JP4062588B2 - Molded coil manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a mold coil manufacturing method, a mold coil, and a relative movement device using the same, in which a permanent magnet and a coil are relatively moved.
[0002]
[Prior art]
Conventionally, for example, as shown in Japanese Examined Patent Publication No. 58-49100, two flat coils are provided between permanent magnets arranged so as to have a certain magnetic gap. There is a linear motor that is an example of a relative movement device that allows a coil to move along a magnetic gap path. In this case, a coil is wound around a winding frame to form one flat coil, and two stacked coils are used as a coil array assembly. However, when two flat coils are stacked in this manner to form a coil array, the magnetic gap between the pair of permanent magnets must be increased, which increases the size of the device and uses permanent magnets with a large magnetic force. Otherwise, there was a problem that a large thrust could not be generated in the coil array. In particular, when the coil array is formed from three or more flat coils, the above problem becomes more and more problematic.
[0003]
Japanese Patent Publication No. 8-13184 discloses a linear motor which is an example of a relative movement device that solves such problems. Hereinafter, in this specification, the moving direction of the relative movement device is the “width” direction, and the magnetic gap length between the permanent magnets or the gap length direction between the permanent magnets and the coil is the “thickness” direction. The direction perpendicular to both the “width” direction and the “thickness” direction is referred to as the “up and down” direction. In this linear motor, a pair of permanent magnets separated by a certain magnetic gap are arranged in a line on the yoke so that the opposite poles are opposed to each other and the opposite poles face each other to form a magnetic gap path. A plurality of flat coils of a size spanning two permanent magnets are provided on the road, a carriage is attached to the flat coils to form a mover, and a current is passed through each flat coil in turn, thereby moving the mover into a magnetic gap path. A linear motor that is movable along the first, second, and third flat coils each having a hollow portion and having a coil width that is 1/3 the width of a permanent magnet. The flat coils are sequentially shifted along the magnetic air gap by the width of one flat coil, and the flat coils are arranged on a single substrate so as to be on the same plane in the magnetic air gap. is there.
[0004]
16 is a partial sectional view of the front of the linear motor disclosed in Japanese Patent Publication No. 8-13184, FIG. 17 is a plan view of the coil portion of the linear motor, and FIG. 18 is a side sectional view of the linear motor. 19 is a sectional view taken along line AA in FIG. 17, FIG. 20 is a sectional view taken along line BB in FIG. 17, and FIG. 21 is a sectional view taken along line CC in FIG. FIG. 22 is a sectional view taken along the line DD of FIG. 17, and FIG. 23 is an exploded perspective view showing an example of a state in which the coiled substrate is positioned inside the resin mold. Hereinafter, a conventional linear motor disclosed in Japanese Patent Publication No. 8-13184 will be described with reference to the drawings.
[0005]
A plurality of a pair of permanent magnets 2a and 2b separated by a certain magnetic gap 1 are arranged in a line so that a plurality of pairs of permanent magnets 2a and 2b are sequentially opposite in polarity and opposite to each other. Each permanent magnet 2a, 2b is attached to the upper yoke 4 and the center yoke 5, and a coiled substrate 99B, which will be described later, is movably provided in the magnetic gap passage 3. In order to provide two substrates with coils 99B, another pair of permanent magnets 2a and 2b are sequentially arranged between the center yoke 5 and the lower yoke 7 so as to be opposite to the upper yoke side. A coiled substrate 99B is disposed in the magnetic gap path 3 between the two. Side yokes 8 are provided at end portions of the upper yoke 4, the center yoke 5, and the lower yoke 7 to form a magnetic circuit. In addition, the upper and lower two coiled substrates 99B are guided by movement of the magnetic gap path 3 by a device (not shown), and an object to be moved is attached to a portion protruding from the magnetic gap 1 of each permanent magnet. The coiled substrate 99B is configured by providing flat coils on both sides of the substrate 99A and arranging a plurality of sets of flat coils 96a, 96b, 96c that are continuous with each other. The flat coils of each set are sequentially shifted along the magnetic gap path 3 by the coil width of the flat coils. As shown in FIGS. 19 to 22, the flat coils 96 a, 96 b, and 96 c of each set overlap with each other at the portions that are exposed to the outside from the magnetic air gap 3. The coil portion is placed in the same plane and arranged on the same plane to form a short gap between the pair of permanent magnets forming the magnetic gap path. Each set of flat coils 96a, 96b, 96c is sized to span two permanent magnets 2a, 2b, and each set of flat coils is sequentially energized.
