JP4638303B2 - Bobbinless coil assembly and method for manufacturing bobbinless coil assembly - Google Patents

Description

The present invention relates to a bobbinless coil assembly in which a coil cover is molded using a die on both axial end surfaces and an outer peripheral surface of a bobbinless coil configured by winding a conductive wire in a cylindrical shape, and a manufacturing method thereof.

A coil used for an electromagnetic actuator or a motor is generally wound around an insulator called a bobbin. A bobbinless coil that eliminates this bobbin is known from Patent Document 1 below.
Japanese Patent Laid-Open No. 10-172823

  By the way, since the surface shape of the conventional bobbinless coil is an uneven surface with continuous conductive wires, when the bobbinless coil is housed in the mold and the coil cover is molded, the inner wall of the mold and the bobbinless coil It is inevitable that a gap is generated between the coil surface, and molten resin may leak from the cavity through the gap and adhere to the inner peripheral surface of the bobbinless coil, or a burr may occur. .

  The present invention has been made in view of the above circumstances, and a bobbinless coil assembly is obtained by integrally molding a synthetic resin coil cover on both the outer peripheral surface and the axial end surfaces except for the inner peripheral surface of a cylindrical bobbinless coil. It is an object of the present invention to prevent molten resin from leaking to the inner peripheral surface side of the bobbinless coil.

In order to achieve the above object, according to the first aspect of the present invention, a coil cover is formed by using dies on both axial ends and outer peripheral surfaces of a bobbinless coil formed by winding a conducting wire in a cylindrical shape. mold was a bobbin-less coil assembly, said coil cover in a state where the inner circumferential surface of the bobbin-less coil and placed on the outer periphery of the mold, and the outer peripheral surface and axial end surfaces of the bobbin-less coil It is molded by injecting molten resin into a cavity partitioned by the mold, at least in part adjacent to the inner peripheral surface of the axial end faces of the bobbin-less coil, the molten resin in the inner peripheral surface A bobbinless coil assembly is proposed, characterized in that a flat sealing surface is formed to prevent wraparound .

  According to the invention described in claim 2, in addition to the structure of claim 1, a bobbinless coil assembly is proposed in which the seal surface is formed of a potting material.

  According to a third aspect of the present invention, in addition to the configuration of the first aspect, a bobbinless coil assembly is proposed in which the sealing surface is formed by a press surface.

  According to a fourth aspect of the present invention, in addition to the configuration of the first aspect, a bobbinless coil assembly is proposed in which the sealing surface is formed by the conductive wire made of a rectangular wire.

  According to a fifth aspect of the present invention, in addition to the configuration of the first aspect, the seal surface is formed by first and second plates provided on both axial end surfaces of the bobbinless coil. A bobbinless coil assembly is proposed.

  According to the invention described in claim 6, in addition to the configuration of claim 1, there is proposed a bobbinless coil assembly characterized in that the bobbinless coil assembly is used as a drive source of an electromagnetic actuator. The

  According to a seventh aspect of the present invention, there is provided a method for manufacturing a bobbinless coil assembly according to any one of the first to sixth aspects, wherein the bobbinless coil is wound around the conductive wire. A step of forming the sealing surface on the bobbinless coil, a cavity facing the outer peripheral surface and both axial end surfaces of the bobbinless coil, and the bobbin in a mold that is in close contact with the sealing surface A method for manufacturing a bobbinless coil assembly is proposed, which includes a step of inserting a coilless coil and a step of injecting molten resin into the cavity and molding the coil cover.

  According to an eighth aspect of the present invention, there is provided a manufacturing method of the bobbinless coil assembly according to the fifth aspect, wherein the first and second plates are prepared, and the first and second plates are prepared. The bobbinless coil is formed by winding a conductive wire between the plates, and has a cavity facing the outer peripheral surface and both axial end surfaces of the bobbinless coil, and the bobbinless in a mold that is in close contact with the seal surface A method of manufacturing a bobbinless coil assembly is proposed, which includes a step of inserting a coil and a step of injecting molten resin into the cavity and molding the coil cover.

According to the invention described in claim 9, in addition to the configuration of claim 7 or claim 8, a winding jig for winding the conducting wire constitutes at least a part of the mold. A method for manufacturing a bobbinless coil assembly is proposed.

