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JP6085580B2 - Method for manufacturing ignition coil for internal combustion engine - Google Patents
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JP6085580B2 - Method for manufacturing ignition coil for internal combustion engine - Google Patents

Method for manufacturing ignition coil for internal combustion engine Download PDF

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JP6085580B2
JP6085580B2 JP2014077538A JP2014077538A JP6085580B2 JP 6085580 B2 JP6085580 B2 JP 6085580B2 JP 2014077538 A JP2014077538 A JP 2014077538A JP 2014077538 A JP2014077538 A JP 2014077538A JP 6085580 B2 JP6085580 B2 JP 6085580B2
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ignition coil
internal combustion
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伸也 山根
伸也 山根
雅之 西村
雅之 西村
山田 修司
修司 山田
鈴木 大輔
大輔 鈴木
和利 細田
和利 細田
一樹 安永
一樹 安永
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Diamond Electric Manufacturing Co Ltd
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Description

本発明は、内燃機関用点火コイルの製造方法に関し、特に、内燃機関用点火コイルの構造形成に関する。   The present invention relates to a method for manufacturing an ignition coil for an internal combustion engine, and more particularly to the structure formation of an ignition coil for an internal combustion engine.

近年、自動車等に用いられる内燃機関では、プラグホールの各々に点火コイルを配備させた直接点火方式が採用されている。かかる点火コイルの構造体は、使用環境又は耐久性の観点からこれに適う材質が選択され、例えば、ポリアミド系樹脂又はポリエステル系樹脂といった熱可塑性樹脂が使用される(特開2001−352012号公報)。   In recent years, an internal combustion engine used for an automobile or the like employs a direct ignition system in which an ignition coil is provided in each plug hole. A material suitable for this ignition coil structure is selected from the viewpoint of use environment or durability. For example, a thermoplastic resin such as a polyamide resin or a polyester resin is used (Japanese Patent Laid-Open No. 2001-352012). .

このうち、ポリアミド樹脂については「PA6,PA66」、ポリエステル樹脂については「PBT」、この他の熱可塑性樹脂としては「変性PPE」等が其の使用例の代表とされている。   Of these, “PA6, PA66” for the polyamide resin, “PBT” for the polyester resin, “modified PPE”, etc. as other thermoplastic resins are representative examples.

特開2001−352012号公報JP 2001-352012 A

内燃機関用点火コイルでは、高電圧(数十kV程度)を発生させる二次コイルの周辺が確実に絶縁されるよう、熱可塑性樹脂によって二次コイル周辺を隙間なく含浸させることが要求される。しかしながら、特許文献1を読む限り、二次コイルの巻線間といった狭い空隙へ熱可塑性樹脂を程よく行きわたらせる工夫は十分に述べられていない。   An ignition coil for an internal combustion engine is required to impregnate the periphery of the secondary coil with a thermoplastic resin without gap so that the periphery of the secondary coil that generates a high voltage (several tens of kV) is reliably insulated. However, as long as Patent Document 1 is read, there has not been sufficiently described a device for distributing the thermoplastic resin moderately in a narrow gap such as between the windings of the secondary coil.

また、超臨界流体を熱可塑性樹脂へ溶解させ、当該熱可塑性樹脂の粘性を調整させる製法も考えられる。しかし、かかる製法では、熱可塑性樹脂が投入される金型キャビティを適宜に圧力調整させねば、当該樹脂に溶解した超臨界流体の気相化を招き二次コイル周辺でボイドが発生してしまう。   Further, a production method in which a supercritical fluid is dissolved in a thermoplastic resin and the viscosity of the thermoplastic resin is adjusted is also conceivable. However, in such a manufacturing method, unless the pressure of the mold cavity into which the thermoplastic resin is introduced is appropriately adjusted, the supercritical fluid dissolved in the resin is vaporized and voids are generated around the secondary coil.

本発明は上記課題に鑑み、二次コイル周囲の樹脂含浸体を高品質で形成させ得る点火コイル製造方法の提供を目的とする。   In view of the above problems, an object of the present invention is to provide an ignition coil manufacturing method capable of forming a resin-impregnated body around a secondary coil with high quality.

上記課題を解決するため、本発明では次のような内燃機関用点火コイルの製造方法とする。即ち、キャビティ内に二次コイルがセットされたキャビティ空間へ予圧を与える予圧工程と、超臨界流体を溶融させた溶融物質混成流体を前記予圧工程の後に前記キャビティ空間へ投入する樹脂供給工程と、を実施させる内燃機関用点火コイルの製造方法において、
前記樹脂供給工程は、前記超臨界流体の気相化を回避する圧力制御を続けながら前記溶融物質混成樹脂流体を前記キャビティ空間へ投入し、
前記予圧工程は、気体の投入によって予圧を制御させ、
前記気体は、前記サブキャビティの内部へ投入されることで、前記樹脂排出ゲートを介して前記キャビティ空間へ投入されることとする。
In order to solve the above problems, the present invention provides the following method for manufacturing an ignition coil for an internal combustion engine. That is, a preloading step for applying a preload to the cavity space in which a secondary coil is set in the cavity, and a resin supplying step for introducing a molten material mixed fluid obtained by melting a supercritical fluid into the cavity space after the preloading step; In the method of manufacturing an ignition coil for an internal combustion engine that implements
In the resin supply step, the molten material mixed resin fluid is introduced into the cavity space while continuing pressure control to avoid gasification of the supercritical fluid,
In the preloading step, the preload is controlled by introducing gas,
The gas is introduced into the cavity space through the resin discharge gate by being introduced into the subcavity.

また、キャビティ内に二次コイルがセットされたキャビティ空間へ予圧を与える予圧工程と、超臨界流体を溶融させた溶融物質混成流体を前記予圧工程の後に前記キャビティ空間へ投入する樹脂供給工程と、を実施させる内燃機関用点火コイルの製造方法において、A preloading step for applying a preload to the cavity space in which a secondary coil is set in the cavity; and a resin supplying step for introducing a molten material mixed fluid obtained by melting a supercritical fluid into the cavity space after the preloading step; In the method of manufacturing an ignition coil for an internal combustion engine that implements
前記樹脂供給工程は、前記超臨界流体の気相化を回避する圧力制御を続けながら前記溶融物質混成樹脂流体を前記キャビティ空間へ投入し、  In the resin supply step, the molten material mixed resin fluid is introduced into the cavity space while continuing pressure control to avoid gasification of the supercritical fluid,
前記キャビティは、樹脂投入ゲートと、当該樹脂投入ゲートとは異なる位置に設けられた樹脂排出ゲートと、当該樹脂排出ゲートを介して連通されるサブキャビティと、を備え、  The cavity includes a resin charging gate, a resin discharging gate provided at a position different from the resin charging gate, and a subcavity communicated with the resin discharging gate.
前記樹脂供給工程では、前記樹脂投入ゲートから前記樹脂排出ゲートへ向けて前記溶融物質混成樹脂流体が流動し、当該溶融物質混成樹脂流体を前記サブキャビティへ導かせることとする。  In the resin supply step, the molten substance mixed resin fluid flows from the resin charging gate to the resin discharge gate, and the molten substance mixed resin fluid is guided to the subcavity.