[0006]
In the conventional linear motor, a flat coil is bonded to the substrate 99A to form the coiled substrate 99B. However, when the heat resistance temperature of the adhesive is exceeded, the adhesive force is weakened and the strength of the coiled substrate 99B is reduced. And since the heat resistance temperature of this adhesive is lower than the heat resistance temperature of the flat coil, when the temperature of the flat coil rises due to energization of the flat coil, it exceeds the heat resistance temperature of the adhesive before exceeding the heat resistance temperature of the flat coil. . For this reason, there is a problem that the current value of the flat coil cannot be increased due to the heat resistance temperature of the adhesive, and the thrust of the linear motor cannot be increased. Further, the fixing work with the adhesive has a problem that it is complicated and has low workability. In order to solve the above problem, the coiled substrate 99B is encapsulated with resin. Hereinafter, in this specification, encapsulating with resin is referred to as “resin mold”, and a substrate with a coil encapsulated with resin is referred to as “mold coil”.
[0007]
[Problems to be solved by the invention]
When the resin molding is performed, it is necessary to accurately position the coiled substrate inside the mold for resin molding. In the conventional linear motor, at least the positions above and below the paper surface of FIG. At least one location at each position on the left and right (ie, width direction) of FIG. 17 and at least one location on each of the front and back sides (ie, thickness direction) of FIG. Positioning is performed by abutting positioning means such as a positioning pin protruding inside. A molding die 924 shown in FIG. 23 includes a first mold member 920 and a second mold member 921. Four thickness direction positioning pins 920a project from the mold inner surface side of the first mold member 920, and four thickness direction positioning pins 921a extend from the mold inner surface side of the second mold member 921. The four vertical positioning pins 921b and the two width direction positioning pins 921c are projected to form a total of 14 positioning pins as the molding die 924 as a whole. The vertical direction positioning pins 921b and the width direction positioning pins 921c can be extracted on the outer surface side of the mold. The coiled substrate 99B is inserted into the second mold member 921 and positioned by the positioning pins, and the inner surface edge (not shown) of the first mold member 920 and the second mold member 921 are positioned. The resin is injected after the first mold member 920 and the second mold member 921 are combined such that the inner surface edge portion 921d contacts and the thickness direction positioning pin 920a contacts the coiled substrate 99B. The coiled substrate 99B is resin-molded to form a molded coil. Then, the first mold member 920 is separated from the second mold member 921, the vertical direction positioning pins 921b and the width direction positioning pins 921c are extracted to the outer surface side of the mold, and the molded coil is formed by a knockout pin (not shown). Is extruded out of the second mold member 921. Note that the thickness direction positioning pin 921a can be knocked out to the first mold member 920 side, and can be used in place of the knockout pin.
[0008]
However, contacting the positioning pins, which are positioning means, at least at six locations in this example shown in FIG. 23 as described above, is troublesome, inferior in workability, complicated in the mold, and expensive to manufacture. Become. Further, a hole which is a trace of the positioning means is formed in the resin of the mold coil, and the number of holes is the same as the number of positioning means and is at least 6. In a linear motor used in a clean room, the holes are closed in order to prevent (or reduce) dust generation from the coils and leakage of volatile substances, but at least six holes are used as described above. Closing takes time and labor, resulting in poor workability and high manufacturing costs. For this reason, it has been required to reduce the number of positioning means as much as possible.
[0009]
An object of the present invention is to solve the above problems, and to provide a method for manufacturing a mold coil that has a small number of positioning means for resin mold, good workability, and low manufacturing costs.
[0010]
[Means for Solving the Problems]
Book The invention In order to solve the above problems, Multiple flat coils are substrates At least one surface of Fixed to With coil array Board with coil Is placed inside the mold, and resin is injected around the substrate with the coil to mold it. In the method of manufacturing a molded coil, At both ends of the coil row and On the part of the substrate not covered by the flat coil And a front end portion that contacts one surface of the substrate and penetrates the substrate. First positioning A first mold member having a pin locked thereon, and a tip hole which is in contact with the other surface of the substrate and into which the tip portion is inserted; Second positioning With the second mold member with the pin locked Mold Forming , Inside it It is characterized by injecting resin.
[0021]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the invention will be described below with reference to the drawings.
<Embodiment 1>
[0022]
FIG. 1 is a cross-sectional view of a main part of a linear motor which is an example of a relative movement device showing Embodiment 1 of the present invention. FIG. 1 also serves as a cross-sectional view of a main part of a second embodiment described later. FIG. 2 is an enlarged cross-sectional view of the mold coil of the mover shown in FIG. 1. In order to make the internal structure easy to understand, a substrate and a flat coil that are wrapped in resin and are not actually visible are shown. The coil energization terminal pins, magnetic field or position detection elements, detection element terminal pins, and insert nuts for fastening the carriage to the mold coil are omitted as necessary. FIG. 3 is an enlarged view of a later-described inclined portion on the upper side of the sheet of FIG. FIG. 4 is a cross-sectional view taken along the line BB in FIG. 1, and particularly shows a flat coil and a permanent magnet. FIG. 4 shows only one of the permanent magnets arranged on both sides of the flat coil. FIG. 5 is a cross-sectional view taken along the line AA in FIG. 1, and particularly shows three flat coils of φa, φb, and φc, a substrate, a permanent magnet, and a yoke, which will be described later. FIG. 6 is a schematic diagram for explaining the operation. FIG. 7 is a cross-sectional view in the same direction as FIG. 2 with the coiled substrate mounted on the molding die. FIG. 8 is a partially enlarged view of the pin and substrate of FIG. FIG. 9 is a view showing a modification in which holes in the substrate are provided on the outer side in the width direction of the coil array in FIG. FIG. 10 is an exploded perspective view showing a state where the coiled substrate (the one shown in FIG. 9) is positioned inside the molding die. The same parts are denoted by the same reference numerals as those in FIGS.
