JP4863555B2 - Cement molded product molded by mold having moderate water permeability / breathability and method for producing the same - Google Patents

Description

【００３０】
上記表の結果からもわかるように、アルミケースでは撥水処理をしても離型性が著しく低く、通水／通気性の無いアルミやポリエチレンフィルムでは極端に乾燥時間が長くなり表面に水浮きが原因してクラックが発生してしまう。しかしながら、実施例に示されるような紙で作製した型枠では以上のような問題はなく、離型性、乾燥性、および成型物の外観からも最も適していることがわかった。
【００３１】
なお、得られたセメント成型物は、そのままで使用してもかまわないが、着色、防水性付与、表面硬度改善等必要な場合、種々の塗材を用いてコーティングすることも可能である。
【００３２】
実施例３
図６〜図１１は、本発明を縦型の電気抵抗器に適用した例であり、型枠３０は外枠３１と仕切枠３５とで構成されている。
図７に示すように、外枠３１を構成するブランクは方形の厚紙で作成され、底部と両側壁部とで構成されており、両部の境界には折り線３４、３４が形成されている。また、仕切枠３５を構成するブランクも、外枠３１を構成するブランクと同質の方形の厚紙で作成されており、複数の折り線３６、３６、…が平行に形成されている。
【００３３】
上記各ブランクの作成過程において、外枠３１及び仕切枠３５の各部の寸法は、巻線抵抗体４１の周囲に必要量のセメント層が形成できるように決定する。
また、外枠３１及び仕切枠３５に設ける各折り線をミシン目で構成すると共に、外枠３１の側壁及び底壁に、１製品単位の幅でミシン目を設けておくと、製造後の型枠の取り外し、製品の分割が容易になる。
【００３４】
図８に示すように、上記構成の、外枠３１用のブランクを折り線３４、３４に沿って折り曲げてチャンネル状の外枠３１を形成し、仕切枠３５用ブランクを、複数の折り線３６、３６、…に沿って山折り−谷折り−谷折り−山折りの順に折り曲げ、同一方形状の凹部と凸部が交互に形成された仕切枠３５を形成する。次いで、仕切枠を外枠の側壁３３、３３間に、底壁３２挿入し、仕切枠３５の外枠３１の側壁３３、３３内面と接触する部分を、溶融パラフィンにて接着し、複数の直方体の充填部を備えた型枠３０を形成する。
【００３５】
抵抗組立体４０は、図９〜１１に示すように、巻線抵抗体４１と、巻線抵抗体４１の頂部に取り付けた端子４２と、巻線抵抗体４１の底部に取り付けられた端子４３とで構成されており、端子４２及び４３は巻線抵抗体４１に平行になるように折り曲げられており、型枠３０の充填部に効率的に挿入できるように構成されている。
【００３６】
上記のように構成した型枠３０内に、無機セメントを充填し、チャックの付いた挿入機（図示せず）により、所定の場所に設置された型枠３０に、抵抗組立体４０を振動させながら挿入し、所定位置に挿入されたらチャックを解放しセメントを乾燥させた後、型枠３０を取り除き製品を得た。
なお、図示実施例３では、型枠３０の直線状に並んだ複数の充填部（封入部）の一つ置きに抵抗組立体４０を挿入し、間に無挿入部として製品の分割を容易にしている。
【００３７】
チャック解放後は、無機セメントの高いチクソ性により過度の衝撃がない限り抵抗体が挿入位置から大きくずれることがなく、また、振動させながら挿入することにより、脱泡と小さな力でスムーズに挿入することができる。
【００３８】
上記のように構成したセメント成型物は、実施例１及び２のセメント成型物と同様の結果が得られた。
【００３９】
本実施例で得られたセメント成型物は、そのままで使用してもかまわないが、実施例１のセメント成型物と同様に、着色、防水性付与、表面硬度改善等必要な場合、種々の塗材を用いてコーティングすることも可能である。
【００４０】
【発明の効果】
セラミックや樹脂ケース製造に費やされていたエネルギー、コスト、時間が大幅に削減でき、更に、得られる電気部品の軽量化、放熱性が大幅に向上し、それらを組み込む電気製品そのものの性能も向上させることが可能になる。
【００４１】
型枠を紙で作製したので、製造コストも軽減でき、更に、適度の通水／通気性を持っていることに加え、上面だけでなく型枠の側面や底面からの乾燥も促進され、成型物全体が均一に乾燥することができ、それゆえ乾燥過程で生じるクラック、水浮き、極端なヒケ等の発生を防止することができ、歩留まりが良い。
【００４２】
さらには、セメント成型物の製造に、連続した型枠を使用するので、保形性、生産性が向上する。また、抵抗組立体を型枠に挿入、充填した状態で、切断等の加工を施すことにより短冊状やロール状にして保管することができる。
【図面の簡単な説明】
【図１】巻線抵抗組立体を型枠内にセットした状態を示す正面図である。
【図２】巻線抵抗組立体を型枠内にセットした状態を示す側面図である。
【図３】型枠作成用ブランクの展開図である。
【図４】横型巻線抵抗組立体の正面図である。
【図５】横型巻線抵抗組立体の側面図である。
【図６】実施例３のセメント成型品の断面図である。
【図７】型枠作成用ブランクの展開図である。
【図８】図７の展開図をもとに形成された連続型を説明する図面である。
【図９】縦型巻線抵抗組立体の正面図である。
【図１０】縦型巻線抵抗組立体の左側面図である。
【図１１】縦型巻線抵抗組立体の右側面図である。
【符号の説明】