また、当該製造方法では、前記樹脂供給工程が進行すると、前記キャビティの内部へ負圧が与えられるのが好ましい。Moreover, in the said manufacturing method, it is preferable that a negative pressure is given to the inside of the said cavity when the said resin supply process advances.

好ましくは、前記サブキャビティは、内部容積が制御可能とされることとする。
Preferably , the internal volume of the subcavity is controllable.

好ましくは、前記予圧工程は、気体の投入によって予圧を制御させることとする。
Preferably, in the preloading step, the preload is controlled by introducing gas.

好ましくは、前記予圧工程は、前記超臨界流体の主成分と同組成の気体を利用していることとする。
Preferably, the preloading step uses a gas having the same composition as the main component of the supercritical fluid.

好ましくは、前記予圧工程は、前記気体を二酸化炭素としていることとする。
Preferably, in the preloading step, the gas is carbon dioxide.

好ましくは、前記樹脂供給工程の後、前記超臨界流体の気相化を回避する圧力制御を続けながら前記溶融物質混成樹脂流体を固相化させる固相化工程、を実施させることとする。
Preferably, after the resin supply step, a solid phase step of solidifying the molten material mixed resin fluid is performed while continuing pressure control to avoid gas phase formation of the supercritical fluid.

本発明に係る内燃機関用点火コイルの製造方法によると、二次コイルの周辺における絶縁構造は、超臨界流体を熱可塑性樹脂へ溶解させ、当該熱可塑性樹脂の粘性を調整させる物性調整製法が採用される。このため、二次コイルへ絶縁樹脂を含浸させる工程では、熱可塑性樹脂の粘性が低く調整されるので、二次コイルの周辺隙間部へ熱可塑性樹脂が確実に行きわたることとなる。   According to the method for manufacturing an ignition coil for an internal combustion engine according to the present invention, the insulating structure around the secondary coil employs a physical property adjusting method for dissolving the supercritical fluid in the thermoplastic resin and adjusting the viscosity of the thermoplastic resin. Is done. For this reason, in the step of impregnating the secondary coil with the insulating resin, the viscosity of the thermoplastic resin is adjusted to be low, so that the thermoplastic resin reliably reaches the peripheral gap portion of the secondary coil.

これに加え、かかる製造方法によると、これを実現させる樹脂注型装置について以下のようなメリットを齎す。即ち、物性調整製法による熱可塑性樹脂は、二次コイル周辺の構造領域に限定して形成されるため、キャビティ圧を調整すべき加圧容積が格段に狭められる。このため、当該製法方式の樹脂注型装置は、加圧容積低下に伴いコンプレッサ等の要求出力が最小限に抑えられ、当該装置の大型化及び高コスト化から免れる。   In addition, according to this manufacturing method, the following merits are given to the resin casting apparatus that realizes this. That is, since the thermoplastic resin produced by the physical property adjustment manufacturing method is formed only in the structural region around the secondary coil, the pressurizing volume for adjusting the cavity pressure is remarkably reduced. For this reason, in the resin casting apparatus of the manufacturing method, the required output of the compressor or the like is suppressed to the minimum as the pressurization volume decreases, and the apparatus is freed from an increase in size and cost.

また、かかる製造方法によると、キャビティ圧が適宜に制御されるので、超臨界流体の気相化を回避させる圧力制御が維持させつつ、溶融物質混成樹脂流体をキャビティ空間へ投入させることが可能となる。このため、同製造方法は、二次コイルの樹脂含浸体について、ボイドを極力排除させた高品質な製品を提供することとなる。   Further, according to such a manufacturing method, since the cavity pressure is appropriately controlled, it is possible to introduce the molten material mixed resin fluid into the cavity space while maintaining the pressure control that avoids the vaporization of the supercritical fluid. Become. For this reason, the manufacturing method provides a high-quality product in which voids are eliminated as much as possible for the resin-impregnated body of the secondary coil.

実施の形態に係る二次コイルの組立工程を説明する図。The figure explaining the assembly process of the secondary coil which concerns on embodiment. 実施の形態に係る二次コイルの樹脂形成工程を説明する図。The figure explaining the resin formation process of the secondary coil which concerns on embodiment. 実施の形態に係る低圧部品組立工程を説明する図。The figure explaining the low voltage | pressure component assembly process which concerns on embodiment. 実施の形態に係る低圧部品組立工程を説明する図。The figure explaining the low voltage | pressure component assembly process which concerns on embodiment. 実施の形態に係る被服工程を説明する図。The figure explaining the clothing process which concerns on embodiment. 実施の形態に係る点火コイルの製造工程のうち含浸工程を説明する図。The figure explaining the impregnation process among the manufacturing processes of the ignition coil which concerns on embodiment.

以下、本発明に係る実施の形態につき図面を参照して具体的に説明する。図1は、本実施の形態に係る二次コイルの組立工程が示されている。当該製造工程は、先ず、二次ボビン110が準備され、これに導線が巻回され二次コイル111が形成される。また、二次ボビン110の所定箇所には中継端子112が設けられている。この中継端子112の一端には二次コイル111の出力端が接続され、其の他端には高圧端子113が電気的に接続される。即ち、二次コイル111の巻線内側に急峻な磁界変化が生じた場合、当該二次コイル111は、これによって誘起電圧を発生させ、これを高圧端子113から後段導通部(点火プラグ等)へ出力させる。   Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 shows an assembly process of a secondary coil according to the present embodiment. In the manufacturing process, first, a secondary bobbin 110 is prepared, and a conductive wire is wound around the secondary bobbin 110 to form a secondary coil 111. A relay terminal 112 is provided at a predetermined location of the secondary bobbin 110. The output terminal of the secondary coil 111 is connected to one end of the relay terminal 112, and the high voltage terminal 113 is electrically connected to the other end. That is, when a steep magnetic field change occurs inside the winding of the secondary coil 111, the secondary coil 111 generates an induced voltage thereby, and this is transferred from the high-voltage terminal 113 to a subsequent conduction part (such as a spark plug). Output.