[0023]
Reference numeral 19 denotes a base, which is formed in a flat plate shape by a ferromagnetic material such as mild steel. Reference numeral 11 denotes a yoke, which is formed into a flat plate shape using the same material as the base 19 and is fixed on the base 19 with a gap. Then, a plurality of pairs of permanent magnets 2a, 2b separated by a certain magnetic gap 1 are arranged in a line so that the plurality of pairs of permanent magnets 2a, 2b are sequentially opposite in polarity and opposite to each other, and are fixed to the yoke 11 so that the magnetic gap path 3 is formed. A magnetic circuit is formed.
[0024]
The flat coils 6a and 6b, which are arranged so as to interlink with the magnetic flux generated by the permanent magnet and have a hollow portion in the center, are each composed of a flat portion 6f and inclined portions 6t which are extending portions at both ends thereof. Hf is the vertical dimension of the flat part 6f, and Wc is the widthwise dimension of the flat part 6f. The inclined portion 6t of the flat coil 6a is inclined to the left side of the paper surface of FIG. 2, and the inclined portion 6t of the flat coil 6b is inclined to the right side of the paper surface of FIG. The only difference between the flat coils 6a and 6b is the direction of the inclined portion 6t, and the other flat coils 6a and 6b are the same. That is, the flat coils 6a and 6b are symmetrical with each other in the left-right direction of the paper surface of FIG. The widthwise dimension Wc of the flat portion 6f is substantially 1/3 of the widthwise dimension Wm of the permanent magnet 2a or 2b. The dimension Wi in the width direction of the cavity is substantially twice Wc. Because of such dimensions, the flat coil 6a can be sized across the two permanent magnets 2a and 2b in the magnetic gap 3 as shown in FIG. Since Wc and Wi of the flat coil 6b are the same dimensions as Wc and Wi of the flat coil 6a, respectively, the flat coil 6b can be sized to span the two permanent magnets 2a and 2b.
[0025]
3 is an enlarged view of the upper inclined portion 6t of the paper surface of FIG. 2, the shape of the lower inclined portion 6t is also symmetric in the vertical direction of the paper surface, and the following description is similarly applied. In FIG. 3, 6cl is the center line of the flat portion 6f of the flat coils 6a and 6b in the thickness direction (left and right direction of the paper), and 6i is the inner edge of the inner peripheral surface of the upper and lower sides of the flat coils 6a and 6b. The ridge line closer to the center line 6cl. As shown in FIG. 3, the ridge line 6i of the flat coil 6a is on the left side of the paper with respect to the center line 6cl, and the ridge line 6i of the flat coil 6b is on the right side of the paper with respect to the center line 6cl. By doing so, the inclined portion 6t of the flat coil 6a passes through without contacting the ridge line 6i of the flat coil 6b, and similarly, the inclined portion 6t of the flat coil 6b also contacts the ridge line 6i of the flat coil 6a. Instead, the flat portions 6f of the flat coils 6a and 6b can be on the same plane. Further, the vertical dimension of the permanent magnets 2a and 2b (that is, the vertical dimension of the magnetic gap path 3) Hm (FIG. 2) is set larger than that of the permanent magnet 2a, 2b, and the portion inserted into the magnetic gap path of the mold coil 14 to be described later. By setting the vertical dimension Hn to be larger than Hm, the portions where the flat coils after resin molding are exposed to the outside from the magnetic air gap 3 are overlapped with each other. The coil array is arranged on one side of one substrate 9A so as to be on the same plane to form a substrate 9B with a coil.
[0026]
Next, the arrangement of the flat coils 6a and 6b will be described with reference to FIG.
(1) For example, the first (left end) flat coil 6a is disposed at the left end.
(2) The second flatness is shifted from the flat coil 6a to the right in the width direction by the width direction dimension 2 × Wc of the two flat coils (that is, to the right in the width direction via the gap 6g of the width direction dimension Wc). A coil 6b is provided. The third flat coil 6a is disposed in the gap between the right flat portion 6f of the first flat coil 6a and the right flat portion 6f of the second flat coil 6b. Here, the symbols φa, φb, and φc for explaining the operation are given to these flat coils, and φb is given to the first flat coil, φa is given to the second flat coil, and φc is given to the third flat coil.