１０ 型枠
１１ 底壁
１２、１３ 側壁
１４ 固定部分
１５、１６ 折り線
２０ 抵抗組立体
２１ 巻線抵抗体
２２ 端子
３０ 型枠
３１ 外枠
３２ 底壁
３３ 側壁
３４ 折り線
３５ 仕切枠
３６ 折り線
４０ 抵抗組立体
４１ 巻線抵抗体
４２、４３ 端子[0001]
[Technical field to which industry belongs]
The present invention relates to a cement molded article in which an electric resistor, a capacitor and the like with self-heating are embedded, and a method for manufacturing the same.
[0002]
[Prior art]
Currently, electrical resistors and capacitors widely used in power supply parts of home appliances are manufactured by filling ceramics or resin cases obtained by injection molding in advance with electrically insulating cement and embedding resistors. It was.
[0003]
However, ceramic and resin cases are expensive, and since they are open only on the top surface, the filled cement solution only dissipates from the top surface, so that the entire molded product can be dried uniformly. Therefore, cracks, water floats, extreme sink marks, etc., which are often problematic in the drying process, are often used as products, and the yield is poor.
[0004]
[Problems to be solved by the invention]
The present invention is a cement molded product that does not use a ceramic or resin case from the viewpoint of weight reduction of parts, manufacturing cost, process simplification, and prevents generation of cracks, water floating, extreme sinks, etc. during the drying process, and It is an object to provide a manufacturing method thereof.
[0005]
[Means for Solving the Problems]
As a result of development studies to solve the above problems, the above problems were solved by using a formwork made of a cellulosic compound, for example, paper, instead of a ceramic or resin case.
[0006]
The present invention provides a fixing part for temporarily fixing a part in a mold of a continuous mold formed of a cellulosic compound and having appropriate water permeability / breathability, and temporarily fixes the part. the manufacturing method of the formwork to remove cement molded product after is filled with dried cured cement has a gist between.
[0009]
In addition, the present invention is to insert a cement into a continuous mold having a proper water permeability / breathability formed of a cellulosic compound , and then insert and bury it in the cement while vibrating the parts. , it is summarized as method for producing a cement molded product removing the formwork after drying and curing the cement.