かかる工程の後、二次コイル111の周辺領域に溶融物質混成樹脂を形成させる(図2参照)。この樹脂形成工程は、超臨界流体を液相状の熱可塑性樹脂へ溶解させた溶融物質混成樹脂流体が用いられ、これが固化された絶縁構造(溶融物質混成樹脂114)は、超臨界流体が溶融された状態で固相化されたものである。即ち、樹脂形成工程は、超臨界流体を利用することで液相段階の熱可塑性樹脂を粘度低下させることになる(物性調整製法による工程)。尚、二次コイル111及び溶融物質混成樹脂より成る構造体を高圧部構造体120と呼ぶことがある。   After this step, a molten material hybrid resin is formed in the peripheral region of the secondary coil 111 (see FIG. 2). In this resin forming process, a molten material mixed resin fluid obtained by dissolving a supercritical fluid in a liquid phase thermoplastic resin is used, and the solidified insulating structure (molten material mixed resin 114) is melted by the supercritical fluid. In this state, it is solid-phased. That is, in the resin formation step, the viscosity of the thermoplastic resin in the liquid phase is reduced by using a supercritical fluid (process by physical property adjustment manufacturing method). A structure made of the secondary coil 111 and the molten material hybrid resin may be referred to as a high-pressure part structure 120.

超臨界流体を伴う樹脂注型装置(以下、超臨界式注型装置と呼ぶ場合がある)は、樹脂形成工程(含浸工程及び固相化工程)を担う装置であり、超臨界流体を生成吐出する機構と通常の射出成型機とが組合わされて構成される。このうち、超臨界流体を生成吐出する機構は、射出成型機からポリマーの溶体を導引させる管状部位、溶融物質が超臨界流体(温度及び圧力を臨界点へ到達させた状態)へ達するよう温度・圧力を制御する超臨界流体生成部位、この超臨界流体を管状部位の管内へ適量吐出させるインジェクタ―部位等から構成される。また、当該管状部位の吐出先には金型のゲートが接続され、其の金型は、ゲートを介して内部のキャビティと管状部位とが連通される。また、金型内に形成されたキャビティは、コンプレッサによる圧力制御と、ヒータによる温度制御とが適宜行われる。   A resin casting apparatus with a supercritical fluid (hereinafter sometimes referred to as a supercritical casting apparatus) is a device that takes charge of the resin forming process (impregnation process and solid phase process), and generates and discharges a supercritical fluid. And a normal injection molding machine. Among them, the mechanism that generates and discharges the supercritical fluid is a tubular part that draws the polymer solution from the injection molding machine, and the temperature at which the molten material reaches the supercritical fluid (the state in which the temperature and pressure reach the critical point). A supercritical fluid generating part that controls the pressure, an injector part that discharges an appropriate amount of this supercritical fluid into the tube of the tubular part, and the like. In addition, a mold gate is connected to the discharge destination of the tubular part, and the cavity communicates with the internal cavity via the gate. Further, the cavity formed in the mold is appropriately subjected to pressure control by a compressor and temperature control by a heater.

かかる構成とされた超臨界式注型装置は、射出成型機からポリマー(絶縁樹脂)の溶体が出力され、この樹脂流体に所定割合の超臨界流体が投入される。このとき、樹脂流体に超臨界流体が溶融し、溶融物質混成樹脂流体が生成される。一方、金型のキャビティ内は、コンプレッサによって圧力制御され、其処へ溶融物質混成樹脂流体が供給される(含浸工程)。   In the supercritical casting apparatus having such a configuration, a polymer (insulating resin) solution is output from an injection molding machine, and a predetermined ratio of supercritical fluid is charged into the resin fluid. At this time, the supercritical fluid is melted into the resin fluid, and a molten material mixed resin fluid is generated. On the other hand, the pressure in the cavity of the mold is controlled by a compressor, and the molten material mixed resin fluid is supplied to the cavity (impregnation step).

このように、本実施の形態に係る内燃機関用点火コイル100の製造方法によると、二次コイル111の周辺における絶縁構造は、超臨界流体を熱可塑性樹脂へ溶解させ、当該熱可塑性樹脂の粘性を調整させる物性調整製法が採用される。このため、二次コイル111へ熱可塑性樹脂(溶融物質混成樹脂流体)を含浸させる工程では、熱可塑性樹脂の粘性が所期の如く低下するので、二次コイルの周辺隙間部へ熱可塑性樹脂(溶融物質混成樹脂)が確実に行きわたることとなる。   As described above, according to the method for manufacturing the ignition coil 100 for the internal combustion engine according to the present embodiment, the insulating structure around the secondary coil 111 dissolves the supercritical fluid in the thermoplastic resin, and the viscosity of the thermoplastic resin is increased. A method for adjusting physical properties is used. For this reason, in the step of impregnating the secondary coil 111 with the thermoplastic resin (molten material mixed resin fluid), the viscosity of the thermoplastic resin is reduced as expected, so that the thermoplastic resin ( The molten material hybrid resin is surely distributed.

その後、超臨界式注型装置は、金型の温度制御を行うことで溶融物質混成樹脂流体を徐々に温度低下させ、この樹脂流体を最終的に固相化させ、溶融物質混成樹脂を形成させる(固相化工程)。この固相化工程では、温度制御と同時にキャビティ内の圧力制御も行われ、超臨界流体に相当する溶融物質が気相変態しないように冷却動作が進められる。   Thereafter, the supercritical casting apparatus gradually lowers the temperature of the molten material hybrid resin fluid by controlling the temperature of the mold, and finally solidifies the resin fluid to form a molten material hybrid resin. (Solid phase step). In this solid phase forming step, pressure control in the cavity is performed simultaneously with temperature control, and the cooling operation is advanced so that the molten material corresponding to the supercritical fluid does not undergo gas phase transformation.

ヘンリーの法則に基づけば、超臨界流体が窒素である場合、母材ポリマー(kg)に対する窒素(mol)の割合Rate1が「Rate1<0.0425×P(MPa)」のとき、ポリマー内の溶存窒素が気相変態(即ち、発砲)しないとされている。また、母材ポリマー(kg)に対する二酸化炭素(mol)の割合Rate2が「Rate2<0.17×P(MPa)」のとき、ポリマー内の溶存二酸化炭素が概ね気相変態しないとされている。尚、本実施の形態では、この溶融物質の割合が数%程度に設定される。特に、二酸化酸素を超臨界流体として用いる場合、窒素の其れと比較して樹脂母材への溶存量が多くなるので、かかる溶融物質の割合調整の自由度が大きくなる。このため、二酸化炭素を超臨界流体として用いる場合、当該自由度に鑑みれば、溶融物質混成樹脂流体の流動性に係る調整が容易となり得る。   Based on Henry's law, when the supercritical fluid is nitrogen, when the ratio Rate1 of nitrogen (mol) to the base polymer (kg) is “Rate1 <0.0425 × P (MPa)”, dissolution in the polymer Nitrogen is said not to undergo gas phase transformation (ie, firing). Further, when the Rate 2 of carbon dioxide (mol) with respect to the base polymer (kg) is “Rate 2 <0.17 × P (MPa)”, it is said that the dissolved carbon dioxide in the polymer does not substantially undergo gas phase transformation. In the present embodiment, the ratio of the molten material is set to about several percent. In particular, when oxygen dioxide is used as a supercritical fluid, the dissolved amount in the resin base material is larger than that of nitrogen, so that the degree of freedom in adjusting the ratio of the molten material is increased. For this reason, when carbon dioxide is used as the supercritical fluid, it is possible to easily adjust the fluidity of the molten material mixed resin fluid in view of the degree of freedom.