(3) The left flat portion 6f of the fourth flat coil 6b is inserted into the gap between the right flat portion 6f of the second flat coil 6b and the right flat portion 6f of the third flat coil 6a. The 4th flat coil 6b is arrange | positioned and the code | symbol (phi) b for an effect | action description is attached | subjected to this 4th flat coil.
(4) The above 2) to 3) are repeated as many times as necessary. (For example, it is repeated three times in FIG. 5)
(5) Insert the flat portion 6f on the left side of the flat coil 6a into the gap between the flat portion 6f on the right side of the flat coil 6a and the flat portion 6f on the right side of the flat coil 6b. The flat coil 6a is provided, and the rightmost flat coil is given a symbol φc for explanation of the action.
By doing this, the flat portions 6f adjacent to each other of the flat coil are repeated in the order of φa, φb, and φc from the left, except for the left and right flat portions 6f. Although the number of flat coils is nine in FIG. 5, it is not limited to nine, but may be three or more, and the number may be determined according to the performance required for the linear motor.
[0027]
The gap 6g is a portion that is in the vicinity of both end portions in the width direction of the substrate with coil 9B and is not covered with the coil. At least one board hole 9Aa, which is a fitting portion, is provided at the two gaps 6g in the board 9A. As a modification of what is shown in FIG. 5, holes in the substrate may be provided on the outer side in the width direction of the coil array as shown in FIG. In the substrate with coil 9CB of FIG. 9, the width direction dimension of the substrate 9C is larger than the width direction dimension of the coil array, and the hole 9Ca of the substrate is provided on the outer side in the width direction of the coil array.
[0028]
7 includes a first mold member 20 and a second mold member 21 having a substantially E-shaped cross section, and a first mold member corresponding to the position of the hole 9Aa on the substrate. Pin holes 20a and 21a are provided at the positions of 20 and the second mold member 21, and pin contact surfaces 20b and 21b are provided on the outer surfaces of the molds of the pin holes 20a and 21a. In FIG. 7, the pin contact surfaces 20b and 21b protrude from the outer surface of the mold, but may be retracted or the same surface. The inner surface edge 20d of the first mold member 20 and the inner surface edge 21d of the second mold member 21 have the same vertical dimension and width dimension, and the inner surface edge 20d and the inner surface edge 21d are in close contact with each other. Finish as you can. As described above, the vertical dimension Hn of the portion inserted into the magnetic gap is set to be larger than Hm and smaller than Hf.
[0029]
The pin 22 as the first positioning means has at least a main body 22a, a tip 22b thinner than the main body 22a, and a base 22e thicker than the main body 22a, and a step 22c between the main body 22a and the tip 22b, and It is a stepped columnar member having a step portion 22d between a main body portion 22a and a base portion 22e. The main body portion 22a is fitted into the pin hole 20a of the first mold member 20 so as to project inside the first mold member 20, and the distal end portion 22b is fitted into the hole 9Aa of the substrate. The pin 22 is inserted into the pin hole 20a from the outside into the pin hole 20a, and the stepped portion 22d contacts the pin contact surface 20b of the first mold member 20. The distance between the pin contact surface 20b of the first mold member 20 and the tip end surface 20e in the mold is T20a, the distance between the pin contact surface 20b and the inner surface edge portion 20d is T20b, and the length dimension L22a of the body portion 22a of the pin 22 is By setting the dimensions of T20a, T20b, and L22a to appropriate values, the thickness dimension Tp1 of the resin encapsulating the flat portion 6f of the flat coil on the side without the substrate 9A can be set to a desired value.
[0030]
The pin 23 which is the second positioning means has at least a main body portion 23a, a front end hole 23b drilled at the front end of the main body portion 23a, and a base portion 23e thicker than the main body portion 23a. It is a stepped columnar member having a step part 23d with a base part 23e. The main body portion 23 a is fitted into the pin hole 21 a of the second mold member 21 and protrudes inside the second mold member 21, and the tip end portion 22 b of the pin 22 can be inserted into the tip hole 23 b.
[0031]
The diameter of the main body portion 22a and the diameter of the main body portion 23a may be the same or different, but it is necessary not to interfere with the coil. By making the value of L22a-T9A, which is the difference between the length (thickness direction) dimension L22a of the tip 22b and the thickness dimension T9A of the substrate 9A, smaller than the depth (thickness direction) dimension L23b of the tip hole 23b. As will be described later, when the tip 22b is inserted into the tip hole 23b and the substrate 9A is sandwiched between the stepped portion 22c and the tip surface 23c, the tip of the tip 22b is prevented from coming into contact with the bottom of the tip hole 23b. If L22a is made smaller than T9A, the tip hole 23b becomes unnecessary. The connecting portion between the stepped portion 22c and the tip end portion 22b is macroscopically not a perfect square shape and a fillet is often left, and if the fillet interferes with the hole 9Aa, the substrate 9A is moved to the stepped portion 22c and the tip end face 23c. It becomes incomplete to pinch. Therefore, by providing the escape portion 22f for removing the fillet, it is possible to prevent the fillet from interfering with the hole 9Aa.
