の点から好ましい。プラズマ処理における処理圧力は、0.1Pa~1330Paの圧力範囲であり、さらに好ましくは、1Pa~266Paの範囲である。 Next, plasma processing will be described with reference to FIG.
The plasma treatment is performed using a discharge generated by applying a direct current or alternating current high voltage between the electrodes. The discharge generated by the application of a high voltage is a corona discharge at atmospheric pressure or a glow discharge in vacuum. The insulating film forming the
図13に示すプラズマ処理機51は、密閉可能な処理室52を有している。処理室52は、内部に処理用ローラ53を収容している。電極54は、この処理用ローラ53の周囲にわずかな隙間を形成して囲んでいる。処理用ローラ53は、アース接続されている。電極54は、高周波電源55に接続している。処理室52は、内部が図示しない真空ポンプに接続されたバルブ56の開放によって減圧される。これとともに、処理室52は、図示しないガス供給源に接続されたバルブ57の開放によって処理用のガスが供給される。処理室52は、内部の圧力を検出する圧力計58が設けられている。
13 has a process chamber 52 that can be sealed. The processing chamber 52 accommodates a processing roller 53 therein. The electrode 54 surrounds the processing roller 53 by forming a slight gap. The processing roller 53 is grounded. The electrode 54 is connected to a high frequency power supply 55. The processing chamber 52 is decompressed by opening a valve 56 connected to a vacuum pump (not shown). At the same time, the processing chamber 52 is supplied with processing gas by opening a valve 57 connected to a gas supply source (not shown). The processing chamber 52 is provided with a pressure gauge 58 for detecting the internal pressure.
ロール状に巻かれた絶縁フィルム42は、供給部59から引出される。引き出された絶縁フィルム42は、処理室52内の複数個の案内ローラ60に案内されながら処理用ローラ53に一周近く巻付けられる。このとき、絶縁フィルム42は、電極54との間の処理部分を通り、ここでプラズマ処理が施される。そして、プラズマ処理が施された絶縁フィルム42は、案内ローラ60に案内されながら巻取部61において巻き取られる。このとき、絶縁フィルム42は、片面または両面にプラズマ処理が施される。絶縁フィルム42の片面にプラズマ処理を施す場合、プラズマ処理が施された面が胴部22の外周側に配置される。
The insulating film 42 wound in a roll shape is drawn out from the supply unit 59. The drawn insulating film 42 is wound around the processing roller 53 while being guided by a plurality of guide rollers 60 in the processing chamber 52. At this time, the insulating film 42 passes through the processing portion between the insulating film 42 and the plasma processing. The insulating film 42 that has been subjected to the plasma treatment is wound around the winding portion 61 while being guided by the guide roller 60. At this time, the insulating film 42 is subjected to plasma treatment on one side or both sides. When plasma processing is performed on one surface of the insulating film 42, the surface subjected to the plasma processing is disposed on the outer peripheral side of the body portion 22.
次に、電気機器用ボビン21の製造手順について図12を参照して説明する。
胴部22を構成する絶縁フィルム42は、表面処理工程が行われる。表面処理工程は、例えば上述のプラズマ処理機51を用いたプラズマ処理である。プラズマ処理されたフィルム状の絶縁フィルム42は、図12(a)に示すように胴部22を展開した形状、すなわち長方形状に裁断される。裁断後の絶縁フィルム42の長辺の長さPは、上側壁22aの左右方向の長さ、左側壁22dの上下方向の長さ、下側壁22bの左右方向の長さ、右側壁22cの上下方向の長さに、必要に応じて糊代を加えた長さに相当する。また、裁断後の短辺の長さQは、胴部22の前後方向、上側壁22aの前後方向の長さに相当する。ここで、絶縁フィルム42の厚さは、0.05~0.5mmに設定されている。 Next, the manufacturing procedure of thebobbin 21 for electrical equipment will be described with reference to FIG.
The insulatingfilm 42 constituting the body portion 22 is subjected to a surface treatment process. The surface treatment process is, for example, plasma treatment using the above-described plasma treatment machine 51. As shown in FIG. 12A, the plasma-treated film-like insulating film 42 is cut into a shape in which the body portion 22 is developed, that is, a rectangular shape. The length P of the long side of the insulating film 42 after cutting is the length in the horizontal direction of the upper side wall 22a, the length in the vertical direction of the left side wall 22d, the length in the horizontal direction of the lower side wall 22b, and the vertical length of the right side wall 22c. This corresponds to the length of the direction plus the glue margin as necessary. Further, the length Q of the short side after cutting corresponds to the length in the front-rear direction of the body portion 22 and the length in the front-rear direction of the upper side wall 22a. Here, the thickness of the insulating film 42 is set to 0.05 to 0.5 mm.
胴部22を構成する絶縁フィルム42は、表面処理工程が行われる。表面処理工程は、例えば上述のプラズマ処理機51を用いたプラズマ処理である。プラズマ処理されたフィルム状の絶縁フィルム42は、図12(a)に示すように胴部22を展開した形状、すなわち長方形状に裁断される。裁断後の絶縁フィルム42の長辺の長さPは、上側壁22aの左右方向の長さ、左側壁22dの上下方向の長さ、下側壁22bの左右方向の長さ、右側壁22cの上下方向の長さに、必要に応じて糊代を加えた長さに相当する。また、裁断後の短辺の長さQは、胴部22の前後方向、上側壁22aの前後方向の長さに相当する。ここで、絶縁フィルム42の厚さは、0.05~0.5mmに設定されている。 Next, the manufacturing procedure of the
The insulating
絶縁フィルム42は、胴部22を展開した形状に成形するとき、または成形の前後に、長辺の両端にそれぞれ係合孔22eに相当する孔が形成される。係合孔22eは、絶縁フィルム42を所定の形状に成形した後に行ってもよく、予め係合孔22eを形成した後に、絶縁フィルム42の成形してもよい。また、金型を用いた打ち抜きプレスなどにより、絶縁フィルム42の成型と係合孔22eの形成とを同時に行ってもよい。
The insulating film 42 is formed with holes corresponding to the engagement holes 22e at both ends of the long side when the body 22 is formed into a developed shape or before and after the forming. The engaging hole 22e may be formed after the insulating film 42 is formed into a predetermined shape, or the insulating film 42 may be formed after the engaging hole 22e is formed in advance. Further, the insulating film 42 and the engagement hole 22e may be formed simultaneously by a punching press using a mold.
成形された絶縁フィルム42は、図12(b)に示すように胴部22に相当する形状に成形される。第1実施形態では、絶縁フィルム42は、角筒状に成形されている。絶縁フィルム42に糊代含んでいるとき、角筒状に折り曲げられた絶縁フィルム42は、糊代の部分が上側壁22aまたは下側壁22bに位置する。また、胴部22を成形するとき、糊代に接着剤などを塗布し、インサート成形前に絶縁フィルム42を仮止めしてもよい。これにより、成形された絶縁フィルム42は、インサート成形時における型崩れが低減される。これら絶縁フィルム42の成形、係合孔22eの形成および胴部形状の成形を行う工程は、胴部整形工程に相当する。
The formed insulating film 42 is formed into a shape corresponding to the body 22 as shown in FIG. In the first embodiment, the insulating film 42 is formed in a rectangular tube shape. When the insulating film 42 includes an adhesive margin, the insulating film 42 bent into a rectangular tube shape has an adhesive margin portion located on the upper side wall 22a or the lower side wall 22b. Further, when the body portion 22 is molded, an adhesive or the like may be applied to the glue margin, and the insulating film 42 may be temporarily fixed before insert molding. As a result, the molded insulating film 42 is less likely to lose its shape during insert molding. The process of forming the insulating film 42, forming the engagement hole 22e, and forming the body shape corresponds to a body shaping process.