この例のように、キャビティ圧について適宜の条件を守りながら冷却させることで、超臨界式注型装置は、超臨界流体に係る溶融物質を発砲させることなく、当該樹脂を液相状態から固相状態へと相変態させることが可能となる。これによれば、溶融物質混成樹脂流体を冷却させる工程で二次コイル周辺にボイドが生じることはないので、当該二次コイル周辺における絶縁構造の品質が保たれる。   As shown in this example, by cooling while keeping appropriate conditions for the cavity pressure, the supercritical casting apparatus can cause the resin to move from the liquid phase to the solid phase without firing the molten material related to the supercritical fluid. It becomes possible to transform into a state. According to this, since no void is generated around the secondary coil in the process of cooling the molten material mixed resin fluid, the quality of the insulating structure around the secondary coil is maintained.

固相化工程が完了した中間製品は、その後、二次コイル周辺に低圧部品を取付ける低圧部品組立工程へと投入される(図3及び図4参照)。本実施の形態に係る低圧部品は、ターミナル中継体131と、閉磁路鉄心132〜133と、中心鉄心134と、一次コイル135と、コネクタ構造体136(図3及び図4では図示されていない)とを指すものである。   The intermediate product for which the solid-phase process has been completed is then put into a low-pressure part assembly process in which low-pressure parts are mounted around the secondary coil (see FIGS. 3 and 4). The low-voltage component according to the present embodiment includes a terminal relay body 131, closed magnetic circuit cores 132 to 133, a central core 134, a primary coil 135, and a connector structure 136 (not shown in FIGS. 3 and 4). It means that.

ターミナル中継体131は、絶縁構造体から成るものであって、上述した高圧部構造体120を受け入れる収容空間が設けられている。当該収容空間は、外部との連通孔が設けられ、組付けられた高圧部構造体120の高圧端子113が連通孔を介して外部の導通構造に接続可能となる。また、ターミナル中継体131の絶縁構造体は、収容空間を囲う如く鍔部が形成され、この鍔部に閉磁路鉄心132〜133,コネクタ構造体136,イグナイタ137といった低圧部品が配置される。   The terminal relay body 131 is made of an insulating structure, and is provided with a receiving space for receiving the high-voltage part structure 120 described above. The accommodation space is provided with a communication hole with the outside, and the high voltage terminal 113 of the assembled high voltage section structure 120 can be connected to the external conduction structure through the communication hole. In addition, the insulating structure of the terminal relay body 131 is formed with a flange so as to surround the accommodation space, and low voltage components such as the closed magnetic circuit cores 132 to 133, the connector structure 136, and the igniter 137 are disposed on the flange.

また、高圧部構造体120には、二次コイル111の内部を貫く挿通孔が設けられており、これに中心鉄芯134及び一次コイル135が各々挿通される。よって、組付けられた中心鉄芯134の周りには、一次コイル135が巻回体として配置され、その外周に二次コイル111が巻回体として設けられる。そして、これらの構成の各々は、絶縁構造によって互いに電気的に絶縁されることとなる。更に、これらの構成のうち中心鉄芯134の端部には閉磁路鉄芯132〜133が配置され、これら全体構成によりコイルアセンブリが形成される。   Further, the high-voltage unit structure 120 is provided with an insertion hole that penetrates the inside of the secondary coil 111, and the central iron core 134 and the primary coil 135 are respectively inserted into the insertion holes. Therefore, the primary coil 135 is disposed as a wound body around the assembled central iron core 134, and the secondary coil 111 is provided as a wound body on the outer periphery thereof. Each of these components is electrically insulated from each other by the insulating structure. Further, among these configurations, closed magnetic circuit iron cores 132 to 133 are disposed at the end of the central iron core 134, and a coil assembly is formed by these overall configurations.

このコイルアセンブリの傍には、コネクタ構造体136(図示なし)及びイグナイタ137が配置される。コイルアセンブリの各コイルは、コネクタ構造体136に内設されたコネクタ端子、又は、イグナイタ137に配備された端子に適宜接続される。コネクタ端子は、電源端子,信号端子,及び,グランド端子等が設けられ、このうち、電源端子は一次コイル135に導通され、信号端子はイグナイタ内のパワートランジスタへ駆動信号を中継する。即ち、かかる構成とされた電磁回路は、点火信号(パルス)が信号端子に与えられると、一次コイル135及びパワートランジスタの直列回路で一次電流を一時的に発生させ、この一次電流が遮断するタイミングで二次コイル111から高電圧(数十kV)を出力させる。尚、自動車等の内燃機関では、其の制御回転数に応じて連続的に点火信号が与えられ、これに応じて点火コイルが連続的に駆動されることとなる。   A connector structure 136 (not shown) and an igniter 137 are disposed beside the coil assembly. Each coil of the coil assembly is appropriately connected to a connector terminal provided in the connector structure 136 or a terminal provided in the igniter 137. The connector terminal is provided with a power supply terminal, a signal terminal, a ground terminal, and the like. Among these, the power supply terminal is conducted to the primary coil 135, and the signal terminal relays the drive signal to the power transistor in the igniter. That is, in the electromagnetic circuit configured as described above, when an ignition signal (pulse) is applied to the signal terminal, a primary current is temporarily generated in the series circuit of the primary coil 135 and the power transistor, and the timing at which the primary current is cut off. Then, a high voltage (several tens of kV) is output from the secondary coil 111. In an internal combustion engine such as an automobile, an ignition signal is continuously given in accordance with the control rotational speed, and the ignition coil is continuously driven in accordance with this.