[0032]
The pin 23 is inserted into the pin hole 21 a from the outside to the inside, and the step portion 23 d comes into contact with the pin contact surface 21 b of the first mold member 21. The distance between the pin contact surface 21b of the second mold member 21 and the tip end surface 21e in the mold is T21a, the distance between the pin contact surface 21b and the inner surface edge portion 21d is T21b, and the length dimension L23a of the body portion 23a of the pin 23, By setting the dimensions of T21a, T21b, and L23a to appropriate values, the thickness dimension Tp2 of the resin encapsulating the flat portion 6f of the flat coil on the side with the substrate 9A can be set to a desired value. In this way, the tip of the first positioning means projecting from the inside of the mold is fitted to the fitting portion provided in the portion of the substrate not covered with the flat coil, and the first positioning means And the second positioning means sandwiches the substrate so that the coiled substrate can be positioned inside the mold while being spaced apart from the inner surface of the mold.
[0033]
Next, a procedure for mounting the coiled substrate 9B on the mold 24 and resin molding will be described. The pin 22 is inserted into the pin hole 20a of the first mold member 20, and the board hole 9Aa is fitted to the tip 22b to attach the coiled board 9B to the pin 22. The pin 23 is inserted into the pin hole 21 a of the second mold member 21. With the inner surface edge 20d of the first mold member 20 and the inner surface edge 21d of the second mold member 21 in contact, the upper and lower sides of the first mold member 20 and the second mold member 21 The mold 24 is assembled by combining the first mold member 20 and the second mold member 21 by aligning the direction position and the width direction position by an alignment means (not shown). As the positioning means, various forms such as abutting surfaces are provided at the vertical position and the width direction position. For example, the tip 22b of the pin 22 and the tip hole 23b of the pin 23 are fitted together. It can also be an alignment means.
[0034]
By injecting resin from an injection port (not shown) and filling the space 25 in the mold, the substrate with coil 9B is resin-molded, the resin portion 13 is formed, and the molded coil 14 is formed. In addition, at the time of the resin molding, a coil energizing terminal pin, a magnetic field or position detecting element, a detecting element terminal pin, an insert nut, etc., which are not shown, can be simultaneously insert-molded as necessary. Then, the first mold member 20 is separated from the second mold member 21, and the molded coil 14 is moved out of the first mold member 20 or the second mold member 21 by a knockout pin (not shown). Extruded.
[0035]
The molded coil 14 thus molded is formed with a total of four pin trace holes (not shown) which are traces of the pins 21 and 22, that is, traces of the positioning means, on both surfaces in the thickness direction. The pin trace hole does not normally need to be closed, but in a linear motor used in a clean room or the like, the pin trace hole is closed to prevent (or reduce) dust generation from the coil and leakage of volatile substances. For example, the same resin as that used for the mold coil 14 is injected into the pin hole and the like, for example.
[0036]
By doing in this way, the positioning pins as positioning means have conventionally been in contact with at least 6 locations (14 locations in the example of FIG. 12), 2 on each side in the thickness direction, 4 in total. If you need to close the pin holes as needed, you can use only four pins, which had previously been 6 pin holes, so it is easy and workable. And the manufacturing cost is low.
[0037]
The mover 17 is formed by fastening the mold coil 14 to the carriage 15 by means such as bolting an aluminum alloy carriage 15 to an insert nut insert-molded in the mold coil 14.
[0038]
Next, the operation of this linear motor will be described. In FIG. 5, the reference numerals for explaining the action of the flat portion row composed of the six flat portions 6 f from the second flat portion 6 f to the seventh flat portion 6 f from the left end of the paper are φa, φb, They are arranged in the order of φc, φa, φb, and φc. For example, φa, φb, and φc in FIG. 6 are coil arrays including the six flat portions 6f.
In FIG. 6, when a current in the same direction is first applied to the flat coils φa and φb, a force acts on the flat coils φa and φb in the direction of arrow A in FIG. When the flat coil moves and the flat coil φa moves to the center of the second permanent magnet 2b, the position is detected by a position detection element (not shown), and the current is supplied to the flat coils φa and φb. It switches to the current supply to the coils φb and φc. The direction of current in the flat coils φb and φc is the same as in the case of φa and φb. By this switching, force is applied to the flat coils φb and φc in the direction of arrow A in FIG. 6B, and the flat coil moves to the state of FIG. Thereafter, the flat coil can be moved by sequentially switching the current to the flat coils φc and φa and the flat coils φa and φb in the coil array and repeatedly supplying the current. And the needle | mover 17 which supports a flat coil integrally can move.
[0039]
Next, when a current in the opposite direction to the flat coil is passed, a force in the opposite direction acts on the flat coil, so that the movable element 17 moves in the opposite direction. Therefore, the mover 17 can be moved to a predetermined position by selecting the energization of the flat coil and the direction of the current.