筒状に成形された絶縁フィルム42は、図12(c)および図12(d)に示すように、下型33が開放している状態、すなわち可動下型37が互いに離れている状態でブロック部35に嵌め込まれる。この絶縁フィルム42を下型33のブロック部35に嵌め込む行程は、胴部配置工程に相当する。筒状に成形された絶縁フィルム42は、ブロック部35に嵌める際、土台部32からわずかに離れている。このように成形した絶縁フィルム42と土台部32とを離して配置することにより、胴部22の軸方向において端部の外側にインサート成形時の樹脂が注入される。その結果、胴部22は、軸方向の端部における強度が高められる。筒状に成形された絶縁フィルム42がブロック部35に配置されると、図12(e)に示すように可動下型37を合わせて、キャビティ38を形成する。これにより、筒状の絶縁フィルム42は、キャビティ38に収容される。この工程は、下型固定工程に相当する。
As shown in FIGS. 12 (c) and 12 (d), the insulating film 42 formed into a cylindrical shape is blocked in a state where the lower mold 33 is opened, that is, the movable lower mold 37 is separated from each other. It is inserted into the part 35. The process of fitting the insulating film 42 into the block part 35 of the lower mold 33 corresponds to a trunk part arranging step. The insulating film 42 formed into a cylindrical shape is slightly separated from the base portion 32 when fitted into the block portion 35. By disposing the insulating film 42 thus formed and the base portion 32 apart from each other, the resin at the time of insert molding is injected outside the end portion in the axial direction of the body portion 22. As a result, the strength of the end portion in the axial direction of the body portion 22 is increased. When the insulating film 42 formed into a cylindrical shape is disposed on the block portion 35, the movable lower mold 37 is combined to form a cavity 38 as shown in FIG. Thereby, the cylindrical insulating film 42 is accommodated in the cavity 38. This process corresponds to a lower mold fixing process.
筒状に成形された絶縁フィルム42がキャビティ38に収容されると、図12(f)に示すように上型34は下型33の上面に取り付けられる。そして、溶融した樹脂は、上型34の貯留部41に注入される。貯留部41に注入された樹脂は、スプールランナー40およびノズル39を経由してキャビティ38に供給される。これにより、筒状に成形された絶縁フィルム42すなわち胴部22をインサート品とするインサート成形が行われ、胴部22は第一鍔部23、第二鍔部24および被係合部25と一体に成形される。すなわち、溶融した樹脂の注入によって、胴部22をインサート品として第一鍔部23、第二鍔部24および被係合部25は胴部22と一体に成形される。この工程は、鍔部成形工程に相当する。このインサート成形によって、樹脂の注入で形成される被係合部25は、胴部22の係合孔22eに進入する。そのため、第一鍔部23および第二鍔部24から一体に突出する被係合部25は、係合孔22eと噛み合った状態となる。
When the insulating film 42 formed into a cylindrical shape is accommodated in the cavity 38, the upper die 34 is attached to the upper surface of the lower die 33 as shown in FIG. Then, the molten resin is injected into the storage portion 41 of the upper mold 34. The resin injected into the storage unit 41 is supplied to the cavity 38 via the spool runner 40 and the nozzle 39. As a result, insert molding is performed using the insulating film 42 formed into a cylindrical shape, that is, the barrel portion 22 as an insert, and the barrel portion 22 is integrated with the first flange portion 23, the second flange portion 24, and the engaged portion 25. To be molded. That is, by injecting molten resin, the first flange portion 23, the second flange portion 24, and the engaged portion 25 are formed integrally with the barrel portion 22 using the barrel portion 22 as an insert. This process corresponds to a buttocks molding process. By this insert molding, the engaged portion 25 formed by resin injection enters the engaging hole 22e of the body portion 22. Therefore, the engaged portion 25 integrally protruding from the first flange portion 23 and the second flange portion 24 is in a state of being engaged with the engagement hole 22e.
予めプラズマ処理などの表面処理を絶縁フィルムに施すことにより、胴部22の表面は濡れ性および接着性が向上される。そのため、第一鍔部23および第二鍔部24を形成する溶融した樹脂は、絶縁フィルム42に沿って流動性が確保される。その結果、第一鍔部23および第二鍔部24を形成する樹脂は、胴部22に十分な範囲で接着する。これにより、胴部22と鍔部とは十分に接合し、成形後における第一鍔部23および第二鍔部24の割れなどは低減される。
The surface of the body portion 22 is improved in wettability and adhesiveness by applying a surface treatment such as plasma treatment to the insulating film in advance. Therefore, the molten resin forming the first flange portion 23 and the second flange portion 24 is ensured to have fluidity along the insulating film 42. As a result, the resin forming the first flange portion 23 and the second flange portion 24 adheres to the body portion 22 in a sufficient range. Thereby, the trunk | drum 22 and a collar part fully join, and the crack of the 1st collar part 23 and the 2nd collar part 24 after a shaping | molding, etc. are reduced.
インサート成形による鍔部成形工程の後、上型34は下型33から取り外される。そして、下型33の可動下型37は型を開放する。このとき、土台部32の突出ピン36を土台部32から突き出すことにより、電気機器用ボビン21は土台部32から取り外される。
After the buttocks forming process by insert molding, the upper die 34 is removed from the lower die 33. The movable lower mold 37 of the lower mold 33 opens the mold. At this time, the protruding pin 36 of the base portion 32 protrudes from the base portion 32, whereby the electric equipment bobbin 21 is removed from the base portion 32.
なお、上述の製造工程の説明では、胴部整形工程を行う前にプラズマ処理などの表面処理工程を実施する例を説明したが、胴部整形工程を行った後、かつ鍔部成形工程を行う前に表面処理工程を施してもよい。例えば表面処理は、絶縁フィルム42を所定の大きさに成形した後、この絶縁フィルム42に施してもよい。また、胴部整形工程を行う前に、および胴部整形工程を行った後、かつ鍔部成形工程を行う前のいずれの時期にも、表面処理工程を実施してもよい。
In the above description of the manufacturing process, the example in which the surface treatment process such as the plasma treatment is performed before the trunk shaping process is described, but after the trunk shaping process is performed, the hip molding process is performed. A surface treatment step may be performed before. For example, the surface treatment may be performed on the insulating film 42 after the insulating film 42 is formed into a predetermined size. Moreover, you may implement a surface treatment process before performing a trunk | drum shaping process, and any time after performing a trunk | drum shaping process and before performing a collar part shaping | molding process.
次に、コイル16を固定子鉄心15のティース部18に取り付ける手順について図1~図4、図6、図11を参照して説明する。
上述の加工で得られた図11に示す電気機器用ボビン21は、胴部22の外周に電線が巻かれる。これにより、電気機器用ボビン21は、図6に示すように胴部22の外周にコイル16が設けられる。また、電気機器用ボビン21は、胴部22の内周側に充填部材26が充填される。コイル16が設けられ充填部材26が充填された電気機器用ボビン21は、図6中の矢印Fで示すように固定子鉄心15の内周側から固定子鉄心15のティース部18に嵌められる。これにより、コイル16は、電気機器用ボビン21を挟んでティース部18に集中巻きされた状態となる。このとき、図1~図4に示すように、ティース部18は、胴部22の右側壁22cおよび左側壁22dよりも内側に収容される。一方、胴部22の上側壁22aおよび下側壁22bは、固定子鉄心15の軸方向においてティース部18の全長よりも外側に位置する。また、胴部22とティース部18との間は、充填部材26によって埋められている。固定子鉄心15は、すべてのティース部18にコイル16が設けられた電気機器用ボビン21が取り付けられる。 Next, a procedure for attaching thecoil 16 to the tooth portion 18 of the stator core 15 will be described with reference to FIGS. 1 to 4, 6, and 11. FIG.
In theelectric equipment bobbin 21 shown in FIG. 11 obtained by the above-described processing, an electric wire is wound around the outer periphery of the trunk portion 22. Thereby, as for the bobbin 21 for electric equipments, the coil 16 is provided in the outer periphery of the trunk | drum 22 as shown in FIG. Further, in the bobbin 21 for electric equipment, a filling member 26 is filled on the inner peripheral side of the body portion 22. The electric machine bobbin 21 provided with the coil 16 and filled with the filling member 26 is fitted into the tooth portion 18 of the stator core 15 from the inner peripheral side of the stator core 15 as indicated by an arrow F in FIG. Thereby, the coil 16 is in a state of being concentratedly wound around the teeth portion 18 with the bobbin 21 for electric equipment interposed therebetween. At this time, as shown in FIGS. 1 to 4, the tooth portion 18 is accommodated inside the right side wall 22c and the left side wall 22d of the body portion 22. On the other hand, the upper side wall 22 a and the lower side wall 22 b of the body part 22 are located outside the full length of the tooth part 18 in the axial direction of the stator core 15. The space between the body portion 22 and the tooth portion 18 is filled with a filling member 26. The stator core 15 is attached with an electric equipment bobbin 21 in which the coils 16 are provided in all the teeth portions 18.