低圧部品組立工程が完了した中間製品は、その後、外周絶縁樹脂140を被覆させる被覆工程に投入される(図5参照)。外周絶縁樹脂140は、上述した低圧部品の全部または一部を覆うように金型で注型される。本実施の形態に係る外周絶縁樹脂140は、図示の如く、コネクタ構造体136の一部を覆うように積層被覆し、また、他の低圧部品の露出箇所が無いように積層被覆している。例えば、溶融物質混成樹脂114について見れば、その一部部位がターミナル中継体131に覆われ、他の部位が外周絶縁樹脂140によって被覆され、これにより、高圧部構造体120の外周の略全体に絶縁構造が形成される。但し、これは一つの実施形態に過ぎず、例えば、溶融物質混成樹脂114によって二次コイルの誘起電圧を確実に絶縁できるのであれば、当該樹脂114が外周絶縁樹脂140から露出するような構造を与えても良い。   The intermediate product for which the low-pressure component assembly process has been completed is then put into a coating process for coating the outer peripheral insulating resin 140 (see FIG. 5). The outer peripheral insulating resin 140 is cast with a mold so as to cover all or part of the low-pressure components described above. As shown in the figure, the outer peripheral insulating resin 140 according to the present embodiment is laminated and coated so as to cover a part of the connector structure 136, and is laminated so that no other low-pressure parts are exposed. For example, in the case of the molten material hybrid resin 114, a part of the molten material hybrid resin 114 is covered with the terminal relay body 131, and the other part is covered with the outer peripheral insulating resin 140. An insulating structure is formed. However, this is only one embodiment. For example, if the induced voltage of the secondary coil can be reliably insulated by the molten material mixed resin 114, a structure in which the resin 114 is exposed from the outer peripheral insulating resin 140 is used. May be given.

かかる外周絶縁樹脂140は、これが注型される際、超臨界流体を伴わずに形成されるものである。即ち、外周絶縁樹脂140に係る樹脂注型装置は、超臨界流体を外周絶縁樹脂140の溶体に混入させる機構は不要である。この樹脂注型装置は、射出成形装置であっても良く、トランスファーモールド成形装置であっても良い。但し、トランスファーモールド成形装置では、溶解した絶縁体を低圧で押圧注入させることが可能なので、低圧部品の配置を崩すことなく適切な配置でモールドさせることが容易となろう。   The outer peripheral insulating resin 140 is formed without a supercritical fluid when it is cast. That is, the resin casting apparatus according to the outer peripheral insulating resin 140 does not require a mechanism for mixing the supercritical fluid into the solution of the outer peripheral insulating resin 140. This resin casting apparatus may be an injection molding apparatus or a transfer mold molding apparatus. However, in the transfer mold forming apparatus, the melted insulator can be pressed and injected at a low pressure, so that it will be easy to mold with an appropriate arrangement without destroying the arrangement of the low-pressure components.

尚、溶融物質混成樹脂は、超臨界流体に係る含有量が数%程度に設定されるところ、これを含有させていない母材ポリマーに対する熱膨張率の差異は大きくないと考えられる。従って、溶融物質混成樹脂及び外周絶縁樹脂は、各々の母材ポリマー(主有機組成物)が同一であるのが熱応力回避の点で好ましい。例えば、PBT(Polybutylene Terephthalate)の溶融物質混成樹脂を用いる場合、外周絶縁樹脂もPBT(Polybutylene Terephthalate)として点火コイルの構造を形成するのが良い。また、PA(Polyamide)の溶融物質混成樹脂を用いる場合、外周絶縁樹脂もPA(Polyamide)として点火コイルの構造を形成するのが良い。   Note that, in the molten substance hybrid resin, the content of the supercritical fluid is set to about several percent, but it is considered that the difference in thermal expansion coefficient with respect to the base polymer not containing this is not large. Therefore, it is preferable in terms of avoiding thermal stress that the base material polymer (main organic composition) is the same in the molten substance hybrid resin and the outer peripheral insulating resin. For example, when a PBT (Polybutylene Terephthalate) molten substance hybrid resin is used, it is preferable that the outer peripheral insulating resin is also PBT (Polybutylene Terephthalate) to form the structure of the ignition coil. Moreover, when using the molten substance hybrid resin of PA (Polyamide), it is good to form the structure of an ignition coil also as outer periphery insulating resin as PA (Polyamide).

このように、本実施の形態に係る製造方法によれば、物性調整製法による絶縁構造(溶融物質混成樹脂114)と、物性調整製法を伴わない絶縁構造(外周絶縁樹脂140)と、の2種類の絶縁構造を点火コイルとして形成させる。従って、物性調整製法による絶縁構造(溶融物質混成樹脂114)は、点火コイル100の全体に対して一部の限られた領域に形成されることとなる。   As described above, according to the manufacturing method according to the present embodiment, two types of insulation structure (melted material hybrid resin 114) by the physical property adjustment manufacturing method and insulating structure (peripheral insulating resin 140) without the physical property adjustment manufacturing method are used. The insulating structure is formed as an ignition coil. Therefore, the insulating structure (molten substance hybrid resin 114) by the physical property adjustment manufacturing method is formed in a limited region with respect to the entire ignition coil 100.

かかる製造方法によると、物性調整製法による溶融物質混成樹脂114は、限定された構造領域に形成されるため、キャビティ圧を調整すべき加圧容積が格段に狭められる。このため、当該製法方式の樹脂注型装置は、加圧容積低下に伴いコンプレッサ等の要求出力が最小限に抑えられ、当該装置の大型化及び高コスト化から免れる。   According to such a manufacturing method, the molten substance hybrid resin 114 obtained by the physical property adjustment manufacturing method is formed in a limited structural region, and thus the pressurizing volume in which the cavity pressure is to be adjusted is remarkably reduced. For this reason, in the resin casting apparatus of the manufacturing method, the required output of the compressor or the like is suppressed to the minimum as the pressurization volume decreases, and the apparatus is freed from an increase in size and cost.

特に、本実施の形態に係る高圧部構造体120は、二次コイル111の周辺,及び,中継端子112及び高圧端子113の周辺に限定して溶融物質混成樹脂114が形成される。従って、超臨界式注型装置は、これによる注型容積が極力制限されるので、コンプレッサの要求出力を抑えることが可能となり、コンプレッサ周辺配管・バルブの耐圧構造等を引き下げることが可能となる。   In particular, the high-voltage part structure 120 according to the present embodiment is formed with the molten material hybrid resin 114 limited to the periphery of the secondary coil 111 and the periphery of the relay terminal 112 and the high-voltage terminal 113. Accordingly, the supercritical casting apparatus is limited in the casting volume as much as possible, so that the required output of the compressor can be suppressed, and the pressure-resistant structure of the compressor peripheral piping and valves can be lowered.