[0012]
[Action]
If it is paper, a formwork can be easily produced and manufacturing cost can also be reduced. Furthermore, in addition to having appropriate water permeability / breathability, drying from not only the top surface but also the side surface and bottom surface of the mold is promoted, and the entire molded product is uniformly dried. Therefore, it is possible to prevent the occurrence of cracks, water floating, extreme sink marks, etc., which are often problematic during the drying process.
[0013]
Further, when a vertical type resistor (see FIG. 10) is taken as an example, a continuous formwork (FIG. 8) obtained by molding is used based on the developed view of FIG. In this way, a large number of products as shown in FIG. 6 can be obtained. By using this continuous formwork, shape retention and productivity are further improved.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
As described above, the invention of the cement molded product is characterized in that it is obtained by filling a mold having moderate water permeability / breathability with cement, drying and curing, and then removing the mold. Furthermore, the mold is formed of a cellulosic compound.
[0015]
In the invention of the method for producing a cement molded article, the part is temporarily fixed in a mold having moderate water permeability / breathability, cement is filled between the mold and the part, and the mold is dried and hardened. It is characterized in that a frame is removed, and further, the mold is formed of a cellulosic compound.
[0016]
Furthermore, in the invention of the method for producing a cement molded article, after filling the mold into a mold having an appropriate water permeability / breathability, the mold is inserted and embedded in the cement, and the mold is dried and hardened. It is characterized by removing the frame, and further, it is characterized by being inserted and buried in the cement while vibrating the parts.
[0017]
The present invention can be achieved as long as the material has appropriate water permeability / breathability, and among them, a cellulosic compound such as paper is preferable. The type of paper is not limited except for special processing such as a laminate with resin in which water permeability / air permeability is completely impaired. The thickness is not particularly limited as long as the shape of the molded product can be sufficiently retained and water / air permeability is secured.
[0018]
The method of manufacturing the formwork is not particularly limited, but the case of paper will be described as an example. Using any method such as a method of punching and assembling a paper sheet with Thomson, a method of obtaining a pulp slurry by pouring it into a mold, etc. Also good. It is preferable that the shape of the mold is set so that an article such as a resistor entering the mold can be buried uniformly.
[0019]
By appropriately water-repelling the paper surface in contact with the cement, the adjustment of water flow / breathability and the release property of the cement are improved. In other words, without water repellent treatment, the water permeability / breathability is too large, and the paper may swell and it may be difficult to maintain the shape. On the other hand, when the water-repellent treatment is excessive, the drying speed of the cement is remarkably slowed, which may cause water floating and surface cracks. There are various types of water repellents, such as natural carbana wax, synthetic polymer (for example, fluorine resin, silicone resin), low molecular fluorine compound, and silicon, but are not limited.
[0020]
Molten paraffin, instant adhesive, paper adhesive tape, hot melt resin, or the like is used for joining when assembling a blank to form a formwork.
[0021]
【Example】
Although the example which implemented this invention to the electrical resistor is demonstrated according to FIGS. 1-11, this invention is not limited at all by this Example.
[0022]
Example 1
FIGS. 1 to 5 are examples in which the present invention is applied to a horizontal electric resistor, and a blank for forming a mold 10 is made from a general untreated cardboard (thickness 0.5 mm) using Thomson. As shown in FIG. 3, side walls 12, 12, 13, 13 are extended on four sides of the rectangular bottom wall 11, and the long side walls 12, 12 have a resistance. Fixing portions 14, 14, 14, 14 for holding terminals attached to the body are extended, and folding lines 15, 15 are formed at the boundary between the bottom wall 11 and the side walls 12, 12. Fold lines 16 and 16 are formed at the boundary between the side walls 13 and 13.
[0023]
The blank side walls 12 and 12 are folded in the same direction along the folding lines 15 and 15 and the side walls 13 and 13 are folded in the same direction along the folding lines 16 and 16, and the joining portions of the adjacent side walls are bonded with molten paraffin. Form a formwork.