上述の加工で得られた図11に示す電気機器用ボビン21は、胴部22の外周に電線が巻かれる。これにより、電気機器用ボビン21は、図6に示すように胴部22の外周にコイル16が設けられる。また、電気機器用ボビン21は、胴部22の内周側に充填部材26が充填される。コイル16が設けられ充填部材26が充填された電気機器用ボビン21は、図6中の矢印Fで示すように固定子鉄心15の内周側から固定子鉄心15のティース部18に嵌められる。これにより、コイル16は、電気機器用ボビン21を挟んでティース部18に集中巻きされた状態となる。このとき、図1~図4に示すように、ティース部18は、胴部22の右側壁22cおよび左側壁22dよりも内側に収容される。一方、胴部22の上側壁22aおよび下側壁22bは、固定子鉄心15の軸方向においてティース部18の全長よりも外側に位置する。また、胴部22とティース部18との間は、充填部材26によって埋められている。固定子鉄心15は、すべてのティース部18にコイル16が設けられた電気機器用ボビン21が取り付けられる。 Next, a procedure for attaching the
In the
ここで、図14を参照して電線の線積率について説明する。図14(b)に示す従来の電気機器用ボビン101は、例えば射出成形などによって胴部102と第一鍔部103および第二鍔部104とが同一の樹脂で継ぎ目なく一体に成形されている。この場合、胴部102の厚さT0は、成形時の制約から、少なくとも樹脂による一体成形後に割れが生じない程度の寸法を確保する必要がある。そのため、胴部102の厚さT0は、例えばT0=1~3mm程度が要求される。
Here, the line product ratio of the electric wire will be described with reference to FIG. In the conventional bobbin 101 for electric equipment shown in FIG. 14B, the body portion 102, the first flange portion 103, and the second flange portion 104 are integrally formed of the same resin and seamlessly by, for example, injection molding. . In this case, the thickness T 0 of the body portion 102 needs to ensure a dimension that does not cause cracking at least after integral molding with a resin due to restrictions during molding. Therefore, the thickness T 0 of the body portion 102 is required to be, for example, about T 0 = 1 to 3 mm.
一方、本実施形態の場合、胴部22のうち右側壁22cおよび左側壁22dは、厚さT1がT1=0.05mm~0.5mmの絶縁フィルムで形成されている。そのため、本実施形態による電気機器用ボビン21の電線の線積率は、従来構成における電気機器用ボビン101に比較して、(T0-T1)に相当する分、高められる。
On the other hand, in the present embodiment, the right side wall 22c and the left side wall 22d of the body portion 22 are formed of an insulating film having a thickness T 1 of T 1 = 0.05 mm to 0.5 mm. Therefore, the line area ratio of the electric wires of the bobbin 21 for electric equipment according to the present embodiment is increased by an amount corresponding to (T 0 -T 1 ) compared to the bobbin 101 for electric equipment in the conventional configuration.
また、一般に、円形のコイル導体に電流I(A)が流れる場合、コイルの軸中心Oの磁束密度Bは、「B=μ0Nl/2r:ただし、μ0は真空の透磁率、Nは1m当たりの巻き数、lはコイルの長さ、rはコイルの半径」で表される。第1実施形態の胴部22は、上述の通り従来の胴部102に比較して薄い。そのため、第1実施形態の胴部22の外周に設けられるコイル16の半径r1は、従来のコイルの半径r0よりも(T0-T1)に相当する分、小さくなる。その結果、第1実施形態の電気機器用ボビン21を用いたコイル16は、従来に比較して磁束密度も高められる。したがって、第1実施形態の電気機器用ボビン21は、磁束密度の観点からも回転電機11の回転効率の向上が図られる。
In general, when the current I (A) flows through a circular coil conductor, the magnetic flux density B at the axial center O of the coil is “B = μ 0 Nl / 2r: where μ 0 is the vacuum permeability, and N is The number of turns per meter, l is the length of the coil, and r is the radius of the coil. The trunk | drum 22 of 1st Embodiment is thin compared with the conventional trunk | drum 102 as above-mentioned. Therefore, the radius r 1 of the coil 16 provided on the outer periphery of the body portion 22 of the first embodiment is smaller than the radius r 0 of the conventional coil by an amount corresponding to (T 0 -T 1 ). As a result, the coil 16 using the electric machine bobbin 21 of the first embodiment has a higher magnetic flux density than the conventional one. Therefore, the electrical equipment bobbin 21 of the first embodiment can improve the rotational efficiency of the rotating electrical machine 11 from the viewpoint of magnetic flux density.
以上説明した第1実施形態によれば、固定子鉄心15のティース部18に嵌められる電気機器用ボビン21の胴部22は、右側壁22cおよび左側壁22dの厚さが0.05~0.5mmの絶縁フィルムから構成される。そのため、胴部22の右側壁22cおよび左側壁22dの厚さは、従来のインサート成形で形成されるボビンよりも薄くなる。したがって、より多くの電線を電気機器用ボビン21の胴部22に巻くことができ、電線の線積率を高めることができる。また、胴部22が薄くなるため、電線から発生した熱は薄い胴部22を経由して固定子鉄心15へ容易に伝達される。したがって、電線で発生した熱を速やかに拡散させることができ、放熱性を高めることができる。放熱性が高まることにより、回転電機11は高出力化および高効率化を図ることができる。
According to the first embodiment described above, the body portion 22 of the bobbin 21 for electric equipment fitted to the teeth portion 18 of the stator core 15 has the thickness of the right side wall 22c and the left side wall 22d of 0.05-0. It is composed of a 5 mm insulating film. Therefore, the thickness of the right side wall 22c and the left side wall 22d of the trunk portion 22 is thinner than a bobbin formed by conventional insert molding. Therefore, more electric wires can be wound around the body portion 22 of the bobbin 21 for electric equipment, and the line area ratio of the electric wires can be increased. Further, since the body portion 22 becomes thin, heat generated from the electric wire is easily transmitted to the stator core 15 via the thin body portion 22. Therefore, the heat generated in the electric wire can be quickly diffused, and the heat dissipation can be improved. By increasing the heat dissipation, the rotating electrical machine 11 can achieve higher output and higher efficiency.
第1実施形態の電気機器用ボビン21は、胴部22の軸方向の端部に係合孔22eを有している。胴部22の軸方向の端部に設けられている第一鍔部23および第二鍔部24は、それぞれ被係合部25が係合孔22eに進入している。これにより、胴部22と第一鍔部23との接合強度、および胴部22と第二鍔部24とは、高い強度で接合される。したがって、胴部22からの第一鍔部23および第二鍔部24の脱落を低減することができる。
The bobbin 21 for an electric device according to the first embodiment has an engagement hole 22e at the end of the body portion 22 in the axial direction. As for the 1st collar part 23 and the 2nd collar part 24 which were provided in the edge part of the axial direction of the trunk | drum 22, the to-be-engaged part 25 has approached into the engagement hole 22e, respectively. Thereby, the joining strength of the trunk | drum 22 and the 1st collar part 23, and the trunk | drum 22 and the 2nd collar part 24 are joined by high intensity | strength. Therefore, the drop-off of the first flange part 23 and the second flange part 24 from the trunk part 22 can be reduced.
第1実施形態では、第一鍔部23および第二鍔部24は、胴部22をインサート品としてインサート成形されている。そのため、胴部22と第一鍔部23および第二鍔部24とを異なる材料で形成する場合でも、製造を容易にすることができる。これとともに、インサート成形により、第一鍔部23および第二鍔部24は、十分な厚さが確保される。したがって、第一鍔部23および第二鍔部24の強度を高めることができる。また、胴部22は、第一鍔部23および第二鍔部24と一体に接合されている。したがって、これらを別材料で形成する場合でも、電気機器用ボビン21は固定子鉄心15などの部品へ容易に取り付けることができる。
In the first embodiment, the first collar part 23 and the second collar part 24 are insert-molded with the body part 22 as an insert. Therefore, even when the body part 22, the first collar part 23, and the second collar part 24 are formed of different materials, manufacturing can be facilitated. At the same time, the first collar 23 and the second collar 24 are sufficiently thickened by insert molding. Therefore, the strength of the first collar part 23 and the second collar part 24 can be increased. Further, the body portion 22 is integrally joined to the first flange portion 23 and the second flange portion 24. Therefore, even when these are formed of different materials, the bobbin 21 for electrical equipment can be easily attached to components such as the stator core 15.
