JPS6210103B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing a wire-wound coreless armature.

Conventionally, wound type ironless armatures have been constructed by winding self-welding wires, temporarily fixing the self-welding wires to each other and between each segment, and shaping the coil into a predetermined shape such as a cup shape or a flat shape. After that, it is made into a rigid body with the shaft, commutator, etc. Making this integral steel body involves making the coil itself rigid after being shaped into a predetermined shape, and
It can be broadly divided into two types: making the commutator a rigid body, and a method in which the commutator is made rigid at the same time by resin molding is often used.

Generally, when making a wire-wound coreless coil into an integral rigid body, pressurized high-viscosity molding resin is filled into the mold by transfer molding or injection molding, but at this time, the injection pressure of the molding resin Due to the movement of the coil, it was common for the coil, which should be completely embedded in the molded resin, to be partially exposed on the armature surface even after molding. As a result, the coil parts exposed on the molded resin surface may be lifted off the armature surface due to centrifugal force or vibration caused by high-speed rotation when the armature is used, because the adhesive force between the coils is insufficient. Problems such as cracks occurring in the exposed coil portions occurred, and as a result, it became difficult to maintain the dimensional accuracy required for the armature and caused electrical failures.

The present invention has been made in view of the above-mentioned conventional drawbacks, and aims to provide a wire-wound coreless armature that prevents the coil from being exposed on the armature surface and has good dimensional stability. .

That is, a composite of a base material made of an organic or inorganic material or a prepreg thereof and a thermosetting resin that is solid or putty-like at room temperature is prepared. The present invention is characterized in that this composite body is arranged at least around the axis of the target ironless coil and molded with a mold.

Here, the composite refers to an inorganic or organic base material alone, or a prepreg made by impregnating them with a thermosetting resin to a semi-cured state, and a thermosetting resin that is solid at room temperature, or a thermosetting resin that is liquid at room temperature. It refers to a composite structure of a putty-like resin obtained by kneading an inorganic filler with a synthetic resin. This shape is generally plate-like,
Sandwich-shaped cross sections with a base material or prepreg on both surfaces and a solid or putty-like thermosetting resin on the inside, or those with a base material or prepreg on only one side, or those with a base material or prepreg on the inside. There is also a configuration in which However, in the case of a material having a somewhat sticky surface, such as a putty-like material, it is easier to handle the material in the form of a composite with a base material or prepreg disposed on the surface.

As the base material used here, glass cloth or nonwoven fabric is suitable for inorganic materials, and polyester cloth or nonwoven fabric for organic materials is suitable from the viewpoint of heat resistance. In addition, prepreg is made by impregnating the base material with a thermosetting resin to make it semi-cured, but it is possible to use the same resin as the thermosetting resin used together, which is solid at room temperature or in the form of a putty. , preferable in terms of characteristics.

The details will be explained below.

Figure 1 is a configuration diagram of a cup motor using a wire-wound ironless armature, Figure 2 is a diagram of a cup-shaped ironless coil shaped into a specified shape, and Figure 3 is a diagram of a flat type ironless coil shaped into a prescribed shape. This is a diagram. In these figures, 1 is a coreless coil, 1' is a single coil of coreless coil 1, 2 is a commutator, 3 is an armature shaft, and 4
is a bearing, 5 is a brush, 6 is a magnet, and 7 is a frame.

FIG. 4 is a sectional view of a cup-shaped coreless armature according to the present invention, in which 1 is a coreless coil, 2 is a commutator, 3 is an armature shaft, and 8 is a solid or putty-like at room temperature according to the present invention. The thermosetting resin cured product 8' is an organic or inorganic woven or nonwoven fabric base material composited with the thermosetting resin cured product.

In the above configuration, a manufacturing method thereof will be explained. First, a predetermined number of single coils 1' each made of a predetermined number of windings of a self-fusing wire having a fusing layer on the surface of the wire are laminated and arranged, and then shaped into a predetermined shape using a mold, and at the same time heated or solvent-coated. The fusion layer on the surface of the wire is melted and solidified to bond the wires together to obtain a coreless coil 1 having a predetermined shape.

Separately, a composite of an organic or inorganic base material or its prepreg body and a thermosetting resin that is solid or putty-like at room temperature is prepared.

The base material 8' is made of organic or inorganic material or a composite thereof, and is a woven or nonwoven fabric having a thickness of about 50 to 100 microns. If this is to be made into a prepreg body, it is preferable to use one of the same type as the thermosetting resin cured product 8 that will be composited later.

As a thermosetting resin that is solid or putty at room temperature, the melt viscosity is around the molding temperature of ironless coils.
It must be 2000 CPS or less, harden in a short time, and be able to be stored for a long time. Epoxy resins, unsaturated polyester resins, etc. are suitable from the viewpoint of mechanical strength after oxidation, adhesiveness, etc., and resins in which inorganic fillers are mixed with these resins are preferred from the viewpoint of curing shrinkage rate and ease of handling. In addition, when the melt viscosity of the coreless coil near the forming temperature is about 500 CPS or less, an additive is used to impart thixotropy to the resin used. Examples of inorganic fillers include fibrous materials such as glass fiber and stone wire, silica, talc,
There are grains of minerals and metal oxides such as red iron oxide and alumina, and desired characteristics can be obtained by using them alone or in combination. In particular, the combined use of a fibrous filler increases the strength of the coil end portion of the iron-core coil on the commutator side, which is advantageous for making the body rigid between the iron-core coil, the shaft, and the commutator.

On the other hand, the thermosetting resin used is composited with the base material or its prepreg, but if it has appropriate adhesiveness, it can be easily composited in advance. To adjust the tackiness, a lubricant-like granular filler such as talc may be used.