[0024]
Note that the shape and dimensions of the blank and the formwork are not limited to the above-described embodiment, and the fixed part is provided in a size and position that can hold the terminal part of the electrical component in the mold to be manufactured. Good.
[0025]
As shown in FIGS. 1 and 2, a winding resistance assembly 20 including a winding resistor 21 and terminals 22 and 22 is set in the mold 10 configured as described above, and a gap between the two. After the cement was filled and dried, the mold 10 was removed to obtain a product.
[0026]
At that time, in order to bury the winding resistance assembly 20 as shown in FIG. 1 uniformly in the cement without unevenness, the terminal 23 of the winding resistance assembly 20 is connected to the mold when the mold 10 is filled with cement. 10 fixed portions 14, 14... Are fixed from the left and right, and serve to position the winding resistance assembly 20, so that the winding resistance assembly 10 is embedded (or encapsulated) in a proper position in the cement. Product) can be obtained.
[0027]
Example 2
The product was obtained through the same steps as in Example 1 except that the contact surface with the blank cement was subjected to wax treatment, and the other points differed from Example 1.
[0028]
The case where the surface wax treatment was made as described above was Example 1, the case where the wax treatment was performed was Example 2, the aluminum case was used (Comparative Example 1), and the wax-treated aluminum case was used (Comparison) Example 2) and polyethylene sheet-incorporated paper form (Comparative Example 3) are used as comparative examples, and are used to fill a commercially available electrically insulating aqueous cement and properties of a molded product obtained after drying and curing. The results of comparison of releasability were as shown in the following table.
[0029]
[Table 1]

[0030]
As can be seen from the results in the table above, the aluminum case has extremely low releasability even after water repellent treatment, and the aluminum and polyethylene films without water / breathability have extremely long drying times and float on the surface. Cause cracks. However, it has been found that the molds made of paper as shown in the examples do not have the above-mentioned problems and are most suitable from the viewpoint of releasability, drying property and appearance of the molded product.
[0031]
The obtained cement molded product may be used as it is, but can be coated with various coating materials when coloring, waterproofing, surface hardness improvement, etc. are required.
[0032]
Example 3
6 to 11 are examples in which the present invention is applied to a vertical electric resistor, and the mold 30 is composed of an outer frame 31 and a partition frame 35.
As shown in FIG. 7, the blank constituting the outer frame 31 is made of rectangular thick paper, and is composed of a bottom portion and both side wall portions, and folding lines 34 and 34 are formed at the boundary between both portions. . Further, the blank constituting the partition frame 35 is also made of rectangular thick paper having the same quality as the blank constituting the outer frame 31, and a plurality of folding lines 36, 36,... Are formed in parallel.
[0033]
In the process of creating each blank, the dimensions of each part of the outer frame 31 and the partition frame 35 are determined so that a necessary amount of cement layer can be formed around the winding resistor 41.
In addition, each fold line provided in the outer frame 31 and the partition frame 35 is constituted by perforations, and if a perforation is provided on the side wall and bottom wall of the outer frame 31 with a width of one product unit, a mold after manufacture is obtained. It is easy to remove the frame and divide the product.
[0034]
As shown in FIG. 8, the blank for the outer frame 31 having the above configuration is folded along the fold lines 34, 34 to form the channel-shaped outer frame 31, and the blank for the partition frame 35 is made up of the plurality of fold lines 36. , 36,... Are folded in the order of mountain fold-valley fold-valley fold-mountain fold to form a partition frame 35 in which concave portions and convex portions having the same rectangular shape are alternately formed. Next, the partition frame is inserted between the side walls 33 and 33 of the outer frame, the bottom wall 32 is inserted, and the portions of the partition frame 35 that are in contact with the inner surfaces of the side walls 33 and 33 are bonded with molten paraffin to form a plurality of rectangular parallelepipeds. A mold 30 having a filling portion is formed.