第1実施形態では、胴部22の内周側には充填部材26が設けられている。充填部材26は、胴部22と第一鍔部23および第二鍔部24との間の段差を埋めている。これにより、電気機器用ボビン21をティース部18に取り付けたとき、胴部22とティース部18との間の隙間は、流動性のある充填部材26によって埋められる。そのため、コイル16を構成する電線で発生した熱は、充填部材26から胴部22を経由して固定子鉄心15に伝達される。したがって、コイル16の放熱性が向上し、コイル16の温度上昇を抑制することができる。
In the first embodiment, a filling member 26 is provided on the inner peripheral side of the body portion 22. The filling member 26 fills a step between the trunk portion 22 and the first and second collar portions 23 and 24. Thereby, when the bobbin 21 for electric equipment is attached to the teeth part 18, the clearance gap between the trunk | drum 22 and the teeth part 18 is filled with the filling member 26 with fluidity | liquidity. Therefore, the heat generated by the electric wires constituting the coil 16 is transmitted from the filling member 26 to the stator core 15 via the trunk portion 22. Therefore, the heat dissipation of the coil 16 is improved, and the temperature rise of the coil 16 can be suppressed.
第1実施形態では、胴部整形工程を行う前に、または胴部整形工程を行った後、かつ鍔部成形工程を行う前に、絶縁材料の表面に濡れ性を良好にする表面処理を施している。これにより、インサート成形時において、第一鍔部23および第二鍔部24を形成する溶融した樹脂は、胴部22を形成する絶縁材料に沿って流動しやすくなる。これにより、第一鍔部23および第二鍔部24を形成する樹脂と胴部22を形成する絶縁材料とは、高い接着性が確保される。したがって、胴部22と第一鍔部23および第二鍔部24との接合強度を高めることができるとともに、成形後における割れなどを低減することができる。
In the first embodiment, a surface treatment for improving wettability is performed on the surface of the insulating material before performing the trunk shaping process or after performing the trunk shaping process and before performing the hip molding process. ing. Thereby, the molten resin which forms the 1st collar part 23 and the 2nd collar part 24 becomes easy to flow along the insulating material which forms the trunk | drum 22 at the time of insert molding. Thereby, high adhesiveness is ensured with the resin which forms the 1st collar part 23 and the 2nd collar part 24, and the insulating material which forms the trunk | drum 22. Therefore, it is possible to increase the bonding strength between the body portion 22, the first flange portion 23, and the second flange portion 24, and it is possible to reduce cracks after molding.
(第2実施形態)
第2実施形態による電気機器用ボビン21の要部を図15に示す。第一鍔部23および第二鍔部24は、ほぼ対称な構造を有している。したがって、図15では第一鍔部23の周囲を図示し、第二鍔部24の図示および説明は省略する。
第一鍔部23は、図15に示すように一対の挟み片23aを有している。一対の挟み片23aは、胴部22の厚さ方向において胴部22を挟む位置に設けられている。挟み片23aは、第一鍔部23と同時に、第一鍔部23と同一の樹脂で一体に成形されている。一対の挟み片23aのうち一方は、胴部22の径方向において内側に位置している。挟み片23aの他方は、胴部22の径方向において外側に位置している。 (Second Embodiment)
The principal part of thebobbin 21 for electric equipment by 2nd Embodiment is shown in FIG. The 1st collar part 23 and the 2nd collar part 24 have a substantially symmetrical structure. Therefore, in FIG. 15, the periphery of the first collar part 23 is illustrated, and illustration and description of the second collar part 24 are omitted.
The1st collar part 23 has a pair of clamping piece 23a, as shown in FIG. The pair of sandwiching pieces 23 a is provided at a position sandwiching the body portion 22 in the thickness direction of the body portion 22. The sandwiching piece 23 a is integrally formed with the same resin as that of the first flange 23 simultaneously with the first flange 23. One of the pair of sandwiching pieces 23 a is located on the inner side in the radial direction of the body portion 22. The other of the sandwiching pieces 23 a is located outside in the radial direction of the body portion 22.
第2実施形態による電気機器用ボビン21の要部を図15に示す。第一鍔部23および第二鍔部24は、ほぼ対称な構造を有している。したがって、図15では第一鍔部23の周囲を図示し、第二鍔部24の図示および説明は省略する。
第一鍔部23は、図15に示すように一対の挟み片23aを有している。一対の挟み片23aは、胴部22の厚さ方向において胴部22を挟む位置に設けられている。挟み片23aは、第一鍔部23と同時に、第一鍔部23と同一の樹脂で一体に成形されている。一対の挟み片23aのうち一方は、胴部22の径方向において内側に位置している。挟み片23aの他方は、胴部22の径方向において外側に位置している。 (Second Embodiment)
The principal part of the
The
第2実施形態の場合、係合孔22eは、胴部22の径方向において両端部が、これら一対の挟み片23aに対向している。すなわち、係合孔22eは、一方の端部が内周側の挟み片23aと対向し、他方の端部が外周側の挟み片23aと対向している。そして、第一鍔部23から突出する被係合部25は、これら一対の挟み片23aを胴部22の径方向において接続している。すなわち、被係合部25は、係合孔22eを貫いて一対の挟み片23a同士を胴部22の径方向に接続している。被係合部25は、両端部がいずれも挟み片23aと一体に形成されている。つまり、第一鍔部23を形成するとき、第一鍔部23となる溶融した樹脂は、挟み片23aを形成するとともに、一部が係合孔22eへ進入し、被係合部25を形成する。これにより、第一鍔部23は、挟み片23aおよび被係合部25を樹脂で一体に形成する。
In the case of the second embodiment, both ends of the engagement hole 22e are opposed to the pair of sandwiching pieces 23a in the radial direction of the body portion 22. That is, one end of the engagement hole 22e is opposed to the inner circumferential side sandwiching piece 23a, and the other end is opposed to the outer circumferential side sandwiching piece 23a. The engaged portion 25 protruding from the first flange 23 connects the pair of sandwich pieces 23 a in the radial direction of the body portion 22. That is, the engaged portion 25 penetrates the engagement hole 22 e and connects the pair of sandwiching pieces 23 a to each other in the radial direction of the trunk portion 22. Both ends of the engaged portion 25 are formed integrally with the sandwiching piece 23a. That is, when forming the first flange portion 23, the molten resin that becomes the first flange portion 23 forms the pinching piece 23a, and part of the resin enters the engagement hole 22e to form the engaged portion 25. To do. Thereby, the 1st collar part 23 forms the pinching piece 23a and the to-be-engaged part 25 integrally with resin.
第2実施形態では、胴部22は、一体の挟み片23aおよび被係合部25によって、周方向へ複数の位置で第一鍔部23とに固定される。したがって、胴部22と第一鍔部23との接合強度をより一層高めることができる。第2実施形態の場合、第二鍔部24は、第一鍔部23と同様の構成である。したがって、第二鍔部24も第一鍔部23と同様に胴部22と強固に接合することができる。
In the second embodiment, the body portion 22 is fixed to the first flange portion 23 at a plurality of positions in the circumferential direction by the integral clip piece 23a and the engaged portion 25. Accordingly, the bonding strength between the body portion 22 and the first flange portion 23 can be further increased. In the case of 2nd Embodiment, the 2nd collar part 24 is the structure similar to the 1st collar part 23. FIG. Therefore, the second flange 24 can be firmly joined to the body 22 in the same manner as the first flange 23.
(第3実施形態)
次に、第3実施形態による電気機器用ボビン71を図16および図17に示す。
図16および図17に示す電気機器用ボビン71は、補強用のつなぎ部72を備えている。つなぎ部72は、第一鍔部23と第二鍔部24とをつなぐ側壁である。このつなぎ部72は、第一鍔部23および第二鍔部24と一体に設けられている。つなぎ部72は、上側壁22aの外周側である上側および下側壁22bの外周側である下側にそれぞれ設けられている。
電気機器用ボビン71は、第1実施形態と同様に胴部22をインサート品としてインサート成形されている。つなぎ部72は、このインサート成形の際に、第一鍔部23および第二鍔部24と一体に形成される。つなぎ部72の厚さは、インサート成形で成形可能な範囲において任意に設定される。つなぎ部72の厚さは、例えば、1~3mmに設定されている。 (Third embodiment)
Next, anelectric equipment bobbin 71 according to a third embodiment is shown in FIGS. 16 and 17.
Thebobbin 71 for electric equipment shown in FIG. 16 and FIG. 17 is provided with a connecting portion 72 for reinforcement. The connecting portion 72 is a side wall that connects the first flange portion 23 and the second flange portion 24. The connecting portion 72 is provided integrally with the first flange portion 23 and the second flange portion 24. The connecting portion 72 is provided on each of the upper side, which is the outer peripheral side of the upper side wall 22a, and the lower side, which is the outer peripheral side of the lower side wall 22b.