A coreless coil 1 that has been shaped into a predetermined shape is placed in a resin molding mold that has been set to a resin molding temperature in advance, and a composite of a thermosetting resin cured product 8 that is solid or putty-like at room temperature and a base material 8' or its prepreg body is formed. The body is installed around the shaft on the commutator side coil end of the coreless coil. Since the resin melts immediately, the mold is generally clamped and heated to harden within 30 seconds, although this varies depending on the curing characteristics of the resin.

As described above, in the resin molding of a coreless coil, the resin used is a composite of an organic or inorganic woven fabric or non-woven fabric base material, or a prepreg thereof, and a thermosetting resin that is solid at room temperature or in the form of putty. The present invention provides a method for manufacturing a wire-wound type iron-core armature, which is characterized in that the iron-core armature is placed on a iron-core coil and then resin-molded.

Examples thereof will be described below.

Example After 7 single coils each made of 49 turns of self-bonding polyurethane insulated wire having a wire diameter of 0.15φ and a butyral resin bonding layer were stacked and arranged, they were shaped into a predetermined shape using a mold and heated at the same time. The fusion layer on the surface of the wire is melted and solidified to bond the wires together and the inner diameter is 19.5.
It is a cup-shaped coreless coil with an outer diameter of 20.8φ and a height of 30.0mm. On the other hand, a commutator bonded to the shaft in advance was used to connect the terminals of the coreless coil. Separately,
A composite according to the present invention was prepared according to the following steps.

A glass nonwoven fabric having a glass density of 11.0±0.5 g/m ² was impregnated with a diallyl phthalate resin having the following composition and dried to obtain a prepreg body having a resin content of 85 to 87% by weight.

Diallyl phthalate prepolymer...95 parts by weight Diallyl phthalate monomer...5 t-butyl barbenzoate...2 Red red iron...5 However, the softening temperature of diallyl phthalate prepolymer is 80 to 110°C (manufactured by Osaka Soda, product) Dap A) A solid thermosetting resin that is sticky at room temperature and has the following formulation was obtained based on a diallyl phthalate prepolymer (Dap L manufactured by Osaka Soda Co., Ltd.) having a softening temperature of 20 to 55°C.

Diaryl phthalate prepolymer...100 parts t-butyl perbenzoate...3 parts Red iron 5 parts Zinc stearate 3 parts After preheating the hot press to 50 to 60°C,
The prepreg body obtained above was placed through the resin obtained above and hot pressed to form a composite body having a sandwich shape and a thickness of 5 mm. Although the internal resin of the composite adheres and softens, the prepreg on the surface has a high softening temperature, so a composite having a specified thickness can be easily obtained. The resulting complex is
It had an outer diameter of 18.0φ with a hole in the center for introducing the shaft, and was punched out at room temperature to a predetermined amount and shape.

A sandwich-like composite body with a predetermined amount and a predetermined shape as described above, and a coreless coil formed by connecting a commutator with a predetermined shape and bonded to the shaft in advance are heated at 150°C.
The resin was molded by placing the mold in a heated mold and clamping the mold. When the mold was opened for 3 minutes after clamping, a resin molded cup armature uniformly filled with resin was obtained. The base material according to the present invention is disposed around the shaft on the end of the commutator side coil, as shown in FIG. 4, for example, and makes a particularly large contribution to making the coreless coil and the shaft rigid.

On the other hand, the resin used to make the coreless coil into a rigid body has a low melt viscosity, so less pressure is required during molding, and as a result, the entire surface of the coreless coil can be completely covered.
Fill the spaces between the coils sufficiently. Moreover, it does not cause deformation of the coil.

When the thermal shock resistance of the cup-shaped armature obtained in this example was tested under the following conditions, no abnormalities were observed.

Cooling: Dry ice-methanol, -30°C Heating: Hot air circulation thermostat, +100°C Number of repetitions: 5 Armatures tested: 5 units Comparative example Coreless coil with the same winding specifications as the example was connected to a commutator that had been glued to the shaft in advance, placed in a mold heated to 150°C, and then the mold was clamped. Next, when transfer molding was performed using a low-pressure diallyl phthalate resin molding material, a portion of the coil of the resulting resin-molded cup armature was exposed, and deformation of the coil was observed. Thermal shock resistance was tested under the same conditions as in the example, but cracks occurred in all five armatures tested.

As is clear from the above description, according to the present invention, after the composite is placed on the armature coil, it is heated and press-molded in a mold, and the pressure during molding is small, and the coil It is possible to obtain a dimensionally stable, high-quality iron-core armature that is less likely to be deformed, eliminates partial exposure of the coil to the armature surface, and is dimensionally stable.

[Brief explanation of the drawing]

Figure 1 is a cross-sectional view of a cup motor using a wire-wound ironless armature, Figure 2 is a perspective view of a cup-type ironless coil shaped into a specified shape, and Figure 3 is a flat-type ironless coil shaped into a specified shape. FIG. 4 is a plan view of the cup-shaped coreless armature of the present invention after it has been shaped. 1... Coreless coil, 1'... Single coil, 2...
... Commutator, 3... Armature shaft, 8... Cured thermosetting resin, 8'... Base material.

Claims (1)

[Claims] 1 A predetermined amount of electric wire is wound to form a coil, the ends of this coil and a commutator are electrically connected to form an armature coil, and this coil, commutator, and shaft are integrally molded in a mold to form a rigid body. In the method of manufacturing a wire-wound coreless armature, which is made into an armature, a plate-shaped composite of a base material or prepreg body made of an inorganic or organic substance and a thermosetting resin that is solid at room temperature or in the form of putty is used. is installed on the armature coil at least around the shaft, and then heated and press-molded in a mold to form a hardened product, thereby making the coil, commutator and shaft integrally rigid. Method of manufacturing iron core armature.