図6では、上述した樹脂形成工程が更に詳しく説明されている。尚、同図では、超臨界流体として二酸化炭素ガスが用いられることとし、溶融物質混成樹脂の母材としてPA(Polyamide/ポリアミド系樹脂)が用いられることとする。即ち、母材ポリマーとしてPA(Polyamide/ポリアミド系樹脂)が用いられ、これに超臨界流体としての二酸化炭素ガスが溶融されて溶融物質混成樹脂流体が生成される。本実施の形態にて二酸化炭素ガスが超臨界流体として利用されるのは、当該二酸化炭素ガスがキャビティ内の溶融物質混成流体との界面において流動性の向上に寄与するからである。   In FIG. 6, the above-described resin forming step is described in more detail. In the figure, carbon dioxide gas is used as the supercritical fluid, and PA (Polyamide / polyamide resin) is used as the base material of the molten material hybrid resin. That is, PA (Polyamide / polyamide resin) is used as a base material polymer, and carbon dioxide gas as a supercritical fluid is melted thereon to generate a molten material mixed resin fluid. The reason why carbon dioxide gas is used as a supercritical fluid in the present embodiment is that the carbon dioxide gas contributes to improvement of fluidity at the interface with the molten material mixed fluid in the cavity.

上述の如く、樹脂形成工程は、二次コイル周辺を溶融物質混成樹脂流体で含浸させる含浸工程と、圧力制御及び温度制御を行って溶融物質を発泡させずに溶融物質混成樹脂流体を固相化させる固相化工程と、から構成されている。このうち、図6に係る含浸工程は、二次コイル周辺圧力を樹脂投入前に予め設定させる予圧工程(図6(a)参照)と、予圧工程の後に溶融物質混成樹脂を二次コイルへ供給する樹脂供給工程(図6(b)参照)と、によって構成されることとなる。   As described above, the resin forming process includes the impregnation process in which the periphery of the secondary coil is impregnated with the molten material mixed resin fluid, and the molten material mixed resin fluid is solidified without foaming the molten material by performing pressure control and temperature control. And a solid phase forming step. Among these, the impregnation step according to FIG. 6 is a preload step (see FIG. 6A) in which the secondary coil peripheral pressure is set in advance before the resin is charged, and the molten material hybrid resin is supplied to the secondary coil after the preload step And a resin supplying step (see FIG. 6B).

予圧工程は、先ず、金型に形成されたキャビティC1の内部へ二次コイルがセットされ、この二次コイル及びキャビティ壁の間隙空間としてキャビティ空間が形成される。そして、かかる予圧工程は、樹脂供給させる前に、二酸化炭素をコンプレッサによって投入させることで、キャビティ圧(キャビティ空間の内圧)を上昇させ二次コイル周辺圧力(即ち、予圧)を適宜に設定しておく。これによれば、溶融物質混成樹脂流体が樹脂投入ゲートGを介してキャビティ内に放出された際(樹脂供給工程の際)、当該樹脂流体が十分な圧力の環境に晒されるので、キャビティ空間と樹脂流体との界面における急激な発泡が抑えられ、二次コイル周辺の絶縁構造が高品質に保たれる。同工程では、キャビティ内でカウンタプレッシャを形成させる為、樹脂投入ゲートGの対面側から二酸化炭素ガスQが加圧注入される。   In the preloading step, first, a secondary coil is set inside the cavity C1 formed in the mold, and a cavity space is formed as a gap space between the secondary coil and the cavity wall. In this preloading process, before supplying the resin, carbon dioxide is introduced by a compressor to increase the cavity pressure (internal pressure in the cavity space) and appropriately set the secondary coil peripheral pressure (ie, preload). deep. According to this, when the molten material mixed resin fluid is discharged into the cavity via the resin charging gate G (during the resin supply process), the resin fluid is exposed to an environment of sufficient pressure. Sudden foaming at the interface with the resin fluid is suppressed, and the insulation structure around the secondary coil is maintained in high quality. In this step, the carbon dioxide gas Q is pressurized and injected from the facing side of the resin charging gate G in order to form a counter pressure in the cavity.

このように、本実施の形態では、キャビティ圧が適宜に制御されるので、超臨界流体の気相化を回避させる圧力制御が維持されつつ、溶融物質混成樹脂流体をキャビティ空間へ投入させることが可能となる。このため、本実施の形態に係る内燃機関用点火コイルの製造方法は、二次コイルの樹脂含浸体について、ボイドを極力排除させた高品質な製品を提供することとなる。尚、本実施の形態では、カウンタプレッシャの状態から樹脂充填が有る程度進行すると、今度はキャビティ内に負圧を与えるようにしている。これによれば、キャビティ空間の樹脂充填されてない部分へ樹脂が行渡るよう促され、結果として、二次コイル周辺の絶縁構造が高品質に保たれる。かかる、負圧を与えるタイミングについては、金型温度、樹脂注入圧、キャビティ空間体積、キャビティ空間の断面積等の条件に応じて適宜決定されるものであり、予め実験を行うことで好ましいタイミングを特定しておくと良い。   Thus, in this embodiment, since the cavity pressure is appropriately controlled, the molten material mixed resin fluid can be introduced into the cavity space while maintaining the pressure control for avoiding the vaporization of the supercritical fluid. It becomes possible. For this reason, the method for manufacturing an ignition coil for an internal combustion engine according to the present embodiment provides a high-quality product in which voids are eliminated as much as possible for the resin-impregnated body of the secondary coil. In this embodiment, when the resin is filled from the counter pressure state to the extent that the resin is filled, a negative pressure is applied to the cavity. According to this, the resin is urged to flow to a portion of the cavity space that is not filled with resin, and as a result, the insulating structure around the secondary coil is maintained in high quality. The timing for applying the negative pressure is appropriately determined according to conditions such as the mold temperature, the resin injection pressure, the cavity space volume, and the cross-sectional area of the cavity space. It is good to specify.

また、樹脂供給工程の後に実施される固相化工程では、超臨界流体の気相化を回避させる圧力状態を維持させ、溶融物質混成樹脂流体を冷却させ固相化させると良い。これにより、冷却期間では、超臨界流体がボイドとなって析出する機会が失われるので、この工程に従って製作された樹脂含浸体は、ボイドのない高品質な製品となる。   Further, in the solid phase process performed after the resin supply process, it is preferable to maintain a pressure state that avoids the vaporization of the supercritical fluid, and to cool and solidify the molten material mixed resin fluid. Thereby, in the cooling period, the opportunity for the supercritical fluid to be deposited as voids is lost, so that the resin impregnated body manufactured according to this process becomes a high-quality product without voids.