Thebobbin 71 for electrical equipment is insert-molded with the body portion 22 as an insert as in the first embodiment. The connecting portion 72 is formed integrally with the first flange portion 23 and the second flange portion 24 during the insert molding. The thickness of the connecting portion 72 is arbitrarily set within a range that can be formed by insert molding. The thickness of the connecting portion 72 is set to 1 to 3 mm, for example.
次に、第3実施形態による電気機器用ボビン71を図16および図17に示す。
図16および図17に示す電気機器用ボビン71は、補強用のつなぎ部72を備えている。つなぎ部72は、第一鍔部23と第二鍔部24とをつなぐ側壁である。このつなぎ部72は、第一鍔部23および第二鍔部24と一体に設けられている。つなぎ部72は、上側壁22aの外周側である上側および下側壁22bの外周側である下側にそれぞれ設けられている。
電気機器用ボビン71は、第1実施形態と同様に胴部22をインサート品としてインサート成形されている。つなぎ部72は、このインサート成形の際に、第一鍔部23および第二鍔部24と一体に形成される。つなぎ部72の厚さは、インサート成形で成形可能な範囲において任意に設定される。つなぎ部72の厚さは、例えば、1~3mmに設定されている。 (Third embodiment)
Next, an
The
The
第3実施形態では、つなぎ部72は、第一鍔部23と第二鍔部24との間に設けられている。このつなぎ部72は、胴部22よりも大きな厚さを有している。そのため、胴部22は、特に軸方向からの圧縮に対する強度が増加する。これにより、胴部22は、変形が低減される。したがって、電気機器用ボビン71の強度を高めることができる。
第3実施形態では、つなぎ部72は、上側壁22aおよび下側壁22bの外側にそれぞれ設けられている。一方、胴部22は、右側壁22cおよび左側壁22dが絶縁フィルムで形成されている。そのため、つなぎ部72を設けてもコイル16を構成する電線の巻数には影響が及ばない。したがって、強度を高めつつ電線の線積率を高めることができる。 In the third embodiment, the connectingportion 72 is provided between the first flange portion 23 and the second flange portion 24. The connecting portion 72 has a thickness larger than that of the trunk portion 22. For this reason, the strength of the body portion 22 against compression in the axial direction increases. Thereby, the deformation | transformation of the trunk | drum 22 is reduced. Therefore, the strength of the bobbin 71 for electric equipment can be increased.
In 3rd Embodiment, theconnection part 72 is provided in the outer side of the upper side wall 22a and the lower side wall 22b, respectively. On the other hand, as for the trunk | drum 22, the right side wall 22c and the left side wall 22d are formed with the insulating film. Therefore, even if the connecting portion 72 is provided, the number of turns of the electric wire constituting the coil 16 is not affected. Therefore, the line area ratio of the electric wire can be increased while increasing the strength.
第3実施形態では、つなぎ部72は、上側壁22aおよび下側壁22bの外側にそれぞれ設けられている。一方、胴部22は、右側壁22cおよび左側壁22dが絶縁フィルムで形成されている。そのため、つなぎ部72を設けてもコイル16を構成する電線の巻数には影響が及ばない。したがって、強度を高めつつ電線の線積率を高めることができる。 In the third embodiment, the connecting
In 3rd Embodiment, the
(第4実施形態)
第4実施形態による電気機器用ボビン81を図18および図19示す。
図18および図19に示す電気機器用ボビン81は、補強用のつなぎ部82を備えている。つなぎ部82は、第一鍔部23と第二鍔部24とをつなぐ側壁である。このつなぎ部82は、第一鍔部23および第二鍔部24と一体に設けられている。つなぎ部82は、上側壁22aの内周側である下側および下側壁22bの内周側である上側にそれぞれ設けられている。 (Fourth embodiment)
18 and 19 show anelectric equipment bobbin 81 according to the fourth embodiment.
Thebobbin 81 for electric equipment shown in FIGS. 18 and 19 is provided with a connecting portion 82 for reinforcement. The connecting portion 82 is a side wall that connects the first flange portion 23 and the second flange portion 24. The connecting portion 82 is provided integrally with the first flange portion 23 and the second flange portion 24. The connecting portions 82 are respectively provided on the lower side, which is the inner peripheral side of the upper side wall 22a, and the upper side, which is the inner peripheral side of the lower side wall 22b.
第4実施形態による電気機器用ボビン81を図18および図19示す。
図18および図19に示す電気機器用ボビン81は、補強用のつなぎ部82を備えている。つなぎ部82は、第一鍔部23と第二鍔部24とをつなぐ側壁である。このつなぎ部82は、第一鍔部23および第二鍔部24と一体に設けられている。つなぎ部82は、上側壁22aの内周側である下側および下側壁22bの内周側である上側にそれぞれ設けられている。 (Fourth embodiment)
18 and 19 show an
The
電気機器用ボビン81は、第1実施形態と同様に胴部22をインサート品としてインサート成形されている。つなぎ部82は、このインサート成形の際に、第一鍔部23および第二鍔部24と一体に形成される。つなぎ部62の厚さは、インサート成形で成形可能な範囲において任意に設定される。つなぎ部82の厚さは、例えば、1~3mmに設定されている。
第4実施形態も、第3実施形態と同様に、電線の線積率を高めつつ電気機器用ボビン81の強度を高めることができる。 Thebobbin 81 for electric equipment is insert-molded by using the body portion 22 as an insert as in the first embodiment. The connecting portion 82 is formed integrally with the first flange portion 23 and the second flange portion 24 during the insert molding. The thickness of the connecting portion 62 is arbitrarily set within a range that can be formed by insert molding. The thickness of the connecting portion 82 is set to 1 to 3 mm, for example.
Similarly to the third embodiment, the fourth embodiment can also increase the strength of thebobbin 81 for electric equipment while increasing the line area ratio of the electric wires.
第4実施形態も、第3実施形態と同様に、電線の線積率を高めつつ電気機器用ボビン81の強度を高めることができる。 The
Similarly to the third embodiment, the fourth embodiment can also increase the strength of the
(第5実施形態)
第5実施形態による電気機器用ボビン91を図20に示す。
第5実施形態による電気機器用ボビン91は、上記の複数の実施形態におけるインサート成形に代えて、プレス成形している。第5実施形態の場合、胴部22は、図20(b)および図20(e)に示すように軸方向の両端部がそれぞれ外側に折り曲げられている。これにより、胴部22は、軸方向の両端部にフランジ部22fを有している。係合孔22eは、フランジ部22fに配置されている。また、第5実施形態の場合、第一鍔部23および第二鍔部24は、いずれも2層構造である。 (Fifth embodiment)
Anelectric equipment bobbin 91 according to the fifth embodiment is shown in FIG.
Thebobbin 91 for electrical equipment according to the fifth embodiment is press-molded instead of the insert molding in the above-described plurality of embodiments. In the case of the fifth embodiment, as shown in FIGS. 20 (b) and 20 (e), in the case of the body portion 22, both end portions in the axial direction are bent outward. Thereby, the trunk | drum 22 has the flange part 22f in the both ends of an axial direction. The engagement hole 22e is disposed in the flange portion 22f. Moreover, in the case of 5th Embodiment, the 1st collar part 23 and the 2nd collar part 24 are both 2 layer structures.
