CN1201243A - Resin-mold coil - Google Patents

Abstract

A resin molded coil, in which an insulating film and an aluminum foil are wound radially and coaxially to form a unit coil, and multiple unit coils are stacked axially at a certain interval, and the coiling start and end conductors of adjacent units are connected in series, and are integrally formed. Resin molding. The winding terminal conductor of the unit coil is folded vertically toward the winding direction at its outer diameter position, and then further folded towards its inner diameter, so that the winding terminal conductor formed extends diagonally relative to the axial direction, and then the unit is folded at the inner diameter position of the adjacent unit coil. The coil is folded in the winding direction to form the winding starting conductor of the adjacent unit coil.

Description

Resin mold coil

The present invention relates to a power transformer coil molded by insulating resin, in particular to a coil in which a thin conductor including aluminum foil is radially and coaxially wound through an insulating film.

FIG. 42 is a partial sectional view showing the construction of a conventional resin mold coil 1. As shown in FIG. The coil 2 is wound on a cylindrical reel 10, and the periphery of the reel 10 is integrally molded with an insulating resin.

Fig. 43 is a sectional view taken along line A1-A1 in Fig. 42, in which the resin molded coil 1 is composed of a plurality of unit coils 2 (2A, 2B, 2C, 2D, 2E). The unit coils are formed by placing and winding an insulating film around an aluminum foil in the radial direction, and adjacent coils 2 are connected in series through connecting wires 55 to form a single coil as a whole. The lead wire 3A is led out from the top unit coil 2A and connected to the upper terminal 4A partially protruding from the surface of the resin molded coil 1, and the lead wire 3B is similarly drawn out from the bottom unit coil 2E and connected to the lower terminal 4B.

FIG. 44 is an enlarged schematic cross-sectional view around the connection line 55 in FIG. 43 . FIG. 45 is an enlarged cross-sectional view of the unit coil 2 in FIG. 43 , including an insulating film 113 placed and wound on an aluminum foil 100 . The insulating film 113 is formed of, for example, a polyethylene naphthalate film. In FIG. 44 , in the winding operation of the aluminum foil sheet 100 of the unit coils 2B and 2C, the winding start conductor 52 is drawn out to the outer diameter side and the aluminum foil sheet 100 is wound on the reel 10 . After the winding operation of the aluminum foil sheets 100 of the unit coils 2B and 2C is completed, the winding termination conductor 51 is drawn out to the outer diameter side, and the winding start and termination conductors 52 and 51 are connected together by crimping terminals 53 to form a connection line 55 . Vertically adjacent unit coils 2 are connected together as shown in FIG. 44 . Due to the potential difference between the crimping terminal 53 and the unit coil 2C, an insulating gap is maintained between the crimping terminal 53 and the periphery of the unit coil 2C.

Fig. 46 is a side view showing the construction of lead wires in another different conventional resin molded coil. A copper plate 112 is soldered to the aluminum foil 100 and used as a lead. In FIG. 43, lead wires 3A and 3B are connected to the aluminum foil sheets of the top and bottom unit coils 2A and 2E, and copper plates 112 correspond to the lead wires 3A and 3B. The structure in Fig. 43 does not include a tap terminal, but if the tap is drawn from the middle of the unit coil, the structure in Fig. 46 is used.

Fig. 47 is a front view showing a different construction of a conventional resin mold coil. The unit coil (not shown) is covered with mold resin 9 . On the front surface of the molding resin 9 are provided upper and lower connection terminals 4A and 4B and a set of tap terminals 4C. The connection terminals 4A and 4B are connected to the unit coils in the resin molded coil 1 . A set of tap terminals 4C is connected to the middle of a coil (not shown) in the molding resin 9 . A terminal plate 11 connected to an external circuit is fixed to the upper connection terminal 4A by a terminal screw 7 .

Fig. 48 is a front view showing a transformer constructed of another different conventional resin molded coil. There are provided three resin molded coils 1 molded with resin, which are fixed in the core 41 and sandwiched between the upper and lower frames 40A and 40B. Embedded in the front surface of each resin molded coil 1 is a set of tap terminals 4C and a pair of vertical connection terminals 4A and 4B. Interphase lead wires 30 are connected to the connection terminals 4A and 4B and externally connect the three phases of the resin molded coil 1 . In addition, the shorting bar 13 externally short-circuits the tap terminals of the set of tap terminals 4C to determine the number of turns of the coil (not shown) in the resin.

FIG. 49 is a sectional view showing the construction of the resin molded coil 1 in FIG. 48 . The unit coils 2 stacked in multiple stages are covered with a molding resin 9 . The top unit coil 2 is connected to the top connection terminal 4A via the connection lead 3A, and the bottom unit coil 2 is connected to the bottom connection terminal 4B via the connection lead 3B. In addition, the intermediate portion between the intermediate coils 2 is connected to a set of tap terminals 4C through a tap lead C (dotted line).

Fig. 50 is a front view showing a transformer constituted by another different conventional resin molded coil. There are provided three resin molded coils 201 molded with resin, which are fixed in the core 204 and sandwiched between the upper and lower frames 204A and 204B. A high-voltage terminal 211 is provided on the front surface of each resin molded coil 201, and a low-voltage terminal 208 is provided on the back surface thereof.

Fig. 51 is a schematic cross-sectional view taken along line V-V in Fig. 50 . A resin mold coil 201 composed of high and low voltage coils 202 and 203 is wound on a core (not shown) on the right side of the figure. The high and low voltage coils 202 and 203 are respectively resin molded through the air gap 200 . Aluminum coil connection conductors 207 lead upward from each side of the low voltage coil 203 , each conductor being welded to an aluminum interphase connection conductor 209 .

FIG. 52 is a side view showing the joint between the terminal of the aluminum foil sheet 212 and the coil connection conductor 207 in the low voltage coil 203. As shown in FIG. The aluminum foil 212 and the coil connecting conductor 207 are connected together through the welding area 213 .

Fig. 53 is a side view showing a different construction of a conventional resin mold coil. The high and low voltage coils 202 and 203 wound on the core 204 are both resin molded and provided through a cylindrical air gap 223 . A touch-proof plate 226 made of metal foil is wound around the periphery of the low-voltage coil 203 and drawn out to be grounded through a ground lead 227 .

FIG. 54 is a development of the anti-touch plate 226 of FIG. 53 . A ground lead 227 is soldered to the end of the touch guard plate 226 . The anti-touch plate 226 is wound on the outer diameter side of the low voltage coil 203 to prevent the breakdown current of the high voltage coil 202 from flowing into the low voltage coil 203 if a dielectric breakdown occurs between the high and low voltage coils 202 and 203 . The breakdown current flows to the outside through the anti-touch plate 226 and the ground lead 227 , thereby protecting the low-voltage coil 203 .

Fig. 55 is a side view showing a different construction of a conventional resin mold coil. The high and low voltage coils 202 and 203 wound on the core 204 are both resin molded and provided through a cylindrical air gap 223 . A touch-proof plate 226 made of wire mesh is wound around the periphery of the low-voltage coil 203 and drawn out to be grounded through a ground lead 227 .

FIG. 56 shows the detailed structure of the anti-touch plate 226 in FIG. 55 . Fig. 56(a) is an expansion of the anti-touch plate 226 before winding, and Fig. 56(b) is a sectional view taken along line Y3-Y3 in Fig. 56(a). The metal foil 226E is folded to cover the upper and lower ends of the touch guard 226 and soldered to the touch guard 226 .

However, the conventional coil shown in FIG. 42 has a disadvantage that it takes a long time to connect the unit coils 2 together. In FIG. 44, the winding end and start conductors 51 and 52 of each adjacent pair of unit coils 2 must be connected together using crimp terminals 35, and thus this connection operation takes a long time. A first object of the present invention is to provide a resin molded coil having a small number of manufacturing steps.

Furthermore, the conventional coil shown in FIG. 45 appears to short between turns of the aluminum foil 100 . That is, if there are pinholes (small, barely visible through holes) in the insulating film 113, air insulation occurs between the turns of the aluminum foil 100, and a short circuit appears to occur between the turns through the pinholes. During quality control testing at the factory, these coils with short circuits between turns were detected and rejected as rejects. However, such substandard products are economically undesirable. A second object of the invention is to provide a coil which does not short-circuit between two turns.

Furthermore, in the conventional coil shown in FIG. 46, a copper plate 112 is soldered to the aluminum foil 100 and used as a lead wire. Therefore, it takes a lot of time and labor to solder the copper plates. A third object of the present invention is to integrally form the aluminum foil and lead wires to shorten the time required for the soldering operation.

Furthermore, in the conventional coil shown in FIG. 47, the terminal plate 11 is rotated. That is, when the terminal screw 7 is loosened, the terminal plate 11 rotates around the terminal screw 7 to prevent the terminal plate from contacting the external circuit. A fourth object of the present invention is to make the terminal plate non-rotating.

