JPH065977B2 - Method for manufacturing flat coil armature - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION a. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing an armature incorporated in a flat type electric motor used for, for example, blowing air in an air conditioner or driving a power window.

(Prior Art) A flat type electric motor is used as a motor for installing in a narrow space. As such a flat type electric motor, there are a print motor using a thin metal plate cut into a strip shape as an armature, and a type using a conductor wound in a coil shape as an armature.

Among them, in the case of a flat coil type armature that uses a coil-wound conductor wire as an armature, the conductor wire wound and laminated in a disk shape is covered (embedded) with synthetic resin, and the positional relationship of the conductor wires The armature should not be dislocated or the shape of the armature, which should be flat, should not be distorted.

Various methods have been conventionally proposed for manufacturing a flat coil armature by covering a conductor wire wound in a coil shape and laminated in a disk shape with a synthetic resin. First of all, the method disclosed in Japanese Patent Laid-Open No. 52-23601 is described in
A resin composition containing 40 to 90% by weight of an inorganic filler with respect to the total amount of an epoxy resin containing 0% by weight or more of a bisphenol A-based epoxy resin covers a conductor wire wound in a coil shape. .

Secondly, the method disclosed in Japanese Patent Laid-Open No. 51-36505 has a linear expansion such that the difference in expansion coefficient between the conductor wound in a coil shape is 1.5 × 10 ⁻⁵ / ° C. or less. The conductor is covered with an epoxy resin composition having a coefficient.

Thirdly, in the method disclosed in JP-A-53-149603, a conductor wound in a coil shape is prepared by adding 1 mol of ethyleneglycose 2 molt 3,3 ', 4,4'-benzophenone tetracarboxylic acid anhydride. And a diester diacid anhydride obtained by esterification in an organic solvent as a curing agent, a composition of this curing agent and a bisphenol type epoxy resin is coated with a resin-impregnated prepreg sheet, and the above-mentioned prepreg sheet is coated. The conductor is molded with an acid anhydride-curable epoxy resin to make it an integral rigid body.

Fourthly, the method disclosed in Japanese Patent Laid-Open No. 53-149602 discloses a flat molded article having a protrusion and a conductive wire wound in a coil shape, which is composed of a resoftenable resin and an inorganic filler. It is made into an integral rigid body by compression molding.

Fifth, JP-A-59-108332 discloses a method for sealing electronic parts with polyphenylene sulfide.

(Problems to be Solved by the Invention) However, each of the conventional methods for manufacturing the flat coil armature constructed as described above has the following disadvantages.

First, in the first method disclosed in JP-A-52-23601, in order to cure the epoxy resin, 8
It is necessary to perform heating at 0 ° C. for 15 hours and then at 150 ° C. for 15 hours, which requires a very long time to manufacture an armature, resulting in poor productivity.

Although the method disclosed in JP-A-51-36505 is shorter than the first method, it must be heated at 150 ° C. for 10 to 15 hours to cure the epoxy resin composition. After all productivity is bad.

The third method disclosed in JP-A-53-149603 has complicated steps and high manufacturing cost.

Furthermore, the fourth method disclosed in JP-A-53-149602 is unsatisfactory in terms of cost and manufacturing time.

A fifth method disclosed in Japanese Patent Laid-Open No. 59-108332 is to seal an electronic component used statically with polyphenylene sulfide, which is a flat coil which is rotated at a high speed in a high temperature atmosphere. This is different from the manufacturing method for the die armature.

An object of the present invention is to provide a method for manufacturing a flat coil type armature, which eliminates the above-mentioned inconvenience, is low in manufacturing cost, and can manufacture an armature in a short time.

b. Configuration of the Invention (Means for Solving the Problem) A method for manufacturing a flat coil armature according to the present invention is an injection method in which a wire wound in a coil shape is heated to a temperature lower than a heat deformation temperature of a thermoplastic synthetic resin. It is inserted into a molding die, and then a thermoplastic resin molding material containing an inorganic filler is pushed into the injection molding die at a relatively low pressure of 800 to 1000 Kg / cm ² to seal the above-mentioned conductive wire and to integrate it. It becomes a rigid body.