第5実施形態による電気機器用ボビン91を図20に示す。
第5実施形態による電気機器用ボビン91は、上記の複数の実施形態におけるインサート成形に代えて、プレス成形している。第5実施形態の場合、胴部22は、図20(b)および図20(e)に示すように軸方向の両端部がそれぞれ外側に折り曲げられている。これにより、胴部22は、軸方向の両端部にフランジ部22fを有している。係合孔22eは、フランジ部22fに配置されている。また、第5実施形態の場合、第一鍔部23および第二鍔部24は、いずれも2層構造である。 (Fifth embodiment)
An
The
第一鍔部23は、2枚の第一鍔部片23bおよび接着部材92を有している。第一鍔部片23bは、図20(c)および図20(e)に示すように第一鍔部23の厚さを二等分して形成されている。接着部材92は、図20(d)および図20(e)に示すように第一鍔部片23bと胴部22とを接着する。接着部材92は、図20(d)に示すように例えば第一鍔部23と同形状の枠状に形成されている。接着部材92は、両面に接着性を有する接着シートで形成されている。第一鍔部23は、軸方向の端部側から順に、第一鍔部片23b、接着部材92、胴部22のフランジ部22f、接着部材92、第一鍔部片23bを積層して、胴部22と一体に設けられている。このとき、係合孔22eは、2枚の第一鍔部片23bの間に配置される。
The first collar 23 has two first collar parts 23b and an adhesive member 92. As shown in FIGS. 20 (c) and 20 (e), the first flange portion 23b is formed by dividing the thickness of the first flange portion 23 into two equal parts. As shown in FIGS. 20D and 20E, the adhesive member 92 bonds the first flange part 23b and the body part 22 together. As shown in FIG. 20D, the adhesive member 92 is formed in a frame shape having the same shape as the first flange 23, for example. The adhesive member 92 is formed of an adhesive sheet having adhesiveness on both sides. In order from the end side in the axial direction, the first flange portion 23 is formed by laminating the first flange portion 23b, the adhesive member 92, the flange portion 22f of the body portion 22, the adhesive member 92, and the first flange portion piece 23b. It is provided integrally with the body portion 22. At this time, the engagement hole 22e is disposed between the two first flange portions 23b.
同様に第二鍔部24は、2枚の第二鍔部片24bおよび接着部材92を有している。第二鍔部片24bは、図20(e)に示すように第二鍔部24の厚さを二等分して形成されている。接着部材92は、図20(d)および図20(e)に示すように第二鍔部片24bと胴部22とを接着する。接着部材92は、両面に接着性を有する接着シートで形成され、第二鍔部24と同形状の枠状に形成されている。第二鍔部24は、軸方向の端部側から順に、第二鍔部片24b、接着部材92、胴部22のフランジ部22f、接着部材92、第二鍔部片24bを積層して、胴部22と一体に設けられている。このとき、係合孔22eは、2枚の第二鍔部片24bの間に配置される。第5実施形態の場合、2枚の第一鍔部片23bは挟み片に相当する。また、同様に2枚の第二鍔部片24bは、挟み片に相当する。
Similarly, the second collar part 24 has two second collar parts 24 b and an adhesive member 92. As shown in FIG. 20 (e), the second flange part 24 b is formed by dividing the thickness of the second flange part 24 into two equal parts. As shown in FIGS. 20D and 20E, the bonding member 92 bonds the second flange part 24b and the body part 22 together. The adhesive member 92 is formed of an adhesive sheet having adhesiveness on both sides, and is formed in a frame shape having the same shape as the second flange portion 24. In order from the end side in the axial direction, the second flange portion 24 is formed by laminating the second flange portion piece 24b, the adhesive member 92, the flange portion 22f of the body portion 22, the adhesive member 92, and the second flange portion piece 24b, It is provided integrally with the body portion 22. At this time, the engagement hole 22e is disposed between the two second flange pieces 24b. In the case of the fifth embodiment, the two first flange parts 23b correspond to sandwiching pieces. Similarly, the two second flange parts 24b correspond to sandwiching pieces.
次に、第5実施形態による電気機器用ボビン91の製造手順について説明する。
胴部22を構成する絶縁フィルム42は、表面にプラズマ処理などの表面処理が施される。この表面処理を施す工程は、表面処理工程に相当する。表面処理の詳細については、第1実施形態で説明した通りであり、説明を省略する。絶縁フィルム42に表面処理が程こされると、絶縁フィルム42は図20(a)に示すように胴部22の展開した長方形に成形される。このとき、絶縁フィルム42は、図20(b)に示すように長辺において切込み部42aを形成してもよい。切込み部42aを形成することにより、後の工程において折り曲げが容易になる。なお、表面処理を施す時期は、第1実施形態と同様に限定されない。 Next, a manufacturing procedure of thebobbin 91 for electric equipment according to the fifth embodiment will be described.
The surface of the insulatingfilm 42 constituting the body portion 22 is subjected to surface treatment such as plasma treatment. The step of performing the surface treatment corresponds to the surface treatment step. The details of the surface treatment are as described in the first embodiment, and a description thereof will be omitted. When the surface treatment is applied to the insulating film 42, the insulating film 42 is formed into a rectangular shape in which the body portion 22 is developed as shown in FIG. At this time, the insulating film 42 may form a cut portion 42a on the long side as shown in FIG. By forming the cut portion 42a, it becomes easy to bend in a later step. Note that the timing for performing the surface treatment is not limited as in the first embodiment.
胴部22を構成する絶縁フィルム42は、表面にプラズマ処理などの表面処理が施される。この表面処理を施す工程は、表面処理工程に相当する。表面処理の詳細については、第1実施形態で説明した通りであり、説明を省略する。絶縁フィルム42に表面処理が程こされると、絶縁フィルム42は図20(a)に示すように胴部22の展開した長方形に成形される。このとき、絶縁フィルム42は、図20(b)に示すように長辺において切込み部42aを形成してもよい。切込み部42aを形成することにより、後の工程において折り曲げが容易になる。なお、表面処理を施す時期は、第1実施形態と同様に限定されない。 Next, a manufacturing procedure of the
The surface of the insulating
成形された絶縁フィルム42は、図20(b)に示すように角筒状に折り曲げられて、胴部22に成形される。さらに、成形された絶縁フィルム42は、軸方向の両端を外周側に折り曲げられる。これにより、フランジ部22fが形成される。この工程は、胴部整形工程に相当する。
胴部整形工程で形成された胴部22は、鍔部成形工程へ移行する。具体的には、胴部22のフランジ部22fには、図20(e)および図20(f)に示すように第一鍔部片23bおよび第二鍔部片24b、接着部材92が所定の順で積層される。その後、積層された部材は、プレス成形することにより、第一鍔部23および第二鍔部24に成形される。第一鍔部23は、胴部22の軸方向の端部側から第一鍔部片23b、接着部材92、胴部22のフランジ部22f、接着部材92および第一鍔部片23bの順で積層された後、プレス成形される。これにより、接着部材92は各部材を接着する。同様に、第二鍔部24は、胴部22の軸方向の端部側から第二鍔部片24b、接着部材92、胴部22のフランジ部22f、接着部材92および第二鍔部片24bの順で積層された後、プレス成形される。これにより、接着部材92は、各部材を接着する。 The formed insulatingfilm 42 is bent into a rectangular tube shape as shown in FIG. Further, the formed insulating film 42 is bent at both ends in the axial direction to the outer peripheral side. Thereby, the flange part 22f is formed. This process corresponds to a trunk shaping process.
Thebody part 22 formed in the body part shaping process shifts to the hip part forming process. Specifically, as shown in FIGS. 20 (e) and 20 (f), the flange portion 22f of the body portion 22 is provided with a first flange portion 23b, a second flange portion piece 24b, and an adhesive member 92. Laminated in order. Thereafter, the laminated members are formed into the first collar part 23 and the second collar part 24 by press molding. The first flange 23 is in the order of the first flange part 23b, the adhesive member 92, the flange part 22f of the trunk part 22, the adhesive member 92, and the first flange part 23b from the axial end of the body part 22. After being laminated, it is press-molded. Thereby, the adhesive member 92 adheres each member. Similarly, the second flange 24 includes the second flange 24b, the adhesive member 92, the flange 22f of the barrel 22, the adhesive member 92, and the second flange 24b from the end of the barrel 22 in the axial direction. After being laminated in this order, it is press-molded. Thereby, the adhesive member 92 adheres each member.
