JP2009152340A - Coil molded body manufacturing method and coil molded body - Google Patents

Abstract

An object of the present invention is to provide a method for manufacturing a coil molded body that can improve the thermal conductivity and heat dissipation of a coil molded body in which a coil and a resin are integrated, and to provide the coil molded body itself.
A method of manufacturing a coil molded body in which a coil and a resin are integrated by injecting a resin into a molding die 20 on which a coil 11 is arranged, wherein the rectangular wire edgewise winding coil 11 is molded into the molding die 20. The rectangular pressing wire 30 is pressed and held by the coil pressing means 30 so that the adjacent flat portions 11a are in close contact with each other in the coil axis direction, and then the resin is injected into the mold 20 The coil pressing means 30 is retracted from the coil 11 at a timing when the compressed state of the coil 11 is maintained as it is by injecting the coil 11, so that the adjacent flat portions 11 a of the rectangular wire wound around the coil 11 are in close contact with each other. And the coil molded object which resin does not penetrate | invade between each plane part 11a is manufactured.
[Selection] Figure 3

Description

  The present invention relates to a method for manufacturing a coil molded body and a coil molded body.

As a coil used for a motor or the like, for example, there is Patent Document 1 below. Moreover, there exists patent document 2 as a prior art of metal mold | die shaping | molding.
Patent Document 1 is an invention related to a rectangular coil, a method for manufacturing the same, and a manufacturing apparatus. When winding a coil by bending a flat wire in an edgewise manner, that is, bending one of the short sides of a flat wire to be inside. In addition, a technique is disclosed in which a deviation in thickness is suppressed between the outer peripheral side and the inner peripheral side of the coil.
Patent Document 2 is an invention relating to a method for manufacturing a golf ball, and discloses a technique in which a core inserted into a mold cavity is supported by a plurality of pins as a core.
JP 2006-288025 A JP-A-61-213068

However, even if an apparatus as shown in Patent Document 1 is used, the uneven thickness phenomenon of the edgewise winding coil of the rectangular wire is not completely eliminated. For this reason, in the case of a flat wire edgewise winding coil, it has the property that each adjacent flat portion of the flat wire constituting it is easy to open. Then, if the adjacent flat portions of the flat wire are not in close contact with each other and a gap is left, there is a problem that the heat conduction efficiency between the flat wires is poor. In addition, when a flat wire edgewise winding coil is integrated with a resin, such as by covering it with a resin, there is a problem that the resin enters the gap between adjacent flat wires, which is not good in terms of heat dissipation. That is, there arises a problem that it is not preferable for a product or the like that requires a coil molded body having good thermal conductivity and heat dissipation.
Further, in the manufacturing method of Patent Document 2, the pin supporting the core is arranged at a predetermined position called a dimple forming position, which is a technique considering the arrangement of the pins. However, the core is held while being deformed. It does not disclose technology.

  Therefore, the present invention solves the above-described conventional problems, and a method for manufacturing a coil molded body that can improve the thermal conductivity and heat dissipation of a coil molded body in which a coil and a resin are integrated, and the coil molded body itself. The issue is to provide

  The method for manufacturing a coil molded body of the present invention is a method for manufacturing a coil molded body in which a coil and a resin are integrated by injecting a resin into a molding die in which the coil is disposed, and as the coil, Using a rectangular wire edgewise winding coil, the coil is placed in the mold as a core, and the coil is compressed in the coil axial direction by using a coil pressing means, so that each adjacent rectangular wire wound is wound. The flat portions to be held are in close contact with each other in the coil axis direction, and then the resin is injected into the mold, and the injection of the resin keeps the compressed state of the coil as it is. The coil pressing means is retracted from the coil, whereby adjacent flat portions of the rectangular wire wound around the coil are in close contact with each other, and a coil molded body in which no resin enters between the flat portions is manufactured. It is the first feature to be.