また、この方法では、キャビティC1(メインキャビティ)に隣接するサブキャビティC2を用い、キャビティC1とこのサブキャビティC2とが樹脂排出ゲートJで連通されている装置を用いると良い。これによると、樹脂投入ゲートGのみから溶融物質混成樹脂流体がキャビティ空間へ射出される場合、これとは異なる位置に設けられた樹脂排出ゲートJが溶融物質混成樹脂流体の流動先となる。従って、樹脂供給工程では、樹脂投入ゲートGから樹脂排出ゲートJへ向けて溶融物質混成樹脂流体が流動し、樹脂排出ゲートJを介して、この樹脂流体がサブキャビティC2へと導かれることとなる。   Further, in this method, it is preferable to use an apparatus in which the subcavity C2 adjacent to the cavity C1 (main cavity) is used and the cavity C1 and the subcavity C2 are communicated with each other through the resin discharge gate J. According to this, when the molten substance mixed resin fluid is injected into the cavity space only from the resin charging gate G, the resin discharge gate J provided at a position different from this is the flow destination of the molten substance mixed resin fluid. Therefore, in the resin supply process, the molten material mixed resin fluid flows from the resin charging gate G to the resin discharging gate J, and the resin fluid is guided to the subcavity C2 through the resin discharging gate J. .

一般に、二次コイルの周辺構造によっては、溶融物質混成樹脂流体を投入したときの樹脂流速を局所的に上昇させる場合があるので、溶融物質混成樹脂流体が局所的且つ一時的に圧力降下を招いてしまうことがある。しかし、本実施の形態では、溶融物質混成樹脂流体の移動先にサブキャビティC2を設けているので、このサブキャビティC2に気泡化した溶融物質が集められることとなる。サブキャビティC2で形成される樹脂構造体は、高圧部構造体120から切落される端材であるところ、二次コイル周辺における絶縁構造の品質に影響を与えるものではない。このようにして、高圧部構造体120は、二次コイル周辺にボイド等を伴わない、高品質の絶縁構造が形成されることとなる(図6(c)参照)。   In general, depending on the peripheral structure of the secondary coil, the resin flow rate when the molten material mixed resin fluid is introduced may be locally increased, so that the molten material mixed resin fluid causes a local and temporary pressure drop. Sometimes. However, in the present embodiment, since the subcavity C2 is provided at the destination of the molten substance hybrid resin fluid, the bubbled molten substance is collected in the subcavity C2. The resin structure formed by the subcavity C2 is an end material cut off from the high-voltage part structure 120, but does not affect the quality of the insulating structure around the secondary coil. In this way, the high-voltage unit structure 120 is formed with a high-quality insulating structure without a void or the like around the secondary coil (see FIG. 6C).

更に、サブキャビティC2よりも先にメインキャビティC1の方が樹脂流体で満たされるから、当該キャビティC1(即ち、製品として使用される樹脂含浸体に相当する部位)は、気体の圧力変化の影響を受けるリスクが減る。このため、キャビティCでは、ボイドの無い樹脂含浸体が製作されるのである。   Further, since the main cavity C1 is filled with the resin fluid before the subcavity C2, the cavity C1 (that is, the portion corresponding to the resin impregnated body used as a product) is affected by the change in pressure of the gas. Reduced risk. For this reason, in the cavity C, a resin-impregnated body without voids is manufactured.

特に、かかる製造方法では、樹脂排出ゲートJを介して、キャビティ空間へ二酸化炭素ガスQを投入させると良い。これによると、ガス供給路を別途設けることなく、金型及びその周辺機器の構造が簡素化される。より好ましくは、サブキャビティの内部とコンプレッサ(二酸化炭素を供給するコンプレッサ)の吐出口とを連通させておけば、コンプレッサから二酸化炭素ガスを供給するだけで、容易に、当該二酸化炭素ガスをキャビティ空間へ与えることが可能となる。   In particular, in such a manufacturing method, the carbon dioxide gas Q is preferably introduced into the cavity space via the resin discharge gate J. According to this, the structure of the mold and its peripheral devices is simplified without providing a separate gas supply path. More preferably, if the inside of the sub-cavity and the discharge port of the compressor (the compressor supplying carbon dioxide) are communicated with each other, the carbon dioxide gas can be easily supplied to the cavity space simply by supplying carbon dioxide gas from the compressor. It becomes possible to give to.

また、サブキャビティC2は、其の内部容積を変更可能とさせるよう、容積調整機構が設けられていると良い。これによると、メインキャビティC1の条件が変わる場合、又は、二次コイルの寸法等が変化する場合でも、この条件変化に応じてキャビティ容積を変化させ、サブキャビティの内部容積を常に好ましい状態に設定することができる。   The subcavity C2 is preferably provided with a volume adjustment mechanism so that its internal volume can be changed. According to this, even when the condition of the main cavity C1 changes or when the size of the secondary coil changes, the cavity volume is changed according to this condition change, and the internal volume of the subcavity is always set to a preferable state. can do.

更に、上述したサブキャビティC2については、容積調整機構についての制御機能を併せ持たせても良い。キャビティ空間の圧力制御については、コンプレッサによる制御よりも、キャビティの内部容積(キャビティCとサブキャビティの総容積)を制御する方が、当該圧力制御の応答性が良い場合もある。かかる容積調整機構が設けられると、急激な圧力上昇を生じさせることも可能となるので、キャビティ内で生じた偶発的な圧力不足が即座に補われ、この偶発事象に起因する不良発生を回避できる。   Further, the above-described subcavity C2 may have a control function for the volume adjusting mechanism. Regarding the pressure control of the cavity space, there is a case where the pressure control response is better when the internal volume of the cavity (the total volume of the cavity C and the subcavity) is controlled than the control by the compressor. If such a volume adjustment mechanism is provided, it is possible to cause a sudden pressure increase, so that an accidental pressure shortage occurring in the cavity is immediately compensated, and the occurrence of defects due to this incidental event can be avoided. .

尚、溶融物質混成樹脂の母材ポリマー(主有機組成物)は、PBT(Polybutylene Terephthalate)又は変性PPE(Modified- Polyphenylen Eether)に置換えても良い。ここで、PBT(Polybutylene Terephthalate)について検討すると、化学組成構造から吸水性が低いことが明らかであり、PBT分子間の結合が強固とされる。一方、PA(Polyamide)にあっては、親水基(アミド基)を有するため吸水性が高い。即ち、双方を比較した場合、PA(Polyamide)の方が、ポリマーを構成する分子間距離が離れることになり、溶体樹脂投入時の流動性に優れた性質を示すことになる。特に、PA6及びPA66についてこの利点が顕著である。更に、PA(Polyamide)は、PBT(Polybutylene Terephthalate)よりも加水分解されにくいことからも、構造体として利用するに適していることが解る。   The matrix polymer (main organic composition) of the molten material hybrid resin may be replaced with PBT (Polybutylene Terephthalate) or modified PPE (Modified-Polyphenylen Eether). Here, when examining PBT (Polybutylene Terephthalate), it is clear from the chemical composition structure that water absorption is low, and the bond between PBT molecules is strengthened. On the other hand, PA (Polyamide) has high water absorption because it has a hydrophilic group (amide group). That is, when both are compared, PA (Polyamide) has a larger intermolecular distance that constitutes the polymer, and exhibits better fluidity when the solution resin is charged. In particular, this advantage is significant for PA6 and PA66. Furthermore, since PA (Polyamide) is less likely to be hydrolyzed than PBT (Polybutylene Terephthalate), it is understood that it is suitable for use as a structure.