胴部整形工程で形成された胴部22は、鍔部成形工程へ移行する。具体的には、胴部22のフランジ部22fには、図20(e)および図20(f)に示すように第一鍔部片23bおよび第二鍔部片24b、接着部材92が所定の順で積層される。その後、積層された部材は、プレス成形することにより、第一鍔部23および第二鍔部24に成形される。第一鍔部23は、胴部22の軸方向の端部側から第一鍔部片23b、接着部材92、胴部22のフランジ部22f、接着部材92および第一鍔部片23bの順で積層された後、プレス成形される。これにより、接着部材92は各部材を接着する。同様に、第二鍔部24は、胴部22の軸方向の端部側から第二鍔部片24b、接着部材92、胴部22のフランジ部22f、接着部材92および第二鍔部片24bの順で積層された後、プレス成形される。これにより、接着部材92は、各部材を接着する。 The formed insulating
The
胴部22のフランジ部22fを挟む2枚の接着部材92は、一部がフランジ部22fの係合孔22e内に進入する。そして、フランジ部22fの両側の接着部材92は、係合孔22eにおいて互いに接着する。これにより、胴部22のフランジ部22fは、接着部材92によって第一鍔部片23bおよび第二鍔部片24bと強固に接合する。この場合、接着部材92のうち係合孔22e内に位置する部分は、被係合部に相当する。
得られた電気機器用ボビン91は、第一実施形態の電気機器用ボビン21と同様にして、図1に示す固定子鉄心15のティース部18に嵌められる。これにより、固定子鉄心15のティース部18に嵌められる電気機器用ボビン91の胴部22のうち少なくとも固定子鉄心15内に位置する部分には胴部22の絶縁フィルムが位置する。 A part of the twoadhesive members 92 sandwiching the flange portion 22f of the body portion 22 enters the engagement hole 22e of the flange portion 22f. Then, the adhesive members 92 on both sides of the flange portion 22f adhere to each other in the engagement hole 22e. Thereby, the flange part 22f of the trunk | drum 22 is firmly joined with the 1st collar part piece 23b and the 2nd collar part piece 24b by the adhesive member 92. FIG. In this case, a portion of the adhesive member 92 located in the engagement hole 22e corresponds to the engaged portion.
The obtainedelectrical equipment bobbin 91 is fitted into the teeth portion 18 of the stator core 15 shown in FIG. 1 in the same manner as the electrical equipment bobbin 21 of the first embodiment. Thereby, the insulating film of the trunk | drum 22 is located in the part located in the stator core 15 at least among the trunk | drums 22 of the bobbin 91 for electric equipments fitted to the teeth part 18 of the stator core 15. FIG.
得られた電気機器用ボビン91は、第一実施形態の電気機器用ボビン21と同様にして、図1に示す固定子鉄心15のティース部18に嵌められる。これにより、固定子鉄心15のティース部18に嵌められる電気機器用ボビン91の胴部22のうち少なくとも固定子鉄心15内に位置する部分には胴部22の絶縁フィルムが位置する。 A part of the two
The obtained
上述の第5実施形態によれば、第1実施形態と同様に、胴部22の厚さは低減される。そのため、電気機器用ボビン91には、コイル16を形成するより多くの電線が巻かれる。したがって、回転電機の高出力化および高効率化を図ることができる。
また、第5実施形態では、インサート成形に代えて、プレス成形により第一鍔部23および第二鍔部24を胴部22に一体に形成することができる。 According to the fifth embodiment described above, the thickness of thebody portion 22 is reduced as in the first embodiment. Therefore, more electric wires than the coil 16 are wound around the bobbin 91 for electric equipment. Therefore, high output and high efficiency of the rotating electrical machine can be achieved.
Moreover, in 5th Embodiment, it replaces with insert molding and the1st collar part 23 and the 2nd collar part 24 can be integrally formed in the trunk | drum 22 by press molding.
また、第5実施形態では、インサート成形に代えて、プレス成形により第一鍔部23および第二鍔部24を胴部22に一体に形成することができる。 According to the fifth embodiment described above, the thickness of the
Moreover, in 5th Embodiment, it replaces with insert molding and the
(第6~第10実施形態)
以下、第6実施形態から第9実施形態を説明する。
第6実施形態では、図21に示すように係合孔22gは、断面が四角形状に形成されている。また、第7実施形態では、図22に示すように係合孔22hは、断面が三角形状に形成されている。さらに、第8実施形態では、図23に示すように係合孔22iは、一部が絶縁フィルム42の外縁に開口している。第8実施形態の場合、係合孔22iは、絶縁フィルム42の内側ほど内径が大きくなることが好ましい。このような形状の係合孔22iは、進入した被係合部25と固く噛み合う。したがって、胴部22と第一鍔部23および第二鍔部24との相対的な位置ずれをより低減することができる。このように、係合孔22g~22iの形状は、任意に設定することができる。第9実施形態では、図24に示すように、電気機器用ボビン21は、胴部22の内周側に充填部材を設けていない。例えばコイル16で発生する熱が少ない場合、第9実施形態に示すように充填部材26を省略させてもよい。 (Sixth to tenth embodiments)
Hereinafter, sixth to ninth embodiments will be described.
In the sixth embodiment, as shown in FIG. 21, theengagement hole 22g has a square cross section. In the seventh embodiment, as shown in FIG. 22, the engagement hole 22h has a triangular cross section. Furthermore, in the eighth embodiment, as shown in FIG. 23, a part of the engagement hole 22 i is opened at the outer edge of the insulating film 42. In the case of the eighth embodiment, it is preferable that the inner diameter of the engagement hole 22i increases toward the inner side of the insulating film 42. The engagement hole 22i having such a shape is tightly engaged with the engaged portion 25 that has entered. Therefore, the relative position shift of the trunk | drum 22 and the 1st collar part 23, and the 2nd collar part 24 can be reduced more. Thus, the shapes of the engagement holes 22g to 22i can be arbitrarily set. In the ninth embodiment, as illustrated in FIG. 24, the bobbin 21 for an electric device does not include a filling member on the inner peripheral side of the trunk portion 22. For example, when the heat generated in the coil 16 is small, the filling member 26 may be omitted as shown in the ninth embodiment.
以下、第6実施形態から第9実施形態を説明する。
第6実施形態では、図21に示すように係合孔22gは、断面が四角形状に形成されている。また、第7実施形態では、図22に示すように係合孔22hは、断面が三角形状に形成されている。さらに、第8実施形態では、図23に示すように係合孔22iは、一部が絶縁フィルム42の外縁に開口している。第8実施形態の場合、係合孔22iは、絶縁フィルム42の内側ほど内径が大きくなることが好ましい。このような形状の係合孔22iは、進入した被係合部25と固く噛み合う。したがって、胴部22と第一鍔部23および第二鍔部24との相対的な位置ずれをより低減することができる。このように、係合孔22g~22iの形状は、任意に設定することができる。第9実施形態では、図24に示すように、電気機器用ボビン21は、胴部22の内周側に充填部材を設けていない。例えばコイル16で発生する熱が少ない場合、第9実施形態に示すように充填部材26を省略させてもよい。 (Sixth to tenth embodiments)
Hereinafter, sixth to ninth embodiments will be described.
In the sixth embodiment, as shown in FIG. 21, the
さらに、電気機器用ボビン21は、図25に示すように胴部22、第一鍔部23および第二鍔部24を二つに分割してもよい。これにより、電気機器用ボビン21は、固定子鉄心15のティース部18に取り付けるとき、ティース部18を挟み込むことができる。なお、電気機器用ボビン21は、二つ以上に分割してもよく、分割位置も上記に限らず任意に設定可能である。
Furthermore, as shown in FIG. 25, the bobbin 21 for an electric device may divide the body portion 22, the first flange portion 23, and the second flange portion 24 into two. Thereby, the bobbin 21 for electric equipment can pinch | interpose the teeth part 18 when attaching to the teeth part 18 of the stator core 15. FIG. The electric equipment bobbin 21 may be divided into two or more, and the division position is not limited to the above and can be arbitrarily set.
(その他の実施形態)
なお、本発明は上記し且つ図面に示す実施形態に限定されず、次のような変形、拡張が可能である。
胴部22は、上側壁22a、下側壁22b、右側壁22cおよび左側壁22dを絶縁フィルムで構成する例を説明した。しかし、胴部22は、少なくとも右側壁22cおよび左側壁22dが絶縁フィルムで構成されていればよい。この場合、上側壁22aおよび下側壁22bは、第一鍔部23および第二鍔部24と同じ材料で第一鍔部23および第二鍔部24と一体に形成してもよい。 (Other embodiments)
The present invention is not limited to the embodiment described above and shown in the drawings, and the following modifications and expansions are possible.
The trunk | drum 22 demonstrated the example which comprises theupper side wall 22a, the lower side wall 22b, the right side wall 22c, and the left side wall 22d with the insulating film. However, it is only necessary that the body 22 has at least the right side wall 22c and the left side wall 22d made of an insulating film. In this case, the upper side wall 22 a and the lower side wall 22 b may be formed integrally with the first flange portion 23 and the second flange portion 24 with the same material as the first flange portion 23 and the second flange portion 24.
なお、本発明は上記し且つ図面に示す実施形態に限定されず、次のような変形、拡張が可能である。
胴部22は、上側壁22a、下側壁22b、右側壁22cおよび左側壁22dを絶縁フィルムで構成する例を説明した。しかし、胴部22は、少なくとも右側壁22cおよび左側壁22dが絶縁フィルムで構成されていればよい。この場合、上側壁22aおよび下側壁22bは、第一鍔部23および第二鍔部24と同じ材料で第一鍔部23および第二鍔部24と一体に形成してもよい。 (Other embodiments)
The present invention is not limited to the embodiment described above and shown in the drawings, and the following modifications and expansions are possible.