According to the first feature of the present invention, since a rectangular wire edgewise winding coil is used as the coil, the space factor can be improved as compared with the case of using a round wire. Therefore, the coil can be reduced in size.
In particular, by arranging the coil as a core in the mold and compressing the coil in the coil axial direction using the coil pressing means, the adjacent flat portions of the wound rectangular wire are mutually connected in the coil axial direction. Then, the resin is injected into the mold, and the coil pressing means is retracted from the coil at a timing when the compression state of the coil is maintained as it is by the injection of the resin. Since it is as a structure, it can be made to integrate with resin, with each adjacent plane part of the wound rectangular wire closely_contact | adhered to each other. That is, it is possible to manufacture a coil molded body in which flat portions of rectangular wires constituting a coil are in close contact with each other and no resin enters between adjacent flat portions. Therefore, it is possible to produce a coil molded body having excellent heat dissipation and thermal conductivity.

  In addition to the first feature of the present invention, the coil pressing means of the present invention is a pin jig for pressing the coil by moving forward and backward from the outside of the mold. Is the second feature.

  According to the second feature of the present invention, in addition to the function and effect of the first feature of the present invention, the coil pressing means advances and retracts from the outside of the mold so as to press the coil. Therefore, it is possible to easily operate the timing of retreating from the advanced state by holding the coil in a compressed state by using a pin jig so that the coil can be moved forward and backward from the outside of the mold.

  In addition to the first or second feature, the method for producing a coil molded body of the present invention has a third feature that the coil is pressed from one side in the coil axial direction.

  According to the third feature of the present invention, since the coil is pressed from one side in the coil axial direction in addition to the operational effects of the first or second feature, the other side is in a fixed state. The coil can be held in a compressed state in a stable state.

  In addition to the first or second feature, the method for manufacturing a coil molded body of the present invention has a fourth feature of pressing the coil from both sides in the coil axial direction.

  According to the fourth aspect of the present invention, the coil is pressed from both sides in the coil axial direction in addition to the operational effects of the first or second characteristic, so that the coil is compressed from both sides. Therefore, the coil can be pressed in a balanced manner and held in a close contact state.

  In addition to the features described in any one of the first to fourth aspects, the method for manufacturing a coil molded body of the present invention is arranged in a mold together with a core member that is a core of the coil, and is made of resin. The fifth feature is that it is integrally removed after molding.

  According to the fifth aspect of the present invention, in addition to the function and effect of any one of the first to fourth aspects, the coil is disposed in the mold together with the core member that becomes the core of the coil. Since it is configured to be integrally taken out after molding with resin, the coil and the core member can be integrated with resin in the mold. Therefore, the coil with the core member can be configured at a stretch, and the number of components as a component unit can be reduced and the number of manufacturing steps can be reduced. Of course, since the core member and the coil are integrated with the resin, problems such as rattling and gaps between the core member and the coil can be reduced.

  In addition to the feature described in the fifth aspect, the method for producing a coil molded body of the present invention has a sixth feature that the core member is a core member constituting a divided stator of a motor.

  According to the sixth aspect of the present invention, in addition to the function and effect of the fifth aspect, the core member is a core member that constitutes the divided stator of the motor. The core member and the coil constituting the stator can be integrated with resin. Therefore, not only can the heat dissipation of the stator be improved, but also the rattling of the coil can be surely prevented, and the burden of forming the subsequent divided stator can be reduced. Can be improved.

  In addition to the feature described in the fifth aspect, the method for manufacturing a coil molded body of the present invention has a seventh feature that the core member is a core member constituting a transformer.

  According to the seventh feature of the present invention, in addition to the function and effect of the feature described in the fifth feature, since the core member is a core member constituting the transformer, the transformer is provided in the mold. The core member and coil which comprise can be integrated with resin. Therefore, not only can the heat dissipation of the transformer be improved, but also the rattling of the coil can be reliably prevented and the work efficiency of the subsequent production of the transformer transformer can be improved.

  In addition to the feature described in the fifth aspect, the method for manufacturing a coil molded body according to the present invention has an eighth feature that the core member is a core member constituting a reactor.