[0035]
9 to 11, the resistance assembly 40 includes a winding resistor 41, a terminal 42 attached to the top of the winding resistor 41, and a terminal 43 attached to the bottom of the winding resistor 41. The terminals 42 and 43 are bent so as to be parallel to the winding resistor 41 and are configured to be efficiently inserted into the filling portion of the mold 30.
[0036]
The mold 30 configured as described above is filled with inorganic cement, and the resistance assembly 40 is vibrated in the mold 30 installed at a predetermined place by an insertion machine (not shown) with a chuck. Then, after being inserted into a predetermined position, the chuck was released to dry the cement, and then the mold 30 was removed to obtain a product.
In Example 3 shown in the figure, the resistor assembly 40 is inserted into every other filling portion (encapsulation portion) arranged in a straight line on the mold 30, and the product can be easily divided as a non-insertion portion therebetween. ing.
[0037]
After releasing the chuck, the resistor does not deviate greatly from the insertion position unless there is an excessive impact due to the high thixotropy of the inorganic cement, and it can be smoothly inserted with defoaming and small force by inserting it while vibrating. be able to.
[0038]
The cement molded product configured as described above gave the same results as the cement molded products of Examples 1 and 2.
[0039]
The cement molded product obtained in this example may be used as it is. However, as in the case of the cement molded product of Example 1, various coatings may be used when coloring, waterproofing, surface hardness improvement, etc. are required. It is also possible to coat with a material.
[0040]
【Effect of the invention】
The energy, cost, and time spent for manufacturing ceramic and resin cases can be greatly reduced. In addition, the weight of the resulting electrical components and heat dissipation are greatly improved, and the performance of the electrical products that incorporate them is also improved. It becomes possible to make it.
[0041]
Since the formwork is made of paper, manufacturing costs can be reduced, and in addition to having moderate water permeability / breathability, drying is promoted not only from the top but also from the side and bottom of the formwork. The entire object can be dried uniformly, and therefore, the generation of cracks, water floating, extreme sink marks, etc. that occur during the drying process can be prevented, and the yield is good.
[0042]
Furthermore, since a continuous formwork is used for manufacturing a cement molding, shape retention and productivity are improved. In addition, the resistance assembly can be stored in a strip shape or a roll shape by performing processing such as cutting in a state where the resistance assembly is inserted and filled in the mold.
[Brief description of the drawings]
FIG. 1 is a front view showing a state in which a winding resistance assembly is set in a mold.
FIG. 2 is a side view showing a state in which a winding resistance assembly is set in a mold.
FIG. 3 is a development view of a blank for creating a formwork.
FIG. 4 is a front view of a horizontal winding resistance assembly.
FIG. 5 is a side view of a horizontal winding resistance assembly.
6 is a cross-sectional view of a cement molded product of Example 3. FIG.
FIG. 7 is a development view of a blank for forming a mold.
8 is a drawing for explaining a continuous type formed based on the development of FIG. 7. FIG.
FIG. 9 is a front view of a vertical winding resistance assembly.
FIG. 10 is a left side view of the vertical winding resistance assembly.
FIG. 11 is a right side view of the vertical winding resistance assembly.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 10 Form 11 Bottom wall 12, 13 Side wall 14 Fixed part 15, 16 Folding line 20 Resistance assembly 21 Winding resistor 22 Terminal 30 Mold 31 Outer frame 32 Bottom wall 33 Side wall 34 Folding line 35 Partition frame 36 Folding line 40 Resistance assembly 41 Winding resistor 42, 43 Terminal

Claims (2)

Fasten the part provided with a fixed portion for temporarily stopping the parts into a mold frame of successive mold having an appropriate water flow / ventilation being formed by cellulose-based compound temporary, between the mold and the component method for producing a cement molded product removing the formwork to after the cement was filled dry curing. After filling the formwork of a continuous formwork made of cellulosic compound with moderate water permeability / breathability, insert and bury it in the cement while vibrating the parts, and dry and harden the cement manufacturing method of the formwork to remove cement molded product after the.

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