100 内燃機関用点火コイル, 110 二次スプール, 111 二次コイル, 112 中継端子, 113 高圧端子, 114 溶融物質混成樹脂, 120 高圧部構造体, 122〜123 閉磁路鉄芯, 124 中心鉄芯, 125 一次コイル, 126 コネクタ構造体, 140 外周絶縁樹脂。   DESCRIPTION OF SYMBOLS 100 Ignition coil for internal combustion engines, 110 Secondary spool, 111 Secondary coil, 112 Relay terminal, 113 High voltage terminal, 114 Molten material hybrid resin, 120 High pressure part structure, 122-123 Closed magnetic circuit iron core, 124 Center iron core, 125 Primary coil, 126 Connector structure, 140 Perimeter insulation resin.

Claims (8)

キャビティ内に二次コイルがセットされたキャビティ空間へ予圧を与える予圧工程と、超臨界流体を溶融させた溶融物質混成流体を前記予圧工程の後に前記キャビティ空間へ投入する樹脂供給工程と、を実施させる内燃機関用点火コイルの製造方法において、
前記樹脂供給工程は、前記超臨界流体の気相化を回避する圧力制御を続けながら前記溶融物質混成樹脂流体を前記キャビティ空間へ投入し、
前記予圧工程は、気体の投入によって予圧を制御させ、
前記気体は、サブキャビティの内部へ投入されることで、樹脂排出ゲートを介して前記キャビティ空間へ投入されることを特徴とする内燃機関用点火コイルの製造方法。
A preloading step for applying a preload to the cavity space in which the secondary coil is set in the cavity, and a resin supplying step for introducing a molten material mixed fluid obtained by melting a supercritical fluid into the cavity space after the preloading step are performed. In the method of manufacturing an ignition coil for an internal combustion engine,
In the resin supply step, the molten material mixed resin fluid is introduced into the cavity space while continuing pressure control to avoid gasification of the supercritical fluid,
In the preloading step, the preload is controlled by introducing gas,
The method of manufacturing an ignition coil for an internal combustion engine, wherein the gas is introduced into the cavity space through a resin discharge gate by being introduced into the subcavity.
キャビティ内に二次コイルがセットされたキャビティ空間へ予圧を与える予圧工程と、超臨界流体を溶融させた溶融物質混成流体を前記予圧工程の後に前記キャビティ空間へ投入する樹脂供給工程と、を実施させる内燃機関用点火コイルの製造方法において、
前記樹脂供給工程は、前記超臨界流体の気相化を回避する圧力制御を続けながら前記溶融物質混成樹脂流体を前記キャビティ空間へ投入し、
前記キャビティは、樹脂投入ゲートと、当該樹脂投入ゲートとは異なる位置に設けられた樹脂排出ゲートと、当該樹脂排出ゲートを介して連通されるサブキャビティと、を備え、
前記樹脂供給工程では、前記樹脂投入ゲートから前記樹脂排出ゲートへ向けて前記溶融物質混成樹脂流体が流動し、当該溶融物質混成樹脂流体を前記サブキャビティへ導かせる、ことを特徴とする内燃機関用点火コイルの製造方法。
A preloading step for applying a preload to the cavity space in which the secondary coil is set in the cavity, and a resin supplying step for introducing a molten material mixed fluid obtained by melting a supercritical fluid into the cavity space after the preloading step are performed. In the method of manufacturing an ignition coil for an internal combustion engine,
In the resin supply step, the molten material mixed resin fluid is introduced into the cavity space while continuing pressure control to avoid gasification of the supercritical fluid,
The cavity includes a resin charging gate, a resin discharging gate provided at a position different from the resin charging gate, and a subcavity communicated with the resin discharging gate.
In the resin supply step, the molten material mixed resin fluid flows from the resin charging gate toward the resin discharge gate, and the molten material mixed resin fluid is guided to the subcavity. Manufacturing method of ignition coil.
前記樹脂供給工程が進行すると、前記キャビティの内部へ負圧が与えられることを特徴とする請求項1又は請求項2に記載の内燃機関用点火コイルの製造方法。3. The method of manufacturing an ignition coil for an internal combustion engine according to claim 1, wherein a negative pressure is applied to the inside of the cavity when the resin supply process proceeds. 前記サブキャビティは、内部容積が制御可能とされることを特徴とする請求項1乃至請求項3の何れか一項に記載の内燃機関用点火コイルの製造方法。   4. The method of manufacturing an ignition coil for an internal combustion engine according to claim 1, wherein an internal volume of the subcavity is controllable. 5. 前記予圧工程は、気体の投入によって予圧を制御させることを特徴とする請求項1乃至請求項4の何れか一項に記載の内燃機関用点火コイルの製造方法。   The method for manufacturing an ignition coil for an internal combustion engine according to any one of claims 1 to 4, wherein the preloading step controls the preloading by introducing gas. 前記予圧工程は、前記超臨界流体の主成分と同組成の気体を利用していることを特徴とする請求項1乃至請求項5の何れか一項に記載の内燃機関用点火コイルの製造方法。   The method for manufacturing an ignition coil for an internal combustion engine according to any one of claims 1 to 5, wherein the preloading step uses a gas having the same composition as a main component of the supercritical fluid. . 前記予圧工程は、前記気体を二酸化炭素としていることを特徴とする請求項6に記載の内燃機関用点火コイルの製造方法。   The method of manufacturing an ignition coil for an internal combustion engine according to claim 6, wherein the preloading step uses carbon dioxide as the gas. 前記樹脂供給工程の後、前記超臨界流体の気相化を回避する圧力制御を続けながら前記溶融物質混成樹脂流体を固相化させる固相化工程、を実施させることを特徴とする請求項1乃至請求項7の何れか一項に記載の内燃機関用点火コイルの製造方法。   The solid phase step of solidifying the molten material mixed resin fluid is performed after the resin supply step, while continuing pressure control to avoid gasification of the supercritical fluid. The manufacturing method of the ignition coil for internal combustion engines as described in any one of thru | or 7 thru | or 7.
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