  According to the eighth aspect of the present invention, in addition to the function and effect of the fifth aspect, the core member is a core member that constitutes the reactor. Therefore, the reactor is constituted in the mold. The core member and the coil can be integrated with resin. Therefore, it is possible to improve the heat dissipation of the reactor, as well as to reliably prevent the rattling of the coil, and to reduce the burden of forming the subsequent reactor and improve the working efficiency. .

  The coil molded body of the present invention is a coil molded body in which a coil and a resin are integrated, and the coil is composed of a flat wire edgewise winding coil, and each adjacent rectangular wire wound around the coil. The flat portions are in close contact with each other in the coil axis direction, and the resin does not penetrate between adjacent flat surfaces of the rectangular wire wound around the coil, and the outer peripheral surface, the inner peripheral surface, and both end surfaces of the coil. The ninth feature is to cover the surface.

According to the ninth aspect of the present invention, a coil molded body in which a coil and a resin are integrated, and the coil is configured by a flat wire edgewise winding coil, and therefore a round wire is used. The space factor can be improved compared to the case. Therefore, the coil can be reduced in size.
Further, since the adjacent flat portions of the rectangular wire wound around the coil are configured to be in close contact with each other in the coil axis direction, the heat conduction between the rectangular wires can be improved. Therefore, the heat dissipation of the coil can be improved.
Furthermore, since the resin is configured to cover the outer peripheral surface, the inner peripheral surface, and both end surfaces of the coil without entering between adjacent flat surfaces of the flat wire wound around the coil, the resin is wound. The coil is covered with a resin in a state where adjacent flat portions of the rectangular wire are in close contact with each other in the coil axial direction. Therefore, in addition to the fact that the rectangular wires of the coil are in close contact with each other, the thermal conductivity is improved, and since there is no gap between the coil surface and the resin, the presence of air or resin in the gap is also eliminated. The heat dissipation can be sufficiently improved. In addition, since the outer surface of the coil is in close contact with the resin, it is possible to prevent air from intervening and to release heat from the coil outward. Of course, the outer surface of the coil can be protected with resin.

  In addition to the ninth feature of the present invention, the coil molded body of the present invention has a tenth feature that the coil is integrated with a core member serving as a core of the coil via a resin.

  According to the tenth feature of the present invention, in addition to the function and effect of the ninth feature of the present invention, the coil is integrated with the core member serving as the core of the coil via the resin. Can be reliably prevented, and can be handled as a unit component called a core member with a coil. Therefore, handling becomes easy and the formation burden of a subsequent motor etc. can be reduced, and it becomes possible to improve the work efficiency in apparatus manufacture.

  In addition to the tenth feature of the present invention, the coil molded body of the present invention has an eleventh feature that the core member is a core member constituting a divided stator of the motor.

  According to the eleventh feature of the present invention, in addition to the function and effect of the tenth feature of the present invention, the core member is a core member constituting the split stator of the motor. As a result, it is possible to construct a stator with good heat dissipation. In addition, it is possible to contribute to the production of a split stator in which the coils are integrated with a resin and without backlash. Moreover, it becomes possible to improve the working efficiency of manufacturing a divided stator.

  In addition to the tenth feature of the present invention, the coil molded body of the present invention has a twelfth feature that the core member is a core member constituting a transformer.

  According to the twelfth aspect of the present invention, in addition to the function and effect of the tenth aspect of the present invention, the core member is a core member that constitutes the transformer. Convenience as a part can be expected, and a transformer with good heat dissipation can be configured. Moreover, it becomes possible to contribute to the production of a transformer with no backlash, in which the coil is integrated through a resin. Moreover, it becomes possible to improve the working efficiency of manufacturing a transformer.

  In addition to the tenth feature of the present invention, the coil molded body of the present invention has a thirteenth feature that the core member is a core member constituting a reactor.

  According to the thirteenth aspect of the present invention, in addition to the operational effects of the tenth aspect of the present invention, the core member is a core member that constitutes the reactor. This makes it possible to construct a reactor with good heat dissipation. Moreover, it becomes possible to contribute to manufacture of the reactor with which the coil was integrated via resin and which does not have backlash. Moreover, it becomes possible to improve the working efficiency of reactor manufacture.