In the coil row, the two flat portions 6f of the flat coil φa are flat portions of a single flat coil φa, and the two flat portions 6f of the flat coil φc are also flat portions of the single flat coil φc. The two flat portions 6f of the flat coil φb are flat portions of different flat coils φb, but can be made to have the energization direction shown in FIG. 6 by appropriately selecting the connection and energization direction of the flat coil. The above is an explanation when the flat portions 6f of the flat coils φa, φb, and φc are adjacent to each other. On the other hand, the flat portion 6f of the first flat coil φa (at the left end of the drawing) in FIG. 5 or the flat portion 6f of the flat coil φc at the last (right end of the drawing) is connected to the adjacent flat portion 6f. When there is a gap corresponding to one flat portion between them, a part of the flat coil in the coil array in FIG. 6 is missing. However, by energizing the flat coil that is not chipped, a force acts on the flat coil, and the magnitude of the force is reduced by the amount of the flat coil chipped, but the mover 17 can move in the same direction as described above.
[0040]
<Embodiment 2>
FIG. 1 is a cross-sectional view of a main part of a linear motor which is an example of a relative movement device showing Embodiment 2 of the present invention. FIG. 11 is an enlarged cross-sectional view of the mold coil of the mover shown in FIG. 1. In order to make the internal structure easy to understand, a substrate and a flat coil that are wrapped in resin and are not actually visible are shown. The coil energization terminal pins, magnetic field or position detection elements, detection element terminal pins, and insert nuts for fastening the carriage to the mold coil are omitted as necessary. In the present embodiment, the substrate with coil 9B according to the first embodiment is replaced with a substrate with coil 29B described later, and the rest is the same as in the first embodiment.
[0041]
The flat coil 26a is formed by reducing the thickness dimension of the flat coil 6a of the first embodiment and eliminating the bending at both ends, and the flat coil 26b reduces the thickness dimension of the flat coil 6b of the first embodiment. The bending at both ends is increased. The flat coils 26a and 26b are arranged in the same manner as the coil array of the first embodiment, and the same coil array as that of the first embodiment is formed on one surface in the thickness direction of the substrate 9A similar to the first embodiment. A similar coil array is formed on this surface (that is, a coil array is formed on both surfaces of the substrate 9A) to form a substrate 29B with a coil. Then, similar to the first embodiment, the substrate 9B with the coil is mounted on the mold using the first positioning means, the second positioning means, the pins, and the molding die, similar to those described in the first embodiment. The resin mold is performed, the resin is injected into the cavity of the molding die, the resin portion 213 is molded, the mold coil 214 is molded, and the pin mark hole is closed as necessary. As in the first embodiment, the carriage 15 is attached to form the mover 217.
[0042]
By doing so, as in the case of the first embodiment, no labor is required, the workability is good, the mold is simplified, and the manufacturing cost is reduced.
[0043]
<Embodiment 3>
In the first embodiment, only the molded coil 14 is integrally formed of resin and the carriage 15 is made of an aluminum alloy. However, as in the third embodiment described below, the coil and the carriage can be integrally formed. FIG. 12 is a cross-sectional view of an essential part of a linear motor which is an example of a relative movement device showing Embodiment 3 of the present invention, and the same parts are denoted by the same reference numerals as those in FIG. The third embodiment will be described below with reference to the drawings.
[0044]
Reference numeral 18 denotes a mold mover in which a coil and a carriage are integrally formed, and includes a mold coil portion 18 a corresponding to the mold coils 14 and 214 of the first or second embodiment and a carriage portion 18 b corresponding to the carriage 15. In the mold movable element 18, the same substrate 9 or 29B with a coil as in the first or second embodiment is mounted on a molding die having a cavity corresponding to the outer contour of the mold movable element 18. Positioning is performed by the same positioning means as in the second embodiment, the resin is injected into the cavity of the molding die, the resin portion 313 is molded, and the mold movable element 18 can be obtained. Other than the above, the second embodiment is the same as the first or second embodiment.
[0045]
In Embodiment 1 or 2, for example, an insert nut (not shown) is provided on the carriage side of the resin portion during resin molding, and a bolt (not shown) that passes through a bolt hole (not shown) of the carriage is screwed into the insert nut. In contrast to forming the mover by fixing the mold coil to the carriage by fixing means such as joining, in the third embodiment, the carriage part 18a and the mold coil part 18b are integrally formed to constitute the mold mover 18. Therefore, the work for processing the bolt in the carriage is not required, and the work for screwing the bolt into the insert nut is not required, so that the workability of production and assembly can be further improved.
[0046]
<Embodiment 4>
In the first to third embodiments, the relative movement device is a linear motor that linearly moves. However, as in the fourth embodiment described below, the relative movement device may be a swing motor that swings and moves. FIG. 13 is a plan view of a swing motor that is an example of a relative movement device showing Embodiment 4 of the present invention, and FIG. 14 is a view taken along arrow A-O-B in FIG. Embodiment 4 will be described below with reference to the drawings.