According to the first aspect of the present invention, since the flat seal surface is formed on at least a portion adjacent to the inner peripheral surface of both end surfaces in the axial direction of the bobbinless coil in which the conducting wire is wound in a cylindrical shape, the inner periphery of the bobbinless coil Bobbinless coil assembly by injecting molten resin into the cavity defined by the outer peripheral surface of the bobbinless coil and both axial end surfaces and the mold and molding the coil cover with the surface arranged on the outer periphery of the die When forming a three-dimensional structure, the molten resin leaks out to the inner peripheral surface side of the bobbinless coil with a flat sealing surface, and the molten resin adheres to the inner peripheral surface of the bobbinless coil or burrs are generated. Can be prevented.

  According to the configuration of the second aspect, since the sealing surface of the bobbinless coil is formed of the potting material, the flatness of the sealing surface can be increased and leakage of the molten resin can be reliably prevented.

  According to the configuration of the third aspect, since the sealing surface of the bobbinless coil is formed by a press surface, the flatness of the sealing surface can be increased and leakage of the molten resin can be reliably prevented.

  According to the configuration of the fourth aspect, since the sealing surface of the bobbinless coil is formed by a conducting wire made of a rectangular wire, a special member or special processing for forming the sealing surface is not necessary, which contributes to cost reduction. can do.

  According to the fifth aspect of the present invention, the sealing surface of the bobbinless coil is formed by the first and second plates provided on both end surfaces in the axial direction, so that the flatness of the sealing surface is increased and the molten resin is surely leaked. Can be blocked.

  According to the configuration of the sixth aspect, since the bobbinless coil assembly is used as a drive source of the electromagnetic actuator, the length of the bobbinless coil conducting wire for securing the necessary number of turns can be shortened, and its resistance and inductance Decreases and current response improves.

  According to the configuration of claim 7, when the bobbinless coil is housed in a mold having cavities facing the outer peripheral surface and both axial end surfaces of the bobbinless coil and the coil cover is molded, the sealing surface of the bobbinless coil Prevents the molten resin injected into the cavity from leaking at the sealing surface, and prevents the molten resin from adhering to the inner peripheral surface of the bobbinless coil or generating burrs. be able to.

  According to the configuration of the eighth aspect, when the bobbinless coil is housed in a mold having cavities facing the outer peripheral surface and both axial end surfaces of the bobbinless coil and the coil cover is molded, the axial direction of the bobbinless coil The sealing surfaces of the first and second plates provided on both end surfaces are in close contact with the mold, so that leakage of the molten resin injected into the cavity is prevented by the sealing surface, and the molten resin is formed on the inner peripheral surface of the bobbinless coil. Can be prevented from adhering or generating burrs.

According to the configuration of the ninth aspect, since the winding jig for winding the conducting wire forms at least a part of the mold, the winding can be unwound even if a normal conducting wire that is not a self-bonding wire is used. This can contribute to cost reduction.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below based on examples of the present invention shown in the accompanying drawings.

  1 to 7 show a first embodiment of the present invention. FIG. 1 is a longitudinal sectional view of an active vibration isolating support device, FIG. 2 is an enlarged view of a part 2 in FIG. 1, and FIG. FIG. 4 is a view showing a sealing surface forming step, FIG. 5 is a view showing a coil cover molding step, FIG. 6 is an enlarged view of a portion 6 in FIG. 5, and FIG.

  As shown in FIGS. 1 and 2, an active anti-vibration support device M (active control mount) used for elastically supporting an automobile engine on a body frame is substantially axisymmetric with respect to an axis L. A substantially cup-shaped actuator case having an open upper surface between a flange portion 11a at the lower end of the substantially cylindrical upper housing 11 and a flange portion 12a at the upper end of the generally cylindrical lower housing 12. The outer peripheral flange portion 13a, the outer peripheral portion of the annular first elastic body support ring 14, and the outer peripheral portion of the annular second elastic body support ring 15 are overlapped and joined by caulking. At this time, the annular first floating rubber 16 is interposed between the flange portion 12a of the lower housing 12 and the flange portion 13a of the actuator case 13, and the upper portion of the actuator case 13 and the inner surface of the second elastic body support member 15 By interposing the annular second floating rubber 17 therebetween, the actuator case 13 is floatingly supported so as to be movable