  According to the method for manufacturing a coil molded body and the coil molded body of the present invention, the resin is such that the adjacent flat portions of the rectangular wire wound around the coil are brought into close contact with each other and the resin does not enter between the flat portions. Coated molded bodies can be produced. Therefore, the heat conduction between the rectangular wires can be improved. Therefore, the heat dissipation of the coil can be improved.

  With reference to the following drawings, a coil molded body manufacturing method and a coil molded body according to an embodiment of the present invention will be described to provide an understanding of the present invention. However, the following description is an embodiment of the present invention, and does not limit the contents described in the claims.

  FIG. 1 is a perspective view of a rectangular wire edgewise winding coil used in a coil molded body according to a first embodiment of the present invention. FIG. 2 is a perspective view for explaining a state in which a rectangular wire edgewise winding coil is disposed in a molding die in the coil molded body according to the first embodiment of the present invention. FIGS. 3A and 3B are perspective views for explaining a state in which the coil is pressed using a pin jig. FIG. 3A is a view showing a state before the coil is pressed, and FIG. 3B is a view showing a state where the coil is pressed. . FIG. 4 is a perspective view of a coil molded body according to the first embodiment of the present invention. FIG. 5 is a diagram for explaining a method of manufacturing a coil molded body according to the second embodiment of the present invention, and is a cross section showing a state in which a flat wire edgewise coil is placed in a mold and pressed by a pin jig FIG. FIG. 6 is a perspective view showing Modification Example 1 of the core member used in the coil molded body according to the second embodiment of the present invention. FIG. 7 is a perspective view showing Modification Example 2 of the core member used in the coil molded body according to the second embodiment of the present invention. FIG. 8 is a perspective view showing Modification Example 3 of the core member used in the coil molded body according to the second embodiment of the present invention.

  First, with reference to FIGS. 1-4, the manufacturing method of the coil molded object 10 which concerns on the 1st Embodiment of this invention is demonstrated.

Referring to FIG. 1, a rectangular wire edgewise winding coil 11 is used in the method of manufacturing a coil molded body 10 of the present invention. Thus, by using a flat wire, between each adjacent wire can be made into a plane, and a space factor can be improved compared with the case where a round wire is used.
In the edgewise winding coil 11, in a normal state where no force is applied, a gap 11b is generated between the adjacent flat portions 11a.
As a material of the rectangular wire used for the edgewise winding coil 11, a conductive material such as copper can be used. In addition, a rectangular wire having a rectangular cross section with an insulating layer such as enamel formed on the outer peripheral surface thereof can be used. The width and thickness of the flat wire can be changed as appropriate.

  Next, with reference to FIG. 2, in the manufacturing method of the coil molded object 10 which concerns on 1st Embodiment, the coil 11 is arrange | positioned in the shaping | molding die 20 simplified and shown with the broken line. The size, shape, and the like of the mold 20 can be changed as appropriate.

With reference to FIG. 3A, a coil pressing means 30 is provided for the coil 11 arranged in the mold 20. And as shown to (B) of FIG. 3, each adjacent plane part 11a of the rectangular wire which comprises the coil 11 is mutually_contact | adhered by pressing the coil 11 to a compression direction by the coil press means 30. FIG. In the present embodiment, the coil pressing means 30 presses the coil 11 from one side (upper side in the drawing).
The coil pressing means 30 is composed of a pin jig 31 in this embodiment. The plurality of pin jigs 31 can be advanced and retracted from the outside of the mold 20 to the inside of the mold 20. Using this pin jig 31, the coil 11 is pressed in the axial direction and compressed to hold the adjacent flat portions 11 a of the coil so that they are in close contact with each other. In FIG. 3, each pin jig 31 pushes the coil 11 in the mold 20 vertically downward from above. More specifically, the lower end surfaces of the four pin jigs 31 are brought into contact with the respective central portions of the four corners of the flat portion 11a on the uppermost surface of the coil 11 so as to apply a pressing force.
Further, the pin jig 31 can be provided with an elastic force larger than the elastic repulsive force of the coil 11 in the pressing direction. As a result, the coil 11 can be held in a compressed state with a uniform pressing force on the coil 11. That is, it is possible to prevent the pressing force biased on a part of the coil 11 from being improperly applied.