Furthermore, the conventional coil shown in FIG. 48 has the disadvantage that it requires relatively long interphase leads 30 when integrated into a three-phase transformer. In other words, the long interphase lead 30 has to be extended from the upper connection terminal 4A to the lower connection terminal 4B in another phase, so that the interphase lead 30 requires a large amount of material, and thus, the cost of the resin molded transformer becomes high. A fifth object of the present invention is to provide a coil which shortens the required length of lead wires between phases.

In addition, the conventional coil shown in FIG. 51 has a large number of welded parts, that is, in FIGS. lot of time. A sixth object of the present invention is to reduce welding operations and shorten manufacturing time.

In addition, the conventional coil shown in FIG. 53 requires considerable time to manufacture the anti-touch plate 226. In other words, it takes a lot of time to solder the ground lead 227 to the touch shield 226 . Also in the conventional coil shown in FIGS. 55 and 56, it takes a lot of time to solder the metal foil 226E to the upper and lower ends of the touch guard 226. A seventh object of the present invention is to provide a resin molded coil in which the manufacturing time of the anti-touch panel is shortened.

In order to achieve the first object, the present invention defined in claim 1 can provide a resin molded coil in which a plurality of unit coils are formed by placing an insulating film on an aluminum foil sheet and winding them radially and coaxially to form a unit coil. Stacked at certain intervals in the axial direction; the winding start conductors and winding end conductors of adjacent unit coils are electrically connected together, so that a plurality of unit coils are connected in series, and each unit coil is integrally resin molded, here , the winding terminal conductor of the unit coil is folded vertically relative to the winding direction on its outer diameter position, and then further folded towards its inner diameter, so as to extend diagonally relative to the axial direction, and then the unit is folded at the inner diameter position of the adjacent unit coil The coil is folded in the winding direction to form the winding start conductor of the adjacent unit coil. This structure eliminates the need to use crimp terminals to connect each adjacent pair of unit coils together, thus enabling continuous sheets of aluminum foil to form a single coil.

Furthermore, according to the invention defined in claim 2, the jumper conductor connects the winding end conductor of the unit coil to the winding start conductor of the adjacent unit coil, and the jumper insulator covering the jumper conductor includes a folded an insulating film, and the jumper conductor is sandwiched by the insulating film. Therefore, the insulating sheet sandwiching the jumper conductors can be integrally formed on both sides without unraveling during the winding operation.

Furthermore, according to the invention defined in claim 3, the thickness of the outer layer on the side where the tap leads are drawn out of the resin molded coil can be greater than that on the other side. This structure reduces the width of the coils in the direction in which the multiphase resin molded coils are arranged.

Furthermore, according to the invention defined in claim 4, a prepreg layer impregnated with a non-hardening epoxy resin may be provided in the inner diameter side of the coil, and the coil wound around the prepreg layer is thermally cured. Thus, after heat curing, the prepreg layer becomes similar in properties to glass fiber reinforced plastic (FRP), thus improving the mechanical strength of the coil.

Furthermore, according to the invention defined in claim 5, by laminating corrugated glass fibers on flat glass fibers, the glass fiber mat thus formed is wound between the prepreg layer and the coil, the glass fiber mat can be impregnated with molding resin. . This structure improves the impregnation effect of the resin on the inner diameter side of the coil, thereby reducing the number of defective products.

Furthermore, according to the invention defined in claim 6, it is possible to wind the glass fiber around the outer diameter of the coil and impregnate the glass fiber with the molding resin. Thus, after being impregnated with molding resin, the glass fibers become similar in properties to glass fiber reinforced plastic (FRP), thus increasing the mechanical force of the coil.

Furthermore, according to the invention defined in claim 7, the resin mold can be expanded toward its outer diameter on the side opposite to the side from which the lead wires are drawn, so that the bridge between the unit coils is located at the expanded position of the resin mold. This structure reduces the width of the coil in the direction in which the multiphase resin mold coils are arranged.

In order to achieve the second object, according to the invention defined in claim 8, the aluminum film forming the coil can be wound through a multilayer insulating film. Therefore, even if there are pinholes in the insulating film, the pinholes can be prevented from overlapping each other at the same position when the film is wound, thus reducing the possibility of short circuit between turns.

In order to achieve the third object, according to the invention defined in claim 9, cutting lines can be formed in the aluminum foil sheet at equal intervals in its longitudinal direction from the ends of the foil conductors forming the coil, thereby forming a plurality of cut end strips ; First cut the outermost cutting end at its root; fold the cutting end adjacent to the outermost cutting end vertically at its root to the length direction of the aluminum foil, and then fold the remaining adjacent cutting ends vertically at its root to The length direction of the aluminum foil sheet; the folded cut ends are laminated in the thickness direction to form the leads from the coil. In the prior art, it is necessary to solder the leads to the aluminum foil. This structure enables the formation of unit coils and leads using only aluminum foil.

Furthermore, according to the invention defined in claim 10, an insulating film having a hole is folded at the position of the hole, the root of the lead wire drawn out of the coil is covered with a lead wire insulator including this insulating film, and the lead wire is inserted into the hole of the lead wire insulator middle. Therefore, it is possible to integrally form two insulating sheets sandwiching the jumper conductors at the sides without the insulating sheets being unraveled during the winding operation.

Furthermore, according to the invention defined in claim 11, the L-shaped glass fiber pillow formed by folding the glass fiber can be in contact with the position where the lead wire is drawn from the outer diameter side edge of the unit coil. This structure can maintain a sufficiently large insulation distance between the lead wire and the coil.

In order to achieve the fourth object, the present invention defined in claim 12 provides a resin molded coil, wherein the entire coil is molded with an insulating resin; a pair of vertical connection terminals are embedded in the outer surface of the molded insulating resin , the two ends of the coil are connected to the connection terminals, and the terminal plate connected to the external circuit is fixed to the upper connection terminal. Here, the positioning screw penetrates the terminal plate, and the top end of the positioning screw is inserted into the positioning hole provided on the surface of the molded resin. Among them, this structure enables the set screw to act as a detent.

Furthermore, according to the invention defined in claims 12, 13, it is possible to fix the set screw in the threaded hole formed in the terminal plate, and the tip of the set screw is inserted into the set hole.

In addition, according to the invention defined in claims 12 and 14, it is possible to embed the embedded attachment with the positioning hole formed thereon in the surface of the molding resin, process the positioning hole into a threaded hole, and the positioning screw can pass through the terminal connection. A through hole formed in the plate is screwed into said positioning hole of the embedded attachment.

In order to achieve the fifth object, the present invention according to claim 15 provides a resin molded coil, wherein the entire coil is molded with an insulating resin; a plurality of tap terminals and a pair of vertical connection terminals are embedded in the molded On the outer surface of the resin, connecting terminals are connected to each end of the coil through connecting leads, and the plurality of tap terminals are connected to the middle of the coil through tap leads, wherein the pair of connecting terminals is arranged above the group of tap terminals. This structure shortens the interval between the upper and lower connection terminals, thereby shortening the required length of the interphase leads.

Furthermore, according to the invention defined in claim 16, the rising portion of the connection lead connecting the lower connection terminal and the coil end together may be made of a cylindrical copper material. Copper connection leads can increase the current density and reduce the required thickness of the connection leads. In addition, the connection leads are cylindrical rather than aluminum foil sheets as in the prior art, which keeps the connection leads secure during resin pouring, thus allowing the resin to harden after molding and the connection leads to maintain their exact position.

In order to achieve the sixth object, the present invention as defined in claim 17 can provide a resin molded coil including sheet coils each formed by placing an insulating film on an aluminum foil sheet and winding them coaxially in a radial direction. formed; the coil connection conductors are respectively connected to the winding terminal end and the initial end of the aluminum foil sheet, and are drawn out in the axial direction of the sheet coil; the interphase connection conductors electrically connect a plurality of sheet coils together through the coil connection conductors. The chip coil is integrally molded by mold resin, wherein the coil connecting conductor and the interphase connecting conductor are both copper conductors; the aluminum foil and the coil connecting conductor are pressure-welded together at room temperature; the coil connecting The conductors are bolted together with the phase-to-phase connection conductors. This structure eliminates the need to weld together aluminum foil sheets, coil connection conductors, and phase-to-phase connection conductors, thereby reducing the time required for fabrication. Generally, when an aluminum coil connection conductor is bonded to an aluminum foil at room temperature, the bonded portion is damaged. However, the present inventors have found that a bond between the ductile copper coil connection conductor and the aluminum foil prevents breakage of the bonded portion. Furthermore, since the interphase connecting conductors are made of copper instead of aluminum foil as in the prior art, the electrical conductivity is increased. The copper interphase connection conductor prevents the screw connection between the coil connection conductor and the interphase connection conductor from increasing the contact resistance.

In addition, according to the invention defined in claim 18, the coil connection conductors can be respectively placed at the winding terminal end and the starting end of the aluminum foil; The cube has a raised portion that can be bonded at room temperature.

In addition, according to the invention defined in claim 19, a plurality of protruding portions may be provided on the block; in order to carry out multiple bonding at room temperature, the bonding portion in the overlapping member is formed with the axis of the sheet coil Move in sequence.