The trunk | drum 22 demonstrated the example which comprises the
第3実施形態におけるつなぎ部72および第4実施形態におけるつなぎ部82は、壁状に形成する例について説明した。しかし、つなぎ部72およびつなぎ部82の形状は、例えば複数の柱状に形成するなど、任意に設定することができる。また、第5実施形態における接着部材92は、接着シートを例に説明した。しかし、接着部材92は、接着シートに限らず、一般的な流動性を有する接着剤でもよい。複数の実施形態における表面処理とは、プラズマ処理を例に説明したが、これに限らずコロナ処理や化学処理であってもよい。
The connection part 72 in the third embodiment and the connection part 82 in the fourth embodiment have been described as being formed in a wall shape. However, the shape of the connecting portion 72 and the connecting portion 82 can be arbitrarily set, for example, formed in a plurality of columnar shapes. Further, the adhesive member 92 in the fifth embodiment has been described by taking an adhesive sheet as an example. However, the adhesive member 92 is not limited to an adhesive sheet, and may be an adhesive having general fluidity. The surface treatment in the plurality of embodiments has been described by taking the plasma treatment as an example, but is not limited thereto, and may be a corona treatment or a chemical treatment.
以上説明した実施形態は一例に過ぎず、絶縁フィルムの材質や厚みは、各電気機器用ボビンの使用により適宜決定され、その他、材料、形状、つなぎ部の位置などについても、適宜変更することができる。また、電気機器用ボビンは、変圧器、インバータなどの電気機器の他、アウターロータ形の回転電機にも適用することができる。
The embodiment described above is merely an example, and the material and thickness of the insulating film are determined as appropriate depending on the use of the bobbin for each electric device, and other materials, shapes, positions of connecting portions, etc. can be changed as appropriate. it can. Moreover, the bobbin for electric equipment can be applied not only to electric equipment such as a transformer and an inverter but also to an outer rotor type rotating electrical machine.
Claims (11)
- 絶縁フィルムで筒状に形成されている胴部と、
前記胴部の軸方向の両端部にそれぞれ設けられ、内周側に前記胴部が嵌め込まれ、前記胴部と異なる材料で形成され、前記胴部から径方向外側へ環状に突出している鍔部と、
前記胴部の軸方向の両端部にそれぞれ設けられ、前記胴部を厚さ方向に貫き、前記胴部と対向する前記鍔部の内周側が進入する係合孔と、
を備える電気機器用ボビン。 A barrel formed in a cylindrical shape with an insulating film;
A collar portion provided at each axial end portion of the body portion, the body portion being fitted on the inner peripheral side, formed of a material different from that of the body portion, and projecting annularly from the body portion radially outward. When,
An engagement hole that is provided at each end of the body in the axial direction, penetrates the body in the thickness direction, and enters the inner peripheral side of the flange that faces the body, and
Bobbin for electrical equipment comprising - 前記鍔部は、前記胴部の軸方向の端部を径方向の両側から挟み込む一対の挟み片を有する請求項1記載の電気機器用ボビン。 The bobbin for an electric device according to claim 1, wherein the flange includes a pair of sandwiching pieces for sandwiching the axial end of the body from both sides in the radial direction.
- 前記係合孔は、前記胴部の径方向において両端部がそれぞれ一対の前記挟み片に対向し、
前記鍔部は、対向する前記挟み片の間で前記係合孔を貫いている請求項2記載の電気機器用ボビン。 The engaging hole has opposite end portions in the radial direction of the body portion, each facing a pair of the clip pieces,
The bobbin for an electric device according to claim 2, wherein the flange portion penetrates the engagement hole between the sandwiching pieces facing each other. - 前記胴部および前記鍔部の径方向内側に設けられている充填部材をさらに備える請求項1記載の電気機器用ボビン。 The bobbin for an electrical device according to claim 1, further comprising a filling member provided on a radially inner side of the trunk portion and the flange portion.
- 前記胴部は、厚さが0.05mm~0.5mmである請求項1記載の電気機器用ボビン。 The bobbin for an electric device according to claim 1, wherein the body portion has a thickness of 0.05 mm to 0.5 mm.
- 前記鍔部と一体に形成され、軸方向において前記胴部の軸方向の両端部に設けられている前記鍔部を接続して補強する、つなぎ部をさらに備える請求項1記載の電気機器用ボビン。 The bobbin for an electric device according to claim 1, further comprising a connecting portion that is integrally formed with the flange portion and that connects and reinforces the flange portion provided at both axial end portions of the body portion in the axial direction. .
- 厚さが0.05mm~0.5mmの絶縁材料を筒状の胴部に成形する工程と、
筒状に成形した前記胴部の軸方向の両端部に前記胴部よりも外径が大きな鍔部を、前記胴部と一体に形成する工程と、
を含む電気機器用ボビンの製造方法。 Forming an insulating material having a thickness of 0.05 mm to 0.5 mm into a cylindrical body;
Forming a flange having a larger outer diameter than the body part at both ends in the axial direction of the body part formed into a cylindrical shape integrally with the body part;
Manufacturing method of bobbin for electric equipment including - 前記胴部を成形する工程において、前記胴部の軸方向の端部に前記胴部を厚さ方向へ貫く係合孔を形成する工程をさらに含む請求項7記載の電気機器用ボビンの製造方法。 8. The method for manufacturing an electric equipment bobbin according to claim 7, further comprising a step of forming an engagement hole penetrating the body portion in a thickness direction at an end portion in the axial direction of the body portion in the step of forming the body portion. .
- 前記鍔部を形成する工程では、前記鍔部を射出成形する請求項7記載の電気機器用ボビンの製造方法。 The method for manufacturing a bobbin for an electric device according to claim 7, wherein, in the step of forming the flange portion, the flange portion is injection-molded.
- 前記鍔部を形成する工程では、前記胴部を金型に配置して前記鍔部をインサート成形する請求項7記載の電気機器用ボビンの製造方法。 The method for manufacturing a bobbin for an electrical device according to claim 7, wherein, in the step of forming the flange portion, the barrel portion is disposed in a mold and the flange portion is insert-molded.
- 前記胴部の表面に表面処理を行う工程をさらに含む請求項7記載の電気機器用ボビンの製造方法。 The method for manufacturing a bobbin for an electric device according to claim 7, further comprising a step of performing a surface treatment on the surface of the body portion.
Applications Claiming Priority (4)
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JP2010-103456 | 2010-04-28 | ||
JP2010103456A JP2011234537A (en) | 2010-04-28 | 2010-04-28 | Bobbin for rotating electric machine, manufacturing method of rotating electric machine and bobbin for the same |
JP2010183933A JP2012044780A (en) | 2010-08-19 | 2010-08-19 | Bobbin for electrical apparatus and method for manufacturing the same |
JP2010-183933 | 2010-08-19 |
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WO2011136144A1 true WO2011136144A1 (en) | 2011-11-03 |
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WO2016027494A1 (en) * | 2014-08-20 | 2016-02-25 | 株式会社日立製作所 | Power switchgear |
CN105493386A (en) * | 2013-09-04 | 2016-04-13 | 杜邦帝人先进纸(日本)有限公司 | Motor bobbin and method for manufacturing same |
US9705373B2 (en) | 2015-04-20 | 2017-07-11 | Honda Motor Co., Ltd. | Insulator |
EP3172815B1 (en) * | 2014-07-24 | 2018-12-19 | ThyssenKrupp Presta TecCenter AG | Rotor for an electric motor |
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JP6119076B2 (en) * | 2013-01-24 | 2017-04-26 | デュポン帝人アドバンスドペーパー株式会社 | Bobbin for motor |
WO2017187522A1 (en) * | 2016-04-26 | 2017-11-02 | 三菱電機株式会社 | Stator, electric motor, stator manufacturing method, and electric motor manufacturing method |
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CN105493386B (en) * | 2013-09-04 | 2021-01-26 | 杜邦帝人先进纸(日本)有限公司 | Motor bobbin and method for manufacturing the same |
EP3172815B1 (en) * | 2014-07-24 | 2018-12-19 | ThyssenKrupp Presta TecCenter AG | Rotor for an electric motor |
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KR20120117918A (en) | 2012-10-24 |
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