Although not shown, the pin jig 31 is provided with driving means for moving the pin jig 31 forward or backward. Further, the driving means is added with a control means so that the pin jig 31 can be advanced and retracted at a fixed timing in a series of molding operations in the mold using the mold 20. . Conventionally known technical means can be used for these driving means and control means.
The number of pin jigs 31, the pressing position of the coil 11, the thickness, etc. can be changed as appropriate.

  In the mold 20, the coil 11 and the resin 12 are integrated by forming the inner space of the mold 20 in accordance with the shape of the coil 11 and placing a core (not shown) in the inner hole of the coil 11. In this way, the outer peripheral surface, the inner peripheral surface, and both end surfaces of the coil 11 on which the resin 12 is set are covered with a predetermined thickness.

As shown in FIG. 3B, the coil 11 is pressed downward by the coil pressing means 30, and the adjacent flat portions 11a are in close contact with each other in the coil axis direction.
Then, in a state where the coil 11 is compressed by the coil pressing means 30, the resin 12 is injected into the mold 20 through an injection passage (not shown).
After that, the molten resin 12 is filled in the molding space in the mold 20, and the compression state of the coil 11 is changed by the pin jig 31 depending on the state of the resin 12 and the injection pressure, that is, the injection state of the resin 12. Even if it is not pressed, the pin jig 31 is retracted from the coil 11 at a timing at which the compressed state is maintained as it is. The specific retraction time of the pin jig 31 is determined in advance by experiments and stored in the control means. However, it will be a little before the mold ends.
In the space after the retracted pin jig 31 is removed, excess resin 12 is replenished by the injection pressure.
In addition, as resin 12, what is normally used as mold resin, such as thermosetting resins, such as an epoxy resin, and a thermoplastic resin, can be used.

The coil molded body 10 shown in FIG. 4 is formed through the above steps. That is, the coil molded body 10 is in a state where the adjacent flat portions 11a of the wound rectangular wire are in close contact with each other in the coil axis direction. Since the adjacent flat portions 11a of the rectangular wires wound in this way are in close contact with each other in the coil axis direction, the heat conduction between the rectangular wires can be improved. Therefore, the heat dissipation of the coil molded body 10 can be improved.
In the coil molded body 10, the outer peripheral surface 11 c, the inner peripheral surface 11 d, and both end surfaces 11 e of the coil 11 are covered with the resin 12. Thus, the coil 11 is covered with the resin 12 so that no gap is generated between the surface of the coil 11 and the resin 12. Therefore, the heat generated in the coil 11 of the coil molded body 10 can be smoothly conducted and radiated outwardly through the resin 12 that is in close contact with the coil 11 without passing through an air layer.
Of course, the coil 11 coated with resin has improved insulation and is protected from external damage.

Next, with reference to FIG. 5, 2nd Embodiment of the manufacturing method of the coil molded object 10 which concerns on this invention is described. In the second embodiment, the coil 11 and the core member 50 serving as the core of the coil 11 are arranged together in the mold 20, and after the resin 12 is molded, the coil 11 and the core member 50 are combined with the resin 12. In addition, it is configured to be integrally taken out together.
That is, in the manufacturing method according to the second embodiment, the core member 50 serving as the core of the coil 11 is disposed on the lower mold 21 of the mold 20, the coil 11 is set on the core member 50, and the upper mold 22 is further moved down. The coil 21 is fitted into the mold 21, and the coil 11 is pressed using the pin jig 31 which is the coil pressing means 30, and held in a compressed state.
Further, in the above state, the injection space S of the resin 12 is configured to have a predetermined thickness on each outer side of the outer peripheral surface, the inner peripheral surface, and both end surfaces of the set coil 11.
About another structure, it is the same as the manufacturing method of the coil molded object 10 which concerns on the said 1st Embodiment of this invention. The same member and the same function are given the same number, and the following description is omitted.