Furthermore, according to the present invention defined in claim 20, polyethylene naphthalate coated with a non-hardening heat-resistant epoxy resin ( PET-EPP) film. Therefore, after heating, the epoxy resin coated on the PET-EPP hardens, increasing the mechanical strength of the chip coil.

In addition, according to the invention defined in claim 21, a cooling path including a cylindrical air gap is provided in the sheet coil; it is possible to form the innermost layer and The outermost layer and resin channels where the inner diameter wall and the outer diameter wall of the cooling path are in contact; mold resin is filled between the resin channels except for the cooling path portion. Therefore, the molding resin can be cured at the edge of the chip coil without leakage.

According to the present invention defined in claim 22, a polyethylene naphthalate (PET-EPP) film coated with a non-hardening heat-resistant epoxy resin is wound in the innermost layer of the sheet coil; PET-EPP is used in the insulating sheet of the sheet-shaped coil; a heat-shrinkable tape (EPP-TG) coated with a non-hardening heat-resistant epoxy resin is wound on the outermost layer of the sheet-shaped coil. Therefore, after heating, the epoxy resin coated on the PET-EPP and PEN-TG hardens, increasing the mechanical strength of the chip coil. While heating, PEN-TG thermally shrinks, making the sheet coil tighten toward its inner diameter side, thereby making the molded transformer coil stronger.

Furthermore, the present invention according to claim 23 provides a resin molded coil in which a coil piece and an insulating sheet each including an aluminum foil sheet are put together and coaxially wound; The start and end terminals are pressure-welded to the connection conductors including the copper plate, and the entire device is resin-molded to lead the connection conductors to the outside. Here, the coil pieces are pressure-welded to the connection conductors together with the overlapping sheets including the aluminum foil. This structure can correctly connect the coil pieces, overlapping pieces and connection conductors together. Even if the thickness of the coil sheet is 0.2 mm or less, proper connection can be achieved by setting the total thickness of aluminum (the total thickness of the coil sheet and the overlapping sheet) to at least 0.2 mm.

In this construction, the coil sheet consists of two sheets of aluminum foil that are placed on top of each other and wound, one of which is used as an overlapping sheet. This structure can form a coil in which a plurality of thin coil pieces each having a thickness of 0.2 mm or less are wound together, and the coil pieces are soft and easy to wind, thereby shortening the time required for winding.

In order to achieve the seventh object, the present invention as defined in claim 25 provides a resin molded coil, wherein the high and low voltage coils wound around the core are molded with an insulating resin and configured through a cylindrical air gap; comprising The anti-touch plate of the metal foil is wound around the periphery of the low-voltage coil; a grounding lead is provided and drawn out to the outside, here, the end of the metal foil is cut into a Γ-shaped strip in the winding direction, and It is vertically folded to the winding direction, and then overlapped and folded twice in such a way that the width is reduced to one-third of the original width, and the overlapped and folded strip is covered with a heat shrinkable tube to form a ground lead. This structure enables the ground lead to be formed by simply folding the metal foil and does not require soldering to the touch shield, greatly reducing the time required to manufacture the touch shield.

Furthermore, the present invention defined in claim 26 provides a resin molded coil in which the high and low voltage coils wound around the core are molded with an insulating resin and configured through a cylindrical air gap; The touch plate is wound around the periphery of the low-voltage coil, and the feature is that the insulating film is folded so that the upper and lower ends of the touch-proof plate are curled and wound together with the touch-proof plate. This structure does not need to be soldered to the anti-touch plate, which greatly reduces the time required to manufacture the anti-touch plate.

1 is a schematic perspective view showing the structure of a resin molded coil according to an embodiment of the present invention in claim 1.

Fig. 2 is a sectional view taken along line A-A in Fig. 1 .

FIG. 3 is an expanded view of the bridge portion in FIG. 2 .

4 is a schematic sectional view showing the structure of a resin molded coil according to an embodiment of the present invention in claim 2.

FIG. 5 is an expanded view of the bridge portion in FIG. 4 .

Fig. 6 is a plan view showing a bridging portion of a resin molded coil portion according to an embodiment of the present invention in claims 3-6.

Fig. 7 is a sectional view taken along line B-B in Fig. 6 .

FIG. 8 is a perspective view showing the structure of the glass fiber mat in FIG. 6. FIG.

9 is a schematic sectional view of a resin molded coil according to an embodiment of the present invention in claim 7.

FIG. 10 is a top view of FIG. 9 .

11 is an enlarged schematic sectional view of a resin molded coil according to an embodiment of the present invention in claim 8 .

FIG. 12 is a side view illustrating a process of forming a lead wire in a resin molded coil according to an embodiment of the present invention in claim 9. FIG.

13 is an enlarged schematic sectional view of a resin molded coil according to an embodiment of the present invention in claim 10 .

14 is an enlarged schematic cross-sectional view of a resin molded coil according to another different embodiment of the present invention in claim 10 .

FIG. 15 shows the process of manufacturing the lead insulator 106 of FIG. 13 or 14 from the insulating sheet 107. Referring to FIG.

FIG. 16 is a side view showing insertion of the lead 104 into the hole 108 of the lead insulator 106 of FIG. 15 .

Fig. 17 is a perspective view showing the detailed structure of the glass fiber pillow 105 used in Fig. 13 or 14 according to the embodiment of the present invention in claim 11.

FIG. 18 is a front view showing the structure of a resin molded coil according to an embodiment of the present invention in claim 13. FIG.

FIG. 19 is a front view showing a structure in which a terminal plate 11 is provided in the structure of FIG. 18 .

Fig. 20 is a sectional view taken along line X1-X1 in Fig. 19 .

FIG. 21 is a front view showing the structure of a resin molded coil according to an embodiment of the present invention in claim 14. FIG.

FIG. 22 is a front view showing the structure in which the terminal plate 11 is provided in the structure of FIG. 21. Referring to FIG.

Fig. 23 is a sectional view taken along line Y1-Y1 in Fig. 22 .

Fig. 24 is a front view showing a transformer composed of a resin molded coil according to an embodiment of the present invention in claim 15.

FIG. 25 is a sectional view showing the structure of the resin molded coil 1 in FIG. 24. Referring to FIG.

Fig. 26 is a perspective view showing a pressure welding device for cold pressure welding the aluminum foil and the coil connecting conductor according to the embodiment of the present invention in claims 17 and 18.

FIG. 27 is a top view of FIG. 26 .

Fig. 28 shows a structure in which interphase connecting conductors are connected to resin molded coils. Fig. 28(a) is a front view, and Fig. 28(b) is a side view.

Fig. 29 shows a pressure welding device for cold pressure welding the aluminum foil and the coil connection conductor according to the embodiment of the present invention in claim 19. Fig. 29(a) is a front view, and Fig. 29(b) is a side view.

Fig. 30 is a plan view showing the structure of a resin molded coil according to an embodiment of the present invention in claim 20.

Fig. 31 is a sectional view taken along line X2-X2 in Fig. 30 .

Fig. 32 is a plan view showing the structure of a resin molded coil according to an embodiment of the present invention in claims 21 and 22.

Fig. 33 is a sectional view taken along line Y2-Y2 in Fig. 32 .

Fig. 34 is a sectional view taken along line Z3-Z3 in Fig. 33 .

Fig. 35 is a side sectional view showing a structure of a resin molded coil according to a reference example of the present invention in claim 23.

Fig. 36 is an expanded schematic view of the resin molded coil in Fig. 35 .

FIG. 37 is an enlarged cross-sectional view showing the periphery of the cold-compression welding portion in FIG. 36. FIG.

Fig. 38 is an enlarged sectional view showing the periphery of the cold-compression welding portion of the resin molded coil of the embodiment in claim 23.

FIG. 39 shows the same part of FIG. 38 viewed from the direction indicated by arrow C. FIG.

Fig. 40 is an expanded view illustrating a method of molding the anti-touch panel according to an embodiment of the present invention in claim 25.

FIG. 41 shows a detailed structure of a touch-proof plate according to an embodiment of the present invention in claim 26. FIG. Fig. 41(a) is an expanded view before winding. Fig. 41(b) is a sectional view taken along line X3-X3 in Fig. 41(a).

Fig. 42 is a partial sectional view showing the structure of a conventional resin mold coil.

Fig. 43 is a sectional view taken along line A1-A1 in Fig. 42 .

FIG. 44 is an enlarged schematic cross-sectional view showing the vicinity of the connection line in FIG. 43. FIG.

Fig. 45 is an enlarged sectional view of the unit coil in Fig. 43 .

Fig. 46 is a side view showing another different lead wire lead-out structure of the conventional resin molded coil.

Fig. 47 is a front view showing another structure of a conventional resin molded coil.

Fig. 48 is a front view showing another structure of a conventional resin molded coil.

FIG. 49 is a sectional view showing the structure of the resin molded coil 1 in FIG. 48. FIG.

Fig. 50 is a front view of a transformer composed of another different conventional resin molded coil.

Fig. 51 is a schematic cross-sectional view taken along line V-V in Fig. 50 .

Fig. 52 is a side view showing the joint between the aluminum foil end of the low voltage coil in Fig. 51 and the coil connection conductor.

Fig. 53 is a side view showing another structure of a conventional resin molded coil.