As the thermoplastic resin to be used, a material having high fluidity at the time of injection molding but having sufficient heat resistance and mechanical strength at the time of use as an armature is selected. In order to secure heat resistance during use, it is necessary that the heat exchange temperature is 200 ° C. or higher. As materials satisfying both these conditions and other conditions, polyphenylene sulfide, polyether sulfone, One or a combination of two or more of aromatic polyester and polyether / etherketone can be used.

The inorganic filler is mixed in order to improve the fluidity at the time of injection molding of the thermoplastic resin and to improve the dimensional property and heat resistance, and the mixed amount is 20 to 40% by weight. As the type of the inorganic filler, one or more of silica, clay, quartz glass powder, calcium carbonate, kaolin, mica, hydrated alumina, glass beads, glass fiber, alumina oxide fiber, silicon carbide fiber, etc. are mixed. Then, if necessary, talc or a metal salt such as zinc stearate is added to improve fluidity and releasability.

The present invention uses polyphenylene sulfide (hereinafter referred to as PPS) as a thermoplastic synthetic resin, in which a conductor wire previously wound in a coil shape is coated with PPS mixed with such an inorganic filler to form an integral rigid body. In order to materialize into an armature, the above wire is inserted into an injection molding die, the die is closed, and the PPS is heated in the die to enhance fluidity.
Inject.

The heating temperature of PPS is a temperature at which the fluidity becomes high,
In the present invention, the temperature is 300 to 350 ° C., and the temperature is 120 to 150 ° C.
It was injected into a preheated mold. The injection molding pressure is set as low as possible so that good molding can be performed.
This is because if the injection pressure of the synthetic resin is too high, P
This is because the coil winding wire previously inserted into the molding die is deformed by the momentum of PS flow, and the performance of the armature deteriorates, or the appearance deteriorates and the commercial value decreases. In the present invention, this injection pressure is set to 800 to 1000 Kg / cm ² .

When the injection of PPS into the injection mold is completed, PP
After leaving for a short time until the temperature of S becomes equal to or lower than the heat distortion temperature, the mold is opened and the molded product is taken out. The molded product taken out can be used as it is as an armature by cutting off an extra portion such as a sprue generated at the time of injection molding, and a post-treatment unlike the case where an epoxy resin is used is unnecessary.

(Examples) Next, examples of the present invention will be described.

Example 1 Polyphenyl sulfide was mixed with 40% by weight of quartz glass powder.

In an injection molding mold in which the above mixture is heated to 310 ° C. (similar results can be obtained if the temperature is 300 to 350 ° C.) and melted, and a coil wire is previously inserted and heated to 150 ° C. (120 ° C. or higher) Was injected at a pressure of 1000 Kg / cm ² (800 Kg / cm ² or more can be molded), and after 40 seconds, the molding die was opened and the molded product was taken out. The time required from insertion of the coil winding wire into the molding die to removal of the molded product was 90 seconds.

The dimensions of the molded product taken out are accurate and there is no distortion of the shape,
Satisfactory performance was obtained when it was installed in the motor and used.

Example 2 Polyethersulfone was admixed with 20% by weight of silica.

The above mixture is heated to 350 ° C. to melt, and 120 ° C. in advance.
It was injected at a pressure of 800 kg / cm ² into the heated injection mold, and after 40 seconds, the mold was opened and the molded product was taken out.

Also in the case of this example, the dimensions of the molded product taken out were accurate, and there was no distortion of the shape, and satisfactory performance was obtained when the molded product was assembled and used in an electric motor.

c. EFFECTS OF THE INVENTION The method for manufacturing the flat coil type armature of the present invention is configured as described above, so that the flat coil type armature used under severe conditions of high speed rotation in a high temperature atmosphere has sufficient strength, Since it has rigidity and can be manufactured quickly and efficiently without irregularities in the shape, it is possible to reduce the number of workers and cost and improve the productivity.

Claims (1)

[Claims] 1. A wire wound in advance in a coil shape is inserted into an injection molding die, the molding die is closed, and the molding die is lower than the heat deformation temperature of polyphenylene sulfide.
While warming to a temperature of 150 ° C, add 20
~ 40 wt% inorganic filler, 300-350 ° C
A method for producing a flat coil type armature in which polyphenylene sulfide heated and melted at the temperature is injected at a pressure of 800 to 1000 Kg / cm ² , the polyphenylene sulfide is cooled and solidified, and then a molding die is opened to take out a molded product.