As shown in FIG. 5, the coil 11 and the core member 50 serving as the core of the coil 11 are both placed in the mold 20 and are integrally taken out after molding with the resin 12. A coil molded body 10 in which the outer peripheral surface 11c, the inner peripheral surface 11d, and both end surfaces 11e of the coil 11 are coated with the resin 12 is formed. At the same time, the coil molded body 10 and the core member 50 are integrated by the resin 12 that covers the inner peripheral surface 11d and the lower end surface 11e of the coil 11. Therefore, the heat generated in the coil 11 is easily conducted to the coil 11 that is in close contact, and is quickly transferred from the coil 11 to the core member 50 through the resin 12 that is in close contact therewith, and is radiated to the outside from the core member 50. I can go. In addition, it is possible to reliably prevent the coil 11 from rattling and to reduce the subsequent burden of forming a motor or the like, thereby improving work efficiency.
The core member 50 may be a powder magnetic material in which metallic magnetic powder that is usually used as a motor core is bonded with a resin.

  Next, with reference to FIG. 6, the modification 1 of the core member 50 which concerns on the 2nd Embodiment of this invention is demonstrated. In the first modification, the core member 50 is used as a core member constituting a divided stator of the motor. About another structure, it is the same as the manufacturing method of the coil molded object 10 which concerns on the said 2nd Embodiment of this invention. The same member and the same function are given the same number, and the following description is omitted.

Thus, by making the core member 50 into a core member that constitutes the divided stator of the motor, the core member 50 that constitutes the divided stator in the mold 20 and the coil 11 can be easily integrated with the resin 12, The divided stator itself can be formed. Further, the obtained divided stator as the coil molded body 10 can be excellent in thermal conductivity and heat dissipation of heat generated in the coil 11. Further, rattling or the like between the coil 11 and the split stator core is prevented, and a split stator having the coil 11 stably and securely attached can be efficiently manufactured.
In addition, as the core member 50, the electromagnetic steel plate and powder magnetic body normally used as a core member which comprises a division | segmentation stator can be used.

  Next, with reference to FIG. 7, the modification 2 of the core member 50 which concerns on the 2nd Embodiment of this invention is demonstrated. In the second modification, the core member 50 is used as a core member constituting the transformer. About another structure, it is the same as the manufacturing method of the coil molded object 10 which concerns on the said 2nd Embodiment of this invention. The same member and the same function are given the same number, and the following description is omitted.

Thus, by using the core member 50 as a core member that constitutes the transformer, the core member 50 that constitutes the transformer and the coil molded body 10 can be integrated with the resin 12 in the molding die 20. Therefore, the heat dissipation and thermal conductivity of the transformer as the coil molded body 10 can be improved. In addition, it is possible to reliably prevent the coil 11 from rattling and improve the work efficiency of the subsequent production work of the transformer.
In addition, as the core member 50, a known and unknown material can be used as a core member constituting the transformer.

  Next, with reference to FIG. 8, the modification 3 of the core member 50 which concerns on the 2nd Embodiment of this invention is demonstrated. In the third modification, the core member 50 is used as a core member constituting the reactor. About another structure, it is the same as the manufacturing method of the coil molded object 10 which concerns on the said 2nd Embodiment of this invention. The same member and the same function are given the same number, and the following description is omitted.

Thus, by making the core member 50 into a core member that constitutes the reactor, the core member 50 and the coil 11 that constitute the reactor in the mold 20 can be integrated with the resin 12. Therefore, the heat dissipation and thermal conductivity of the reactor as the coil molded body 10 can be improved. In addition, it is possible to reliably prevent the coil 11 from rattling and to improve the working efficiency of the reactor manufacturing.
In addition, as the core member 50, a known and unknown material can be used as the core member constituting the reactor.

