JPS58201320A - Preparation of resin mold coil - Google Patents

Abstract

PURPOSE:To obtain internal-void-free resin mold coil without using metal mold by insulating a winding conductor of each layer of coil with glass roving member consisting of a bundle of glasses having an intensive strength, impregnating resin thereto and giving the three-layer structure of parallel, helical and parallel structures for each layer to the roving member. CONSTITUTION:An insulative cylinder 1 made of a thermosetting resin such as epoxy resin is removably engaged with a winding shaft 2 and a glass roving member 3 having an intensive strength consisting of a bundle of glass fiber is wound around said cylinder 1 while a thermosetting resin such as epoxy resin is impregnated thereto. After winding the glass roving member for a single layer, the terminating end is cut and bound to a part of roving member wound in order to form an inslating layer (a). Thereafter, the coil conductor 7 of the first layer is wound thereon. Next, the conductor 7a of the second layer is wound through the insulating layers (b, c, d). Such winding is repeated until the desired number of windings can be obtained. In such a structure, the insulating layers (b, c, d) should respectively be parallel, helical and parallel and the insulating layer should be the three-layered structure.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a resin molded coil, and its purpose is to economically manufacture a molded coil with good electrical and mechanical properties without using a mold. It is about the method.

Conventionally, mold filling involves winding a bare coil with a glabella insulator interposed between each turn of the coil conductor.
This raw coil was housed in a mold, and resin mixed with a filler was poured into the raw coil in the mold, and then heated and solidified. However, this manufacturing method requires a mold, and moreover, the mold release process, 9 assembly, 9 disassembly, etc.
This has the disadvantage that it takes a lot of time, requires a large number of molds for mass production, and coil design is also limited by the dimensions of the mold.
Fillers are mixed into casting resins to lower the resin curing shrinkage rate and suppress the generation of internal stress during curing to prevent cracks, but this method increases the viscosity of the resin. It does not penetrate into every corner of the coil, and as a result, partial discharge due to the generation of voids is likely to occur, which may lead to dielectric breakdown of the molded coil.

The present invention eliminates the above-mentioned drawbacks, and provides a resin mold that has excellent electrical properties, 9 mechanical strength, and can be manufactured economically without using a mold and without creating any internal voids. The purpose is to obtain a method for installing a coil, and an embodiment of the present invention will be described below with reference to Figure t. It is removably fixed to a winding shaft 2 of a winding machine (not shown). Next, a high-strength fiber material (e.g., glass roving material (glass fibers strained into bundles) 3 is placed on top of the insulating cylinder/liquid resin filled in the resin tank S via a roller device, For example, the glass roving material 3 impregnated with the resin B is immersed in thermosetting resin B such as epoxy resin, and while being moved, the glass roving material 3 impregnated with the resin B is wound one layer in parallel on the surface of the insulating cylinder from one end to the other end. . and,
After winding one layer of the glass roving material 3, the terminal end thereof is cut and tied to a part of the wound glass roving material to form an insulating layer a. Next, an insulating layer 8 impregnated with resin B. After forming the first layer of wound conductor 7at- by winding it around the coil conductor 71 at a position with a slight internal force from both ends thereof, the terminal end of the wound conductor 7a is cut off and temporarily fixed to the winding shaft 2. , After this, glass roving material 3 dipped in resin O
are wound in parallel on the wound conductor 7a from one end of the insulating tube lP to the other end with the wound conductor 7a completely covered, and an insulating layer is formed on the insulating layer. , this time, the glass roving material 3 is shaped into a helical shape e
An insulating layer C is provided by winding the insulating cylinder from end to end and back and forth, and furthermore, an insulating layer d is provided by winding the glass roving material 3 in parallel on the insulating layer C. Each of these insulating layers (c, d) thus constitutes an interlayer insulation gap:
! / form a winding layer. Next, the coil conductor 7 is electrically connected to the terminal end of the first-layer wound conductor 7a by brazing 11, and the coil conductor 7 is placed on the insulating layer d with a slightly smaller number of turns than the first-layer wound conductor 7a. A wound conductor 7b is formed, and after winding, its terminal end is cut off. After this, the second layer of wound conductor 7b
As with the first layer of the wound conductor 7a, the second layer of the wound conductor 7b, including its both ends and connection points, is surrounded by the glass rope pin material 3 soaked in resin A, and then wrapped in a parallel shape. , a second winding layer a is formed by winding in a three-layer shape of helical shape and parallel shape and providing interlayer insulation lra. Similarly, each time the coil conductor 7 is wound in seven layers, the number of turns is sequentially decreased from that of the previous layer. . . . are the wound conductors 7, 7 of each layer.
8......... to be covered including both ends thereof - from this, a predetermined number of winding layers, a...
. . . are sequentially wound in a stepwise manner to form a stacked coil IO.

After forming the elementary coil 10, the entire outer circumference of the elementary coil 10 is coated with a thermosetting resin mixed with a coloring agent.