Fig. 54 is an expanded view of the anti-touch plate in Fig. 53 .

Fig. 55 is a side view showing another structure of a conventional resin molded coil.

Fig. 56 shows the detailed structure of the anti-touch plate in Fig. 55. Fig. 56(a) is an expanded view before winding. Fig. 56(b) is a sectional view taken along line Y3-Y3 in Fig. 56(a).

It will be described below based on an embodiment of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1 is a schematic perspective view showing the structure of a resin molded coil according to an embodiment of the invention of claim 1. Fig. 2 is a sectional view taken along line A-A in Fig. 1 . Jumper conductors 62 replace the connecting wires 55 in FIGS. 43 and 44 , and they are arranged at the same positions as the connecting wires 55 . The other structures in Figs. 1 and 2 are the same as those of the conventional device, so similar elements with the same reference numerals and their detailed descriptions are omitted.

In FIGS. 1 and 2, the unit coil 2B has a vertically folded winding terminal conductor 61 extending downward in a diagonal direction from outside to inside, like a jumper conductor 62, introduced on the reel 10, where it It is vertically folded again to form the winding start conductor 63 of the unit coil 2C. The unit coil 2C is introduced into the unit coil 2D by a jumper conductor in the same manner. At the same time, the aluminum foil can continue to be wound with the coil. In FIG. 1, the reel and the molded insulating resin are omitted. The molding resin is also omitted in FIG. 2 .

FIG. 3 is an extension of the bridging portion 62 in FIG. 2 . An insulating sheet 65 is provided along the bridging portion 62 . The insulating sheet 65 and another insulating sheet 64 sandwich the jumper portion 62 shown in FIG. 2 to prevent the jumper portion 62 from coming into contact with the unit coils 2B and 2C. The construction shown in Figures 1 to 3 eliminates the disadvantage of the conventional coil of Figure 37 that it takes considerable time to connect the unit coils together.

4 and 5 are schematic cross-sectional views showing the structure of a resin molded coil according to an embodiment of the present invention as claimed in claim 2. Figures 4 and 5 are cross-sectional views taken along line A-A in Figure 1, but slightly different from Figures 2 and 3. In other words, the insulating sheet 164 covering both sides of the bridging portion 62 is folded at the folded portion 165 . Other structures in FIGS. 4 and 5 are the same as those in FIGS. 2 and 3 . The insulating sheets 164 on both sides of the bridging portion 62 are integrally formed so as not to unravel during winding. This facilitates operation and reduces operator fatigue, thereby improving work efficiency.

Fig. 6 is a plan view showing a part of a bridging region of a resin molded coil according to an embodiment of the present invention according to claims 3 to 6. Fig. 7 is a sectional view taken along line B-B in Fig. 6 . FIG. 8 is a perspective view showing the structure of the glass fiber mat in FIG. 6. FIG.

6 and 7, a prepreg layer 23 impregnated with an uncured epoxy resin, a glass fiber mat 22, a unit coil 2, a glass fiber 21, and a molding resin 9 are formed on the periphery in order from the inner diameter side of the coil. The lead wire 3A is pulled out from the unit coil 2 and connected to the connection terminal 4A, which is connected to an external circuit (not shown), as shown in FIG. 6 .

In FIG. 8, the glass fiber mat 22 is constituted by flat glass fibers 22A on which corrugated glass fibers 22B are laminated. Due to the entanglement of the yarns in the fibers, the glass fibers 22A and 22B will not separate unless they are cut with a cutter. Since there are gaps between the flat glass fibers 22A and the corrugated glass fibers 22B, they are well impregnated with molding resin.

Referring back to FIG. 7 , the prepreg layer 23 is wound around the left spool (not shown) and the fiberglass mat 22 is wound around the outer diameter of the prepreg layer 23 . The element coil 2 is wound around the outer diameter of the glass fiber mat 22 and the glass fiber 21 is wound around the outer diameter of the element coil 2 . After removing the spool, the layers on the inner diameter side of the fiberglass mat 21 are housed in a mold and impregnated entirely with epoxy resin to form the mold resin 9, followed by heating the layers. Therefore, the glass fiber 21, the glass fiber mat 22, and the prepreg layer 23 all change to characteristics similar to FRP in order to increase the mechanical force of the coil. Conventional technology has no glass fibers inside the molding resin 9, as shown in Fig. 43, thus limiting the mechanical force in the coil. The structure in Fig. 7 increases the mechanical force of the coil, thus improving its short-circuit capability and improving the reliability of the transformer.

Furthermore, in the prior art, the unit coil 2 is wound using an insulating cylinder as the reel 10, and as shown in FIG. 43, the reel 10 functions as an insulator of the coil. As a result, when the mold resin 9 is impregnated with the epoxy resin, the epoxy resin is prevented from advancing between the unit coil 2 and the bobbin 10, thus increasing the chance of defective products. Since the fiberglass mat 22 is well impregnated with epoxy resin, as described above, the chance of rejecting the product is greatly reduced, ie almost to zero.

In FIG. 6, the thickness XX of the mold resin 9 on the side where the leads 3A are drawn out is larger than the thickness YY on the other side. The thickness XX is required to extend the leads 3A in the mold resin 9 , but the leads 3A are not drawn out on the other side of the mold resin 9 . Although not shown in the figure, a coil tap lead is drawn from the portion of thickness XX. Therefore, the vertical width of the coil in FIG. 6 is reduced. This configuration allows for vertical alignment of the polyphase coils and also allows for the provision of vertically long yokes of the core. Therefore, the reduction in thickness YY reduces the size of the core window and thus the size of the overall transformer.

9 is a schematic sectional view of a resin molded coil according to an embodiment of the present invention according to claim 7. FIG. 10 is a top view of FIG. 9 . In FIG. 9 , a lead wire 3A and a lead wire 3C are drawn out from the left side of the unit coil 2 . On the other hand, the unit coils 2 are connected together by the jumper conductor 62 on the right side of the coil 2 . The connecting lead leads to the external circuit, while the tap lead switches the number of turns in the coil. The lead wire 3A is an example of a connection lead drawn from the end of the unit coil 2 to the connection terminal 4A, and the lead wire 3C is an example of a tap lead drawn from the middle of the unit coil 2 to the connection terminal 4C. In FIG. 10, the thickness X of the lead wire drawn from the outside of the unit coil 2 is larger than the thickness Y of the resin mold 9 in the direction perpendicular to the thickness X. The protrusions of the resin mold 9 on the lead side are similar to those shown in FIG. 6 . On the other hand, the thickness Z of the resin mold 9 on the bridge side of the unit coil 2 is also larger than the thickness Y in the direction perpendicular to the thickness Z. This structure reduces the width of the coils in the direction in which the multiphase coils are arranged (the vertical direction in FIG. 10 ), thereby reducing the size of the core window and the size of the entire transformer.

11 is an enlarged schematic sectional view of a resin molded coil according to an embodiment of the present invention according to claim 8 . The aluminum foil 100 is wound with two insulating films 113 to form the unit coil 2 . Other structures are the same as the conventional structure in FIG. 45 .

In FIG. 11, even if there are pinholes in the insulating film 113, when the insulating film 113 is wound, these pinholes are prevented from overlapping each other at the same position, reducing the possibility that the unit coil 2 is short-circuited between turns. Thus, the probability of substandard products is reduced to close to zero. Although in Fig. 11, the aluminum foil 100 is wound through two layers of insulating films 113, if the aluminum foil 100 is wound through more than two layers of insulating films 113 (usually there are multiple layers of insulating films 113), it can further prevent inter-turn short circuit.

FIG. 12 is a side view showing a process of forming a lead wire of a resin molded coil according to an embodiment of the present invention of claim 9. FIG. Leads are formed in the order of (a) to (e) in FIG. 12 . In FIG. 12( a ), cut lines 101 are formed at equal intervals from right to left in an aluminum foil sheet 100 forming a unit coil. This step forms four cut end strips 102A, 102B, 102C, 102D of equal width. In the next step shown in FIG. 12( b ), the outermost (bottom in the figure) cut end 102A is cut at its root 103 . In the next step shown in FIG. 12( c ), the cut end 102B adjacent to the cut end 102A is vertically folded at its root to the longitudinal direction of the aluminum foil sheet 100 (transverse direction in the figure). In the next step shown in Figure 12(d), the cut end 102C is folded down in the figure at its root. In this case, the folded cut ends 102B and 102C are stacked on each other in the thickness direction. In the next step shown in Figure 12(e), the cut end 102D is folded down in the figure at its root and placed over the cut end 102C. The cut ends 102B, 102C, and 102D are put together to form a lead wire 104, which is connected to the connection terminal 4A or 4C (FIG. 9). In the conventional device shown in Fig. 46, a copper plate 112 is soldered to an aluminum foil 100 and used as a lead. Therefore, it takes considerable time and labor to solder the copper plate 112 . In the case of FIG. 12 , the unit coil and the lead wire 104 can be integrally formed using only the aluminum foil sheet 100 . Thus, the time required to manufacture the leads is reduced, improper soldering is prevented, and reliability is fundamentally improved.