[0047]
Reference numeral 419 denotes a base composed of a flat plate portion 419a and a shaft portion 419b. Reference numeral 411 denotes a yoke, which is formed in a flat plate shape using a ferromagnetic material such as mild steel. Then, a plurality of pairs of permanent magnets 42a and 42b separated by a certain magnetic gap 41 are arranged in a row so that the plurality of pairs of permanent magnets 42a and 42b are sequentially opposite in polarity and opposite to each other, and are fixed to the yoke 411. A magnetic circuit is formed. The magnetic circuit of the present embodiment has a fan-shaped planar shape centered on the center O of the shaft portion 419b, and the permanent magnets 42a and 42b also have a trapezoidal or fan-shaped planar shape corresponding to the fan shape, The rest is the same as the magnetic circuit of the first embodiment.
[0048]
Flat coils 46a and 46b having a hollow portion in the center also have a trapezoidal or fan-shaped planar shape corresponding to the fan shape, and the plurality of flat coils 46a and 46b are made of a fan-shaped planar glass epoxy resin. The substrate with coil 49B is formed by being disposed and fixed to the substrate (not shown).
[0049]
Then, the coiled substrate 49B is attached to the mold using a molding die similar to that described in the first embodiment and a pin serving as a positioning means, except that the cavity inner shape is a shape corresponding to the fan shape. It is mounted and resin-molded in the same manner as in the first embodiment, and a molded coil 414 similar to that described in the first embodiment is formed except that the planar shape is a fan shape, and pin pin holes are closed as necessary. Done. The mover 417 is formed by fastening the mold coil 414 to the carriage 415 by means such as bolting the carriage 415 to an insert nut insert-molded in the mold coil 414. The mover 417 is attached to the shaft portion 419b via the bearing 450 so as to be relatively movable.
[0050]
The action of the mold coil 414 of the present embodiment is a swinging movement around the center O of the shaft portion 419b, and other actions are the same as those of the first embodiment.
[0051]
As mentioned above, although embodiment of this invention was described, the shape of the said embodiment, a material, the adhering means of members are not limited to the above-mentioned thing, A various change is possible, and it is the optimal thing according to a situation. Just do it. The following modifications are also possible.
(1) In the embodiment, the number of the magnetic gap paths 3 is one, but it may be two as shown in FIG. FIG. 15 is a cross-sectional view of a principal part showing a modification in which the magnetic air gap path 3 has two strips, and the same parts are denoted by the same reference numerals as those in FIG. In FIG. 15, reference numeral 5 denotes a center yoke, which is formed in a flat plate shape using a ferromagnetic material such as mild steel, and is disposed between the two yokes 11 on the base 519 and is sandwiched between the center yoke 5 and the yokes 11. A plurality of a pair of permanent magnets 2a and 2b with a certain magnetic gap 1 are arranged on the surfaces of the center yoke 5 and the yoke 11 facing each other in a row so that the opposite poles face each other and the different poles face each other. A path 3 is formed, and two magnetic gap paths 3 are formed. Hereinafter, two rows of molded coils 214 similar to those in the first or second embodiment are configured and assembled as shown in the figure. Other than the above, the second embodiment is the same as the first embodiment or the second embodiment. Further, by further adding the center yoke 5, it is possible to form three or more magnetic gap paths 3 and three or more rows of molded coils 214.
(2) In the embodiment, a plurality of pairs of permanent magnets 2a, 2b are sequentially arranged in a row so as to be reverse poles, and the magnetic air gap 3 is formed. However, instead of the permanent magnet 2b, a flat plate is formed by a ferromagnetic material such as mild steel. The magnetic air gap path 3 may be formed using a counter yoke formed in a shape. Alternatively, the permanent magnet 2b may be omitted, and the coil may be linked to the magnetic flux between adjacent poles in the width direction of the permanent magnet 2a.
(3) In the embodiment, the base 19 is made of mild steel, but may be made of aluminum alloy or resin, for example.
(4) In the embodiment, the substrate is made of glass epoxy resin, but may not be made of glass epoxy resin as long as it is non-magnetic, non-conductive and satisfies heat resistance and strength.
(5) In the fourth embodiment, the oscillating motor is oscillating and moving. However, it may be a circular motor having a magnetic circuit connected thereto, and may be a rotating motor that rotates and moves by using a slip ring system for feeding power to the coil.
(6) In the embodiment, the coil movable relative movement device is used. However, a magnet movable relative movement device may be used.
(7) In the embodiment, the first positioning means or the second positioning means is a stepped columnar member, but the base portion may be a prismatic shape, the main body portion may be a columnar member, and the corresponding substrate. The hole or pin hole may be a square hole.