Thereafter, the raw coil 10 is mounted on a rotating device (not shown) in a drying oven (not shown), and heated while rotating at a speed that does not scatter the resin B.
The desired resin molded coil is obtained by completely solidifying the resin impregnated into the glass roving material 3 and the resin coated on the outer peripheral surface of the raw coil 10. When the resin hardens, the loose resin is scraped off from the base coil 10 before the resin completely hardens (semi-hardened) to produce a beautiful molded coil.

As described above, the present invention cuts the coil conductor each time it is wound into one layer, and when winding the next layer, separates the winding end of the previously cut coil conductor and the coil conductor for winding the next layer. In other words, each layer of the coil conductor is connected and wound by repeating the cutting and connecting operations each time the coil conductor is wound.
Each time the number of wound layers increases, the number of turns of each layer is sequentially reduced to form the windings in a stepwise manner.
A glass roving material impregnated with a thermosetting resin is wound into three layers of parallel, helical, and parallel shapes to form an elementary coil with interlayer insulation interposed therebetween. This thermosetting resin is coated on the thermosetting resin 1 and heated while rotating, thereby solidifying the thermosetting resin and producing a resin molded coil.
In the process of winding the bare coil, winding glass roving material impregnated with resin in a parallel manner increases the strength of the molded coil in the winding direction. In addition to increasing the strength of the molded coil in the axial direction, the purpose of winding is to increase the strength of the molded coil in the axial direction. There is no possibility that the wound insulating layer e will dig in and cause a short interlayer termination. In addition, in the manufacturing method of the present invention, since the glass roving material is impregnated with resin, the resin oozes out from the gaps between adjacent coil conductors due to the tension when the coil conductors are wound. As a result of being completely filled, it is void-free and has excellent electrical characteristics.
, a molded coil f can be obtained. Furthermore, the wound conductors of each layer are cut layer by layer (eventually, the wound conductors are connected in each layer) and are wound in staggered manner, so these wound conductors are Each layer, including both ends, is completely surrounded by glass roving 4A, and this glass roving material is impregnated with resin and molded integrally with the coil conductor, resulting in a molded coil with outstanding mechanical strength. can be manufactured.

In addition, when reinforcing the ends of the molded coil, soak a nonwoven fabric made of glass fiber in resin and embed it inside the coil by wrapping a glass roving material around the end of each winding layer to strengthen the molded coil. The edges may be rubbed to further strengthen them. Furthermore, a wound conductor can be used. In addition, a bare coil is coated with resin on its outer circumferential surface and then rotated to heat and solidify the resin, so a resin molded coil
The outer surface can be made smooth and beautiful.

As described above, according to the method of manufacturing a resin-molded coil of the present invention, the wound conductor of each layer of the coil is wrapped with a high-strength glass roving material and the nuclide is impregnated with the glass roving material. The resin permeates through every turn of the coil conductor, allowing the coil conductor and the glass roving material to be resin-molded together without creating voids, and the glass roving material has a parallel or helical shape for each layer.

By winding the coil in a parallel three-layer configuration, it is possible to prevent short circuits between layers due to the coil conductor coming too close to the coil conductor in the previous layer. You can get molded coils. or,
For resin molding, we did not use a mold and instead wrapped the glass rope pin U, which forms the interlayer insulation, around the resin-impregnated material, which simplifies the resin molding process and improves the coil design. However, since it is not limited by the mold dimensions, it is easy to manufacture a wide variety of molded coils, and the amount of resin used only needs to be impregnated into the glass roving material. It has many excellent features such as being able to be manufactured economically with a small eave size.

[Brief explanation of drawings]

Fig. 3 is a schematic sectional view of a resin molded coil obtained by the method of the present invention, Fig. 3 is a schematic configuration diagram of an apparatus for carrying out the method of the present invention, and Fig. 3 is a schematic cross-sectional view of a resin molded coil obtained by the method of the present invention. The front view and the cross-sectional view showing the process of manufacturing are explanatory diagrams illustrating the manufacturing state of the resin molded coil obtained by the method of the present invention. 3 Ni glass rolling material 7: Coil conductor g: Ni insulation 10: Raw coil Patent applicant 1 light/ne 1 Ai U-1 Iwaki Kosakusho

Claims (1)

[Claims] A glass roving material impregnated with a thermosetting resin is wound around the outer circumferential surface of an insulating tube in parallel, and a coil conductor is wound in a row over the insulating layer. A wound conductor is formed, its terminal end is cut, and the above-mentioned glass roving material is wound on top of the wound conductor in a three-layer shape of parallel, helical, and parallel shapes with the ends of the wound conductor covered. The wound layer which has been wound to form a no-interval insulation is wound in a predetermined layer while connecting the cut wound conductor to a coil conductor wound in the next layer to form an elementary coil,
A method for producing a resin-molded coil, which comprises applying a thermosetting resin to the outer circumferential surface of the bare coil, and then heating and solidifying the thermosetting resin while rotating the coil.