13 is an enlarged schematic sectional view of a resin molded coil according to an embodiment of the present invention according to claim 10 . This figure shows the structure of the part where the tap lead 104 is drawn out from the unit coil. The coil axis is located on the right side of the figure, and molding resin (not shown) is filled around the unit coil 2 . The lead wire 104 has the same structure as that shown in FIG. L-shaped glass fiber pillows 105 are inserted above and below the lead insulator 106 so that each pillow is in contact with the outer diameter side edge of the unit coil 2 . The lead wire insulator 106 insulates the lead wire 104 from the aluminum foil of the unit coil 2 , and the glass fiber pillow 105 allows a sufficiently long insulating distance between the lead wire 104 and the unit coil 2 to be reliably maintained.

14 is an enlarged schematic sectional view of a resin molded coil according to an embodiment of the present invention as claimed in claim 10 . A tap or a connection lead 104 is drawn from the inner diameter side of the unit coil 2 and connected to an external circuit. Other structures are the same as in Fig. 13 . Thus, fiberglass pillow 105 and lead insulator 106 serve the same function. FIG. 15 shows a process of manufacturing lead insulator 106 from insulating sheet 107 in FIG. 13 or 14 . 15(a) is a plan view showing cutting an insulating sheet 107 for a lead insulator 106, where the insulating sheet 107 (for example polyimide paper) is rectangular with a rectangular hole 108 in the center. Fold 109 at the position indicated by the dotted line in such a way that the hole 108 is bisected. FIG. 15( b ) is a perspective view showing the shape of the lead insulator 106 obtained by folding the insulating sheet 107 at the folding position 109 . The leads are clamped in the insulating sheet 107 and passed through the holes 108 .

FIG. 16 is a side view showing insertion of the lead wire 104 into the hole 108 of the lead wire insulator 106 shown in FIG. 15(b). The hole 108 of the lead wire insulator 106 is provided on the side of the lead wire 104 opposite to the unit coil 2 . Thus, the insulating pieces on both sides of the lead 104 are integrally formed, preventing the lead insulator 106 from unraveling during the winding operation.

FIG. 17 is a perspective view showing the detailed structure of the glass fiber pillow 105 used in FIG. 13 or 14 according to the embodiment of the present invention of claim 11. Referring to FIG. The ribbon-shaped glass fiber 111 is folded at two folding positions 111A in such a way that the folded parts of the glass fiber face each other and the both ends 111B of the fiber abut each other. Then, the fibers are vertically folded at folding positions 111C and 111D, vertically forming an L-shaped fiberglass pillow 105 as shown in FIG. 17 . The glass fiber pillow 105 is a laminate of four glass fibers 111, and can maintain a sufficiently large insulating distance between the lead wire and the unit coil.

18 and 19 are front views showing the structure of a resin molded coil according to an embodiment of the present invention according to claims 12 to 14. Figure 18 shows the case where the terminal plate is omitted, and Figure 19 shows the case with the terminal plate. There is a positioning hole 12 above the connection terminal 4A, and the positioning screw 8 is inserted into the positioning hole 12 .

Fig. 20 is a sectional view taken along line X1-X1 in Fig. 19 . A threaded hole 14 is formed in the connection terminal 4A, allowing a terminal screw to pass through the terminal plate 11 and be fixed in the threaded hole 14, so that the terminal plate 11 is fixed. Positioning holes 12 are provided in the surface of the mold resin 9 above the connection terminals 4A. The threaded hole 15 penetrates the terminal plate 11 , the set screw 8 is a countersunk screw, and the screw shaft is screwed into the threaded hole 15 , thereby penetrating the terminal plate 11 . The top of the positioning screw 8 can be inserted into the positioning hole 12 , and then the positioning screw 8 is screwed into the terminal plate 11 . Even if the terminal screw 7 is loosened, the set screw 8 can prevent the terminal plate 11 from rotating.

21 and 22 are front views showing the structure of a resin molded coil according to an embodiment of the present invention according to claim 15. In FIG. 21 the terminal plate 11 is removed, whereas in FIG. 22 the terminal plate 11 is shown. A set screw 17 having a cross recess is inserted into the fitting 16 provided on the top of the connection terminal 4A.

Fig. 23 is a sectional view taken along Y1-Y1 in Fig. 22 . The embedded fitting 16 is embedded in the surface of the molding resin 9 on top of the connection terminal 4A. A positioning hole 18 having the same shape as the threaded hole is formed in the insert fitting 16 . On the other hand, a hole 11A penetrates the terminal plate 11, and the shaft portion of the set screw 17 penetrates the hole 11A. The tops of the set screws 17 are screwed into the set holes 18 . Even if the terminal screw 7 is loosened, the set screw 17 can prevent the terminal plate 11 from rotating. Since the terminal plate 11 is securely fixed into the insert fitting 16, the embodiment shown in FIG. 23 is more suitable for large capacity coils than that of FIG. 20 .

Fig. 24 is a front view showing a transformer composed of the resin molded coil 1 according to the embodiment of the present invention of claim 15. The connection terminals 4A and 4B are provided above the tap terminal group 4C. Therefore, the interval between the upper and lower connection terminals 4A and 4B is reduced, which in turn reduces the length of the interphase lead 30 as compared with FIG. 48 . Other structures are the same as the conventional structure shown in Fig. 48, and their detailed descriptions are omitted.

FIG. 25 is a sectional view showing the structure of the resin molded coil 1 in FIG. 24. Referring to FIG. The connection terminal 4B is provided above the tap terminal group 4C. The unit coil 2 at the bottom is connected to the connection lead 3B through the connection lead 3B. Other structures are the same as the conventional structure shown in Fig. 49 . The connecting lead 3B and the tap lead 3C are prevented from coming into contact with each other by rising in the peripheral direction of the resin molded coil 1, thereby separating them from each other. In addition, the raised portion of the connection lead 3B is made of a cylindrical copper material.

In FIG. 25, the portion between the connection terminals 4A and 4B must withstand the surge voltage applied to the resin molded coil 1 during the phase-to-phase insulation test. Therefore, although the minimum permissible interval between the connection terminals 4A and 4B is determined by the insulation class of the resin molded coil 1, the terminals can be as close as possible as long as the intermediate portion can withstand the surge voltage. The raised portion of the connection lead 3B is made of copper, so the resistance of the lead is reduced and the current density thereof is increased. Therefore, the thickness of the connection lead 3B can be reduced. In addition, compared with the conventional aluminum foil, since the connecting lead 3B is cylindrical, deflection can be prevented, firmly fixed during the molding of the mold resin 9, and after the resin molding, the resin 9 can be set, and the connecting lead 3B remains in an accurate position superior. This structure prevents the connection lead 3B from approaching or touching the tap lead 3C. As a result, off-spec products are eliminated and coil economics are improved.

FIG. 26 is a perspective view showing cold pressure welding of an aluminum foil 212 and a coil connection conductor 207a with a pressure welding device 215 according to an embodiment of the present invention according to claims 17 and 18. FIG. 27 is a top view of FIG. 26 . In FIGS. 26 and 27, the copper-coil connection conductor 207a is placed on the winding start or end of the aluminum foil 212 forming the sheet coil 210, and the overlapping part is installed on the upper block 216 and the lower block of the pressure bonding device 215. Between 217. The pressure welding device performs cold pressure welding, and a protruding portion 218 is provided on the bottom surface of the upper block 216 . The overlapping portion of the coil connection conductor 207 a and the aluminum foil 212 is located at the position of the protruding portion 218 . During cold press welding, the lower hydraulic cylinder 219 raises the lower block 217 and applies a compressive stress of several hundred Kgf/mm ² to the overlapping portion of the coil connection conductor 207a and the aluminum foil 212 from the protruding portion 218 of the upper block 216 . A pressure welding joint is formed in the middle of the coil connection conductor 207 a in the transverse direction, and the coil connection conductor 207 a moves longitudinally thereof sequentially, thereby forming a plurality of pressure welding joints to connect the conductor to the aluminum foil 212 .

Since the coil connection conductor 207a is made of copper, and copper is more ductile than aluminum, the protruding length of the protruding portion 218 is quite large, which can increase the plastic deformation of the coil connection conductor 207a and give the aluminum foil 212 a compressive force. Welding provides sufficient compressive stress. When the protruding length of the protruding portion 218 is 2.3mm, the thickness of the bonding material is limited, and it is possible to bond the coil connection conductor 207a with a thickness of less than 2mm and the aluminum foil 212 with a thickness of less than 1mm. However, when the protruding length of the protruding portion 218 is 5.2 mm, the 3 mm thick coil connection conductor 207a and the 2.5 mm thick aluminum foil 212 can be cold pressure welded together. In this way, the aluminum foil 212 of the sheet coil 210 and the coil connection conductor 207a can be joined together by means of cold pressure welding, so the time required for the winding operation can be shortened as compared with the conventional structure requiring welding. , eliminating the need for solder heat dissipation.