(8) Although the coil movable relative movement device is used in the embodiment, it may be a magnet movable relative movement device.
(9) In the embodiment, as shown in FIG. 7, the pin contact surfaces 20b and 21b of the mold are protruded to the outside of the mold, but may be retracted to the inside of the mold. Same as
It is good as a surface.
(10) In the embodiment, the number of holes in the substrate, which is the fitting portion provided in the portion that is not covered with the flat coil of the substrate, is two, but the number is three or more, and the number of positioning means corresponding to this is also You may make it increase.
[0052]
In the present invention, the combination of the above modifications or the combination of the embodiment and the modification can be arbitrarily performed. And this invention is not limited to the said embodiment or modification, It can be set as various forms, Of course, various improvement and design change are possible in the range which does not deviate from the meaning of this invention.
[0053]
【The invention's effect】
According to the present invention, it is possible to provide a mold coil manufacturing method, a mold coil, and a relative movement device that have a small number of positioning means for a resin mold, good workability, and low manufacturing costs.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of an essential part showing Embodiments 1 and 2 of a relative movement device of the present invention.
FIG. 2 is an enlarged cross-sectional view of the molded coil according to the first embodiment shown in FIG.
FIG. 3 is an enlarged view of an end portion of the stacked flat coils of FIG. 2;
4 is a cross-sectional view taken along the line BB of FIG. 1, and particularly shows a flat coil and a permanent magnet.
5 is a cross-sectional view taken along line AA in FIG. 1, and particularly shows three flat coils of φa, φb, and φc, a substrate, a permanent magnet, and a yoke, which will be described later.
FIG. 6 is a schematic diagram for explaining the operation.
FIG. 7 is a cross-sectional view in the same direction as FIG. 2 in a state where a coiled substrate is mounted on a molding die.
8 is a partially enlarged view of a pin and a substrate in FIG. 7;
FIG. 9 is a diagram showing a modification in which holes in the substrate are provided on the outer side in the width direction of the coil array in FIG.
FIG. 10 is an exploded perspective view showing a state in which the coiled substrate is positioned inside the molding die.
11 is an enlarged cross-sectional view of a molded coil according to Embodiment 2 of FIG.
FIG. 12 is a cross-sectional view of a main part showing Embodiment 3 of the relative movement device of the present invention.
FIG. 13 is a plan view of a swing motor showing a fourth embodiment of the relative movement device of the present invention.
14 is a view taken along the line AOB of FIG. 10;
FIG. 15 is a cross-sectional view of a principal part showing a modification (1) of the relative movement device of the present invention.
FIG. 16 is a partial cross-sectional view of the front of a conventional linear motor.
17 is a plan view of a coil portion of the linear motor of FIG.
18 is a side cross-sectional view of the linear motor of FIG.
19 is a cross-sectional view taken along line AA in FIG.
20 is a cross-sectional view taken along line BB in FIG.
21 is a cross-sectional view taken along line CC of FIG.
22 is a cross-sectional view taken along the line DD in FIG.
FIG. 23 is an exploded perspective view showing an example of a state where a coiled substrate is positioned inside a conventional resin mold.
[Explanation of symbols]
1, 41 Magnetic gap,
2a, 2b, 42a, 42b Permanent magnet
3, 43 Magnetic gap
5 Center York
6a, 6b, 26a, 26b, 46a, 46b, φa, φb, φc Flat coil
6bf, 6cf flat part
6t slope
6f flat part
6g clearance
6i ridgeline
6cl center line
9A, 9C, 29A substrate
9Aa, 9Ca, 29Aa Hole in the board
9B, 9CB, 29B, 49B Coiled board
11, 411 York
13, 213, 313 Resin part
14, 214, 414 Molded coil,
15, 415 carriage
17, 217, 417 mover
18 Mold mover
18a Molded coil section
18b Carriage part
19, 519 base
20 First mold member
20a, 21a Pin hole
20b, 21b pin for the time being
20d, 21d Inner edge
20e Tip in the mold
21 Second mold member
22, 23 pins
22a, 23a body
22b Tip
22c, 22d, 23d Stepped portion
22e, 23e Base
22f escape
23b Tip hole
23c Tip surface
24 Mold for molding
25 space
6cl center line
6i ridgeline
419 base
419a Flat plate part
419b Shaft
450 bearing

Claims (1)

Manufacture of a molded coil in which a coiled substrate having a coil array in which a plurality of flat coils are fixed to at least one surface of the substrate is mounted inside a mold and resin is injected around the coiled substrate to mold in the method, a first positioning pin having a tip which penetrates the contact and the substrate to the coil array at both ends a and one surface of the hand the substrate at a site that is not enveloped by the flat coils of the substrate of A first mold member that is locked; a second mold member that is locked to a second positioning pin that is in contact with the other surface of the substrate and has a tip hole into which the tip portion is inserted ; in said mold to form, method of manufacturing a molded coil, characterized by injecting resin therein.

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