  INDUSTRIAL APPLICABILITY The present invention can be industrially utilized as a coil molded body of equipment using, for example, a motor, a transformer, a reactor, and other coils, and as a method for manufacturing the molded body.

It is a perspective view of the edgewise winding coil of the flat wire used for the coil fabrication object concerning a 1st embodiment of the present invention. In the coil molded object which concerns on the 1st Embodiment of this invention, it is a perspective view explaining the state which has arrange | positioned the flat wire edgewise winding coil in the shaping | molding die. It is a perspective view explaining the condition which presses a coil using a pin jig, (A) is a figure which shows the state before the press of a coil, (B) is a figure which shows the state by which the coil is pressed. It is a perspective view of the coil molded object which concerns on the 1st Embodiment of this invention. It is a figure explaining the manufacturing method of the coil molded object which concerns on the 2nd Embodiment of this invention, and is sectional drawing which shows the state which has arrange | positioned the flat wire edgewise winding coil to the shaping | molding die, and is pressing with the pin jig. . It is a perspective view which shows the modification 1 of the core member used in the coil molded object which concerns on the 2nd Embodiment of this invention. It is a perspective view which shows the modification 2 of the core member used in the coil molded object which concerns on the 2nd Embodiment of this invention. It is a perspective view which shows the modification 3 of the core member used in the coil molded object which concerns on the 2nd Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Coil molded object 11 Coil 11a Flat part 11b Clearance 11c Outer peripheral surface 11d Inner peripheral surface 11e End surface 12 Resin 20 Mold 21 Lower mold 22 Upper mold 30 Coil pressing means 31 Pin jig 40 Resin 50 Core member S Injection space

Claims (13)

  A method of manufacturing a coil molded body in which a coil and a resin are integrated by injecting resin into a molding die in which a coil is disposed, wherein a rectangular wire edgewise winding coil is used as the coil, The coil is placed in the mold as a core and the coil is compressed in the coil axial direction by using the coil pressing means, so that the adjacent flat portions of the wound rectangular wire are in close contact with each other in the coil axial direction. Then, the resin is injected into the mold, and the coil pressing means is retracted from the coil at a timing at which the compressed state of the coil is maintained as it is due to the injection of the resin. The coil molded body is manufactured by manufacturing the coil molded body in which the adjacent flat portions of the rectangular wire wound around the coil are in close contact with each other and the resin does not enter between the flat portions. Manufacturing method.   2. The method of manufacturing a coil molded body according to claim 1, wherein the coil pressing means is a pin jig that moves forward and backward from the outside of the mold and presses the coil.   The method for producing a coil molded body according to claim 1 or 2, wherein the coil is pressed from one side in the coil axial direction.   The method of manufacturing a coil molded body according to claim 1 or 2, wherein the coil is pressed from both sides in the coil axial direction.   The coil molded body according to any one of claims 1 to 4, wherein the coil is disposed in a molding die together with a core member serving as a core of the coil, and is integrally taken out after molding with a resin. Method.   6. The method for manufacturing a coil molded body according to claim 5, wherein the core member is a core member constituting a divided stator of the motor.   The method for manufacturing a coil molded body according to claim 5, wherein the core member is a core member constituting a transformer.   The method for manufacturing a coil molded body according to claim 5, wherein the core member is a core member constituting a reactor.   A coil molded body in which a coil and a resin are integrated, wherein the coil is formed of a flat wire edgewise winding coil, and adjacent flat portions of the flat wire wound around the coil are mutually in the coil axis direction. The resin is formed by covering the outer peripheral surface, the inner peripheral surface, and both end surfaces of the coil without penetrating between adjacent flat surfaces of the rectangular wire wound around the coil. Coil molded body.   The coil molded body according to claim 9, wherein the coil is integrated with a core member serving as a core of the coil via a resin.   The coil molded body according to claim 10, wherein the core member is a core member constituting a divided stator of the motor.   The coil molded body according to claim 10, wherein the core member is a core member constituting a transformer.   The coil molded body according to claim 10, wherein the core member is a core member constituting a reactor.

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