Fig. 28 shows a structure of a resin molded coil 201 connected to an interphase connection conductor 209a. Fig. 28(a) is a front view, and Fig. 28(b) is a side view. Both the coil connection conductor 207 a and the interphase connection conductor 209 a are made of copper and connected by bolts 220 . Since aluminum is less conductive than copper, a bolted connection between two aluminum materials requires a larger conductor size than copper. In addition, due to the high contact resistance of the aluminum material, the bolt connection needs to increase the contact surface between the coil connection conductor 207a and the interphase connection conductor 209a. The structure in FIG. 28 can reduce the width and thickness of the coil connection conductor 207a and the interphase connection conductor 209a.

Fig. 29 shows the cold pressure welding of the aluminum foil and the coil connection conductor performed by the pressure welding device according to the embodiment of the present invention according to claim 19. Fig. 29(a) is a front view, and Fig. 29(b) is a side view. A plurality of raised portions 218 are provided on the upper block 216 . Other structures are the same as those in Fig. 26 . For example, as shown in FIG. 29(a), by providing three protrusions 218, three bonding joints can be formed at the same time, greatly reducing the time required for bonding.

Fig. 30 is a plan view showing a structure of a resin molded coil according to an embodiment of the present invention according to claim 20. The coil is wound to form a rectangle, and the coil connection conductor 207 extends in the vertical direction. The outermost layer 205A and the innermost layer 205B are made of PET-EPP.

Fig. 31 is a sectional view taken along line X2-X2 in Fig. 30 . However, the lower half of Figure 31 is not shown, but it is completely symmetrical to the upper half. The chip coil 205 is composed of an aluminum foil 205C that is placed on an insulating film 205D and wound around it. The insulating film is made of polyethylene naphthalene (PET) film. A molding resin 221 is filled between the vertically protruding outermost layer 205A and the innermost layer 205B. The entire molded transformer coil is heated and cured. Therefore, the outermost layer 205A, the innermost layer 205B, and the molding resin 221 surrounding the chip coil 205 are provided to form a coil having high mechanical strength.

Fig. 32 is a plan view showing a structure of a resin molded coil according to an embodiment of the present invention according to claims 21 and 22. The analog transformer coil is wound to form a circle, and the coil connection conductor 207 extends in the vertical direction. Cooling paths 223 are formed at the inner periphery of the sheet coil 206 through the spacers 224, each path consisting of an air gap to separate the coil into an outer coil 206A and an inner coil 206B.

Fig. 33 is a sectional view taken along line Y2-Y2 in Fig. 32 . Fig. 34 is a sectional view taken along line Z3-Z3 in Fig. 33 . However, the lower half is not shown in Figure 33, however, it is completely symmetrical to the upper half. The inner and outer coils 206B and 206A are formed by laminating an insulating film 262 made of PEN-EPP and an aluminum foil 261 , and the innermost layer 232 of the inner coil 206B is made of PEN-EPP. In addition, the outermost layer 231 of the outer coil 206A is made of wound EPP-TG material. The resin guide groove 233 is formed so as to protrude vertically from the top end surfaces of the inner and outer layer coils 206A and 206B and contact the outermost layer of the outer layer coil 206A and the inner and outer diameter walls of the cooling path 223 . In addition, the innermost layer 232 of the inner layer coil 206B protrudes upward and is also used as a resin guide groove. Such a molded transformer coil is placed with the sides of the resin guide grooves 233 facing upwards, and the part between the resin guide grooves 233 is filled with the molded resin 221 except for the channel path 223 part, as shown in FIG. 33 . The modulus transformer coil is then heated. Once the molding resin 221 has been set, turn the molded transformer coil upside down, fill the portion between the opposite sides of the resin guide groove 233 with the molding resin 221 except for a specific portion of the channel path 223, and then perform heat treatment.

In the molded coil of the structure shown in FIG. 33, the epoxy resin applied to the PEN-EPP and EPP-TG is cured after heating to significantly increase the mechanical strength of the chip coil 206. Although the conventional technology is not actively filling the epoxy resin in the chip coil 206, the structure in FIG. onto the aluminum foil 261. In addition, the outermost layer of EPP-TG shrinks during heating, so the entire molded transformer coil is tightened towards its inner diameter, increasing its firmness.

In addition, if the ends of the outer layer coil 206A and the inner layer coil 206B are filled with molding resin in FIG. 33, the resin guide groove 233 can also cure the molding resin 221 without leakage. According to the prior art, the innermost layer 232 is composed of an insulating cylindrical roll, and the outermost layer 231 and the resin channel 233 are not provided. Temporarily blocking the cooling path 223, the periphery of the molded transformer coil is immersed in a container containing molded resin. Therefore, the inside of the chip coil 206 is not impregnated with epoxy resin. The purpose of conventional immersion in a molded resin container is not to increase mechanical strength but to prevent sheet coils from absorbing moisture. The structure of Fig. 33 not only prevents the sheet coil from absorbing moisture, but also improves the mechanical strength. The resin guide groove 233 does not need to block the cooling path 223 and enables the mold resin 221 to solidify without leakage.

Fig. 35 is a side sectional view showing the structure of a resin molded coil according to a reference example of the present invention in claim 23. A coil sheet 302 (solid line) made of aluminum foil and an insulating sheet 307 (dashed line) made of plastic film are coaxially wound in several layers around a shaft 308 . The winding start (inner layer) and the winding end (outer layer) of the coil piece 302 are each cold press welded to the connection conductor 301 made of copper plate. The inside of the frame demarcated by the two-dot chain line is molded with resin, and the connection conductor 301 is drawn out from the frame.

In FIG. 35, the right end of the connection conductor 301 is connected to an external circuit or an interphase connection lead. In order to obtain good contact, the connecting conductor 301 is made of copper. This type of coil is used as a low-voltage coil of a resin molded transformer, so a large current can flow. The connection conductor 301 therefore consists of a wide copper plate, and a joint is provided between the connection conductor 301 and the coil piece 302, allowing a large current to flow.

Fig. 36 is an expanded schematic view of the resin molded coil in Fig. 35 . The winding start or end of the coil piece 302 is cold-press welded to the connecting conductor 301 . 310 shown in the figure is a cold-welding part, and the connection conductor 301 and the coil piece 302 are cold-welded at several points to withstand the current flowing through the joint. Cold compression welding presses hard metallic materials together at room temperature while deforming them. The materials interdiffuse at the junction, forming a strong metallic coupling.

FIG. 37 is an enlarged cross-sectional view showing the periphery of the cold-compression welding portion in FIG. 36. FIG. The cold press welding device is shown in dashed lines and consists of an upper block 304 with a raised portion 305 and a lower block 306 . The connecting conductor 301 and the coil piece 302 placed mutually are sandwiched by upper and lower blocks 304 and 306 and pressed by a hydraulic cylinder (not shown). The connection conductor 301 and the coil piece 302 are subjected to a pressure of about 2 kN/mm ² . Accordingly, the connection conductor 301 and the coil piece 302 are deformed by the protruding portion 305 to be recessed into the cold-welding portion 310 . When the cold-compression bonding method has not been established, the connection conductor 301 and the coil piece 302 are brazed together, and the connection takes a considerable time. However, the cold press welding method utilizes a hydraulic cylinder for simple press welding, which simplifies the operation and shortens the time required for the operation.

However, the structure of the above-mentioned reference example cannot press-weld the thin coil sheet to the connection conductor.

A specific example of cold pressure welding involves pressure welding a coil sheet having a thickness between 0.2 mm and 0.8 mm to a connecting conductor having a thickness between 1.6 or 2.0 mm. The protruding part in the cold pressure welding device is designed so that the protruding length X is between 1.6 and 2.3 mm (Figure 37), and pressure is applied until the total thickness of the coil sheet and the connecting conductor reaches a predetermined value (about 50%). However, it has been found that the cold press welding method cannot sufficiently deform coil pieces having a thickness of less than 0.2 mm, resulting in poor connection to the connecting conductor. Therefore, coil pieces having a thickness of less than 0.2 mm must be soldered to connection conductors, and this connection requires a considerably long time.

Fig. 38 is an enlarged sectional view showing the periphery of the cold-compression welding portion of the resin molded coil of the embodiment in claim 23. Fig. 38 shows the purpose of the cold pressure welding part of the resin molded coil to be able to pressure weld the thin coil sheet to the connecting conductor. Blocks 304 and 306 are sandwiched and then compressed by hydraulic cylinders (not shown), as shown in FIG. 38 . The connection conductor 301, the coil piece 302 and the overlapping piece 303 were subjected to a pressure of about 2 kN/mm ² as in the device of the reference example of FIG. 37 . The protrusions 305 deform and pressure-weld the three elements to each other.

Fig. 39 shows the same part of Fig. 38 seen from the direction indicated by arrow C, corresponding to the expanded schematic diagram of the resin molded coil in the reference example of Fig. 36 . This figure differs from FIG. 36 in that an overlapping piece 303 (dotted line) is press-welded to the back surface of the coil piece 302 (the surface opposite to the connection conductor 301).

If the total thickness of one side of the aluminum material in FIG. 38 (the total thickness of the coil sheet 302 and the overlapping sheet 303) is equal to the thickness of the coil sheet 302 configured according to the reference example in FIG. 37, then, if the same pressure is applied, the The degrees of deformation are equal. Therefore, even if the thickness of the coil piece 302 is 0.2 mm or less, the coil piece 302 and the connection conductor 301 can be bonded well by setting the total thickness on the aluminum material side to 0.2 mm or more.

In FIG. 39, the overlapping sheet 303 may have the same width and length as the coil sheet 302, and the coil sheet 302 may be formed of two kinds of aluminum foils placed and wound together. Accordingly, the provided coil may include a plurality of overlappingly wound thin coil pieces 302 with a thickness of less than 0.2 mm. Since the coil pieces 302 are soft, they are easy to wind, which shortens the time required for winding.

FIG. 40 is an expanded view showing a molding method of an anti-touch panel according to an embodiment of the present invention in claim 25. FIG. In the order of Figs. 40(a) to (d), the touch guard 226 is molded. First, one end of the metal foil 226 is cut in the winding direction (transverse direction in the drawing) into a Γ-shape leaving the strip-shaped portion 226A (width D), as shown in FIG. 40( a ). At the root of strip portion 226A (fold 226B), it is folded vertically to the winding direction, as shown in FIG. 40(b). Furthermore, the strip-shaped portion 226A is overlapped and folded (folded 226C) at one-third of the width D, as shown in FIG. 40(c). Then, the strip portion 226A is folded in half, as shown in FIG. 40(d). In FIG. 40( d ), the ground lead 227 is formed by covering the three overlapping folded strip portions 226A with a heat-shrinkable tube 229 . In this way, the ground lead 227 can be formed simply by folding the metal foil 226 . This construction eliminates the need for soldering of the touch guard, thus substantially reducing the time required to manufacture the touch guard 226 . In addition, the anti-touch plate 226 and the ground lead 227 are integrally formed, so there is no possibility of soldering failure, which significantly improves reliability compared with the prior art.

FIG. 41 shows a detailed structure of a touch-proof plate according to an embodiment of the present invention in claim 26. FIG. Fig. 41(a) is an expanded view before winding. Fig. 41(b) is a sectional view taken along line X3-X3 in Fig. 41(a). The insulating film 230 is folded so as to simultaneously wrap the upper and lower ends of the touch-proof plate 226 . Other structures are the same as the traditional structure. In the case shown in FIG. 41, the anti-touch plate 226 is wound around the low voltage coil. The insulating film 230 is simply folded and attached to both ends of the touch guard 226 . This structure does not require soldering to the touch guard 226 , thus reducing the time required to manufacture the touch guard 226 .

According to the present invention defined in claim 1, the unit coil is folded vertically to the winding direction at the position of the outer diameter thereof, and further folded to the inner diameter thereof to form a winding termination conductor so as to extend diagonally with respect to the axial direction, and then in The unit coils are folded in the winding direction at the positions of the inner diameters of the adjacent unit coils to form winding start conductors of the adjacent unit coils. This structure does not require the use of crimp terminals to connect each pair of adjacent unit coils together, and a continuous aluminum foil can be used to form a single coil. As a result, the time required to manufacture the coil is substantially shortened, which in turn reduces the cost of the resin molded coil.

According to the invention defined in claim 2, the jumper conductor connects the winding end conductor of the unit coil to the winding start conductor of the adjacent unit coil, the jumper insulator covering the jumper conductor includes a folded insulating film, said The jumper conductors are sandwiched by an insulating film. Thus, the insulating sheet bridging the two sides of the insulator is integrally formed and does not unravel during the winding operation. Therefore, the operation is simplified, the fatigue of the operator is reduced, and the working efficiency is improved.

According to the invention defined in claim 3, the thickness of the outer layer on the side where the tap leads are drawn out of the resin molded coil is greater than that on the other side. This structure reduces the size and cost of the entire transformer.

According to the invention defined in claim 4, a prepreg layer impregnated with a non-hardening epoxy resin is provided on the inner diameter side of the coil, and the coil wound around the prepreg layer is thermally cured. This structure increases the mechanical force of the coil and improves the reliability of the transformer.

According to the invention defined in claim 5, a glass fiber mat formed by laminating corrugated glass fibers on flat glass fibers is wound between the prepreg layer and the coil, and the glass fiber mat is impregnated with molding resin. This structure improves impregnation of the inner diameter side of the coil with resin, thereby reducing the number of defective products.

According to the invention defined in claim 6, the glass fiber is wound around the outer diameter of the coil, and the glass fiber is impregnated with the molding resin. This structure increases the mechanical force of the coil and further improves the reliability of the transformer.

According to the invention defined in claim 7, the outer diameter of the resin mold is enlarged toward the side opposite to the side from which the lead wires are led out, so that the bridging between the unit coils is located at the enlarged position of the resin mold. This structure reduces the size of the core, thus reducing the size of the entire transformer.

According to the invention defined in claim 8, the aluminum film forming the coil is wound through a multilayer insulating film. This structure prevents turn-to-turn shorts, which in turn reduces the number and cost of rejects.

According to the invention defined in claim 9, cutting lines are formed in the aluminum foil sheet at equal intervals in the longitudinal direction from the ends of the coil-forming foil, thereby forming a plurality of cut-end strips; the outermost cut-end is cut first at its root ; Fold the cutting end adjacent to the outermost cutting end vertically to the length direction of the aluminum foil sheet at its root, and then fold the remaining adjacent cutting ends vertically at its root to the length direction of the aluminum foil sheet; fold the folded cutting end Stacked in the thickness direction to form lead wires drawn out from the coil. This structure greatly reduces the time required to manufacture leads and improves reliability.

According to the invention defined in claim 10, an insulating film with a hole is folded at the position of the hole, the root of the lead wire drawn out from the coil is covered with a lead wire insulator comprising this insulating film, and the lead wire is inserted into the hole of the lead wire insulator middle. Therefore, the insulation sheets on both sides of the lead wire are integrally formed and will not be scattered during the winding operation, thereby improving work efficiency.

According to the invention defined in claim 11, the L-shaped glass fiber pillow formed by folding the glass fiber is in contact with the position where the lead wire is led out from the outer diameter side edge of the unit coil. This structure can maintain a sufficiently large insulation distance between the lead wire and the coil, which can improve reliability.

According to the invention defined in claims 12 to 14, the set screw penetrates into the terminal plate, and the top of the set screw is inserted into the positioning hole provided on the surface of the molding resin. The external circuit maintains normal contact.

According to the invention defined in claim 15, a pair of connection terminals is provided above a group of tap terminals. This structure shortens the required length of the interphase leads, thereby reducing the cost of the device.

According to the invention defined in claim 16, the connection lead rising portion that connects the lower connection terminal and the coil end together is made of a cylindrical copper material. This structure can reduce the thickness of the connecting lead and reduce defective products, thereby further reducing the cost of the device.

According to the invention defined in claim 17, both the coil connecting conductor and the interphase connecting conductor are copper conductors; the aluminum foil and the coil connecting conductor are press-welded together at room temperature; the coil connecting conductor and the interphase connecting conductor are connected together by bolts. This structure allows the omission of all solder connection operations, significantly reducing the time required for manufacture.

According to the invention defined in claim 18, said coil-connecting conductors are placed respectively at the winding end and start end of said aluminum foil; There is a protrusion that can be bonded at room temperature. This construction provides a high reliability bond between the aluminum foil and the coil connection conductor.

According to the invention defined in claim 19, a plurality of protruding parts are provided on the square; in order to carry out multiple pressure welding at room temperature, the pressure welding parts in the overlapping parts are sequentially moved in the axial direction of the sheet coil . This structure increases the speed of pressure welding the aluminum foil to the coil connection conductor.

According to the invention defined in claim 20, polyethylene naphthalate (PET-EPP) coated with a non-hardening heat-resistant epoxy resin is wound in the innermost layer and the outermost layer of the sheet coil. film. This structure significantly increases the mechanical strength of the molded transformer coil, and also enhances the short-circuit capacity of the coil.

According to the invention defined in claim 21, a cooling path including a columnar air gap is provided in the sheet coil; the innermost layer and the outermost layer extending vertically from the upper and lower end surfaces of the sheet coil and touching the sheet coil are formed. layer and the resin channels of the inner and outer diameter walls of the cooling path; except for the cooling path part, the mold resin is filled between the resin channels. This structure allows the resin guide grooves to protrude from the upper and lower end surfaces of the chip coil so that the molding resin at the end of the chip coil can be cured without leakage, thereby eliminating the need to block the cooling path.

According to the present invention defined in claim 22, a polyethylene naphthalate (PET-EPP) film coated with a non-hardening heat-resistant epoxy resin is wound in the innermost layer of the sheet coil; PET-EPP is used in the insulating sheet of the sheet-shaped coil; a heat-shrinkable tape (EPP-TG) coated with a non-hardening heat-resistant epoxy resin is wound on the outermost layer of the sheet-shaped coil. This structure further increases the mechanical strength of the coil of the analog transformer, thus increasing the short-circuit strength of the coil.

According to the invention defined in claim 23, the coil piece is press-welded to the connection conductor together with the overlapping piece comprising the aluminum foil piece. This structure can connect a very thin coil piece to a connection conductor, shortening the time required for connection.

In this structure, according to the invention defined in claim 24, the coil sheet includes two aluminum foil sheets put together and wound, one of which is used as the overlapping sheet. This structure facilitates winding and shortens the time required for winding.

According to the invention defined in claim 25, the end of said metal foil is cut into a Γ-shaped strip in the winding direction, it is folded perpendicularly to said winding direction at its root, and then reduced in width to the original width Fold it overlappingly twice a third of the way, and cover the overlapping folded strip with heat shrink tubing to form the ground lead. This structure enables the ground lead to be formed by simply folding the metal foil and does not require soldering to the touch shield, thus reducing the time required to manufacture the touch shield. In addition, the anti-touch plate is integrated with the ground lead, which greatly improves reliability.

According to the invention defined in claim 26, the insulating film is folded such that the upper and lower ends of the touch guard are curled, and the insulating film and the touch guard are wound together. This structure reduces the time required to manufacture the anti-touch panel, which in turn reduces the cost of the device.

Claims (26)

1. A resin molded coil in which a plurality of unit coils are laminated at certain intervals in the axial direction by placing an insulating film on an aluminum foil sheet and winding them radially and coaxially to form unit coils; The winding start conductor and the winding end conductor are respectively electrically connected together, so that the plurality of unit coils are connected in series, and the unit coils are integrally resin molded, and it is characterized in that: the winding end conductor of the unit coil is Its outer diameter is folded vertically toward the winding direction, and then further folded toward its inner diameter, so that the formed winding termination conductor extends diagonally relative to the axial direction, and then the unit coil is folded toward the winding direction at the inner diameter position of the adjacent unit coil , forming the winding start conductor of the adjacent unit coil. 2. The resin molded coil according to claim 1, wherein the jumper conductor connects the winding terminal conductor of the unit coil to the winding start conductor of the adjacent unit coil, covering the jumper conductor The jumper insulator includes folded insulating films, and the jumper conductors are located between the insulating films. 3. The resin molded coil according to claim 1 or 2, characterized in that: the thickness of the outer layer on the side where the tap leads are drawn out of the resin molded coil is greater than that on the other side. 4. The resin molded coil as claimed in any one of claims 1-3, characterized in that: a prepreg layer impregnated with non-hardening epoxy resin is set on the inner diameter side of the coil, so that the prepreg layer is wound The coil is thermally cured. 5. The resin molded coil according to claim 4, wherein a glass fiber mat formed by laminating corrugated glass fibers on flat glass fibers is wound between said prepreg layer and said coil, The fiberglass mat is impregnated with molding resin. 6. The resin molded coil of claim 5, wherein glass fibers are wound around the outer diameter of the coil and the glass fibers are impregnated with the molding resin. 7. The resin molded coil according to claim 1, characterized in that: the outer diameter of the resin mold on the side opposite to the lead wire side is enlarged, so that the bridge between the unit coils is located at the position where the resin mold expands . 8. The resin molded coil according to any one of claims 1-7, characterized in that the aluminum film forming the coil is wound through a multi-layer insulating film. 9. The resin molded coil according to claim 1, characterized in that: from the end of the foil conductor forming the coil, cut lines are formed at equal intervals in the longitudinal direction on the aluminum foil sheet, thereby forming a plurality of cut end strips; The root first cuts the outermost cutting end; fold the cutting end adjacent to the outermost cutting end vertically to the length direction of the aluminum foil at its root, and then fold the remaining adjacent cutting ends vertically at its root to the aluminum foil. Lengthwise; layer the folded cut ends in the thickness direction to form the leads that emerge from the coil. 10. The resin molded coil as claimed in claim 9, characterized in that: the insulating film with the hole is folded at the position of the hole, and the root of the lead wire drawn from the coil is covered with a lead wire insulator comprising this insulating film; The leads are inserted into holes in the lead insulator. 11. The resin molded coil according to claim 9 or 10, characterized in that: the L-shaped glass fiber pillow formed by folding the glass fiber is in contact with the position where the lead wires are drawn out from the side edge of the outer diameter of the unit coil. 12. A resin molded coil, wherein the entire coil is molded with insulating resin; a pair of vertical connecting terminals are embedded in the outer surface of the molded insulating resin, and the two ends of the coil are connected to the connecting terminals and connected to an external circuit The terminal plate is fixed to the upper connection terminal, and the feature is that the positioning screw is penetrated through the terminal plate, and the top of the positioning screw is inserted into the positioning hole provided on the surface of the molding resin. 13 . The resin molded coil according to claim 12 , wherein the positioning screws are fixed in the threaded holes formed on the terminal plate, and the tops of the positioning screws are inserted into the positioning holes. 14 . 14. The resin molded coil as claimed in claim 12, characterized in that: the embedded parts forming the positioning holes are embedded in the surface of the molding resin; the positioning holes are processed into threaded holes; the positioning screws are passed through the The through hole formed in the terminal plate is screwed into the positioning hole of the embedded fitting. 15. A resin molded coil, wherein the entire coil is molded with an insulating resin; a set of tap terminals and a pair of vertical connection terminals are embedded in the outer surface of the molded resin, and the connection terminals are connected to the coil through connecting leads At each end, the set of tap terminals is connected to the middle of the coil through tap leads, and it is characterized in that: the pair of connecting terminals is arranged above the set of tap terminals. 16. The resin molded coil as claimed in claim 15, wherein the rising part of the connecting lead connecting the lower connecting terminal with the end of the coil is made of cylindrical copper material. 17. A resin molded coil comprising sheet coils, each of which is formed by placing an insulating film on an aluminum foil sheet and radially winding them coaxially; coil connection conductors are respectively connected to the wound coils of the aluminum foil sheet The terminal and the starting end are drawn out in the axial direction of the sheet coil; the interphase connecting conductor electrically connects a plurality of sheet coils together through the coil connecting conductor, and the sheet coil described here is integrally molded by molding resin , characterized in that: the coil connecting conductor and the interphase connecting conductor are both copper conductors; the aluminum foil and the coil connecting conductor are pressure-welded together at room temperature; the coil connecting conductor and the interphase The connecting conductors are bolted together. 18. The resin molded coil according to claim 17, characterized in that: said coil connecting conductors are respectively placed at the winding end and starting end of said aluminum foil; this overlapping part is installed between the pressure welding device squares , each pressure-welding device square has a protruding part capable of pressure-welding at room temperature. 19. The resin molded coil according to claim 18, characterized in that: a plurality of protruding parts are arranged on the square; the pressure-welded parts in the overlapping parts move sequentially in the axial direction of the sheet coil, and Multiple pressure bonding was performed at room temperature. 20. The resin molded coil according to any one of claims 17-19, characterized in that: the innermost layer and the outermost layer of the sheet coil are wound and coated with non-hardening heat-resistant epoxy resin polyethylene naphthalate (PET-EPP) film. 21. The resin molded coil according to any one of claims 17-19, characterized in that: a cooling path including a cylindrical air gap is set in the sheet coil; a cooling path perpendicular to the upper and lower end surfaces of the sheet coil is formed. Resin guide grooves protruding and in contact with the innermost and outermost layers of the chip coil and the inner diameter wall and outer diameter wall of the cooling path; molding resin is filled between the resin guide grooves except for the cooling path portion. 22. The resin molded coil according to any one of claims 17-19, characterized in that: the innermost layer of the sheet coil is wound with polynaphthalene coated with non-hardening heat-resistant epoxy resin Ethylene glycol formate (PET-EPP) film; PET-EPP is used in the insulating sheet of the sheet coil; a thermal film coated with non-hardening heat-resistant epoxy resin is wound in the outermost layer of the sheet coil. Shrink strap (EPP-TG). 23. A resin molded coil, wherein each of the coil piece and the insulation piece includes an aluminum foil piece, they are put together and wound coaxially; The whole device is resin-molded on the connection conductor including the copper plate, and the connection conductor is led out to the outside. The feature is that the coil piece is pressure-welded to the connection conductor together with the overlapping sheet including the aluminum foil. 24. The resin molded coil according to claim 23, wherein the coil sheet comprises two aluminum foil sheets put together and wound, one of which is used as an overlapping sheet. 25. A resin molded coil in which a high and low voltage coil wound around an iron core is molded with an insulating resin, configured through a cylindrical air gap, and a touch-proof plate including a metal foil is wound around the periphery of the low voltage coil ; A grounding lead is set and drawn out, characterized in that: the end of the metal foil is cut into a Γ-shaped strip in the winding direction, and it is vertically folded to the winding direction at its root, and then the width is Reduce it to one-third of the original width and fold it twice, and use a heat shrinkable tube to cover the overlapping folded strip to form a ground lead. 26. A resin molded coil, wherein a high and low voltage coil wound around an iron core is molded with insulating resin, configured through a cylindrical air gap; an anti-touch plate including a wire mesh is wound around the periphery of the low voltage coil, It is characterized in that the insulating film is folded so that the upper and lower ends of the anti-touch plate are curled, and the insulating film and the anti-touch plate are wound together.

Images