JPH0710486Y2 - Mold coil - Google Patents

Description

[Detailed Description of the Invention] A. Field of Industrial Application The present invention relates to a molded coil molded without using a mold.

B. Outline of the Invention In the present invention, a coil conductor is wound between an inner insulating cylinder and an outer insulating cylinder, which are fitted into an iron core and have a substantially rectangular cross section, and are sealed between both ends of the coil conductor and the inner and outer insulating cylinders. In the molded coil filled with the material, at least at the corners of the outer insulating cylinder, by interposing an adhesive between the coil conductor and the outer insulating cylinder and the sealing material, the outer side at the corners of the outer insulating cylinder The insulating cylinder and the sealing material are prevented from peeling off, and a rectangular molded coil can be formed.

C. Conventional Technology A transformer uses a molded coil formed by molding a coil conductor. There are two methods for molding the coil conductor: molding by a mold or molding without using a mold. As a mold coil that is molded without using a mold, there is one using prepreg insulation.

A molded coil with prepreg insulation is shown in Fig. 2 (a).
~ (C). There are two types of mold coil, one is one in which only the mold coil is manufactured in advance separately from the iron core, and then the mold coil is fitted into the other, and one in which the coil is wound directly around the iron core.

A procedure for manufacturing a molded coil by prepreg insulation will be described below. As shown in the drawing, an inner core prepreg 2 as an inner insulating cylinder is wound around an iron core or a winding form 1 having a substantially quadrangular cross section, a coil conductor 4 is wound around the inner layer prepreg 2, and an outer side is wound around the coil conductor 4. The outer layer prepreg 3 as an insulating cylinder is wound. Then, in order to insulate the upper and lower parts of the coil conductor 4 in the figure, after heating and curing the inner and outer layer prepregs 2 and 3, a liquid resin 5 as an encapsulating material is used.
The space between the outer layer prepregs 2 and 3 and the coil conductor 4 is filled and cured. In this manner, the liquid resin 5 is filled above and below the coil conductor 4 and cured. If a winding die is used, remove the mold coil from the winding die.

D. Problem to be Solved by the Invention However, due to contraction when the liquid resin is cured, as shown in FIG. 3, peeling occurs between the outer layer prepreg 3 and the resin 5 to form a gap 6. A liquid elastomer having an adhesive force may be used instead of the liquid resin, but since the adhesive force is weak, peeling occurs in the same manner as described above.

Therefore, the cross-sectional shapes of the iron core and the mold coil cannot be made quadrangular, which hinders downsizing of the transformer. As a liquid thruster, there is Shin-Etsu Chemical Silicon KE1204.

Then, this invention aims at providing the mold coil which solved such a subject.

E. Means for Solving the Problems The constitution of the present invention for achieving the above object is to wind a coil conductor around the outer circumference of an inner insulating cylinder having a substantially rectangular cross section and to insulate the outside of the coil conductor from the outside. Cover with a tube,
In a molded coil in which a sealing material is filled between the coil conductors at both ends of the inner / outer insulating cylinder and the inner / outer insulating cylinder, at least a corner of the outer insulating cylinder is sealed with the coil conductor and the outer insulating cylinder. A molded coil, characterized in that an adhesive agent is interposed between the stopper and the stop material.

F. Action At least at the corners of the outer insulating cylinder, since the adhesive is interposed between the outer insulating cylinder and the coil conductor, and the sealing material, the sealing material is attached to the inner peripheral surface of the corner of the outer insulating cylinder. To be glued.

Therefore, at the corners of the quadrangular outer layer prepreg, peeling does not occur between the outer insulating cylinder and the sealing material as in the conventional case.
Therefore, it is possible to provide a rectangular mold coil.

G. Embodiment Hereinafter, the present invention will be described in detail based on an embodiment shown in the drawings. Since the present embodiment is an improvement of a part of the conventional mold coil, the same parts as those of the prior art are designated by the same reference numerals, and the description thereof will be omitted. Only different parts will be described.

(A) Configuration of the embodiment The configuration of the molded coil according to the present invention is shown in FIG.
A description will be given based on (b).

In this embodiment, a liquid elastomer (for example, Shin-Etsu Chemical KE1204) is used as the sealing material, but since peeling occurs at the corners of the outer layer prepreg, an adhesive elastomer (for example, Shin-Etsu Chemical Silicon KE1820) as an adhesive. Ten
As shown in FIG. 1 (b), the paste-like material is applied to the entire inner and outer layer prepregs 2 and 3 and the end surface of the coil conductor 4. As shown by the broken line in FIG. 1 (a), the area where the adhesive elastomer 10 is applied may be at least the corner portion of the quadrangle formed between the inner and outer layer prepregs 2 and 3, and it is the entire circumference. Good. After this, the inner and outer prepregs 2, 3
Liquid elastomer in the area surrounded by and the coil conductor 4.
Fill 5a and cure. After filling and hardening the liquid elastomer 5a in the upper part of the figure, the upper and lower positions of the mold coil are replaced, and the adhesive elastomer is also applied to the opposite side.
10 and liquid elastomer 5a are filled and cured.

When the winding die is used, when the molding coil is completed, the molding coil is removed from the winding die 1.

(B) Operation of Embodiment Next, the operation of the mold coil will be described.

Since the adhesive elastomer 10 has a strong adhesive force, the elastomer 5a is firmly adhered to the inner / outer prepregs 2 and 3 by the interposition of the adhesive elastomer 10. Therefore, even if the liquid elastomer 5a contracts during the curing process or contracts due to heat deterioration after curing, the adhesive force prevents the peeling between the elastomer 5a and the outer prepreg 10.

In this example, the adhesive elastomer was interposed between the inner / outer layer prepreg and the coil conductor and the elastomer among the corners of the quadrangle formed between the inner / outer layer prepreg. Since it occurs between the elastomer and the elastomer, it is sufficient to interpose the adhesive elastomer between the elastomer and at least the outer layer prepreg and the coil conductor.

H. Effects of the Invention As can be seen from the above description, the molded coil according to the present invention has the following effects.

Since the adhesive is interposed between the coil conductor and the outer insulating cylinder and the sealing material at least at the corner of the outer insulating cylinder, the sealing material is adhered to the inner peripheral surface of the corner of the outer insulating cylinder by the adhesive. To be glued. Therefore, even if the inner / outer insulating cylinder has a quadrangular cross section, the sealing material does not peel off from the outer insulating cylinder at the corners of the outer insulating cylinder.

Therefore, it becomes possible to form a square mold coil,
Thereby, it is possible to provide a compact transformer.

[Brief description of drawings]

1 (a) and 1 (b) relate to an embodiment of the molded coil according to the present invention. FIG. 1 (a) is a plan view showing a main part of the molded coil, and FIG. 1 (b) is a schematic view of the molded coil. 2 to 3 relate to a conventional mold coil, and FIG. 2 (a) is a plan view of the mold coil.
FIG. 2B is a front view of the mold coil, FIG. 2C is a cross-sectional view of a main part of the mold coil, and FIG. 2 ... inner layer prepreg, 3 ... outer layer prepreg, 4 ... coil conductor, 5a ... elastomer, 10 ... adhesive elastomer.

Claims (1)

[Scope of utility model registration request] 1. A coil conductor is wound around the outer periphery of an inner insulating cylinder having a substantially quadrangular cross section, and the outer side of the coil conductor is covered with an outer insulating cylinder. In a molded coil in which a sealant is filled between the outer insulating cylinder and an adhesive, at least a corner portion of the outer insulating cylinder is interposed between the coil conductor and the outer insulating cylinder and the sealant. Molded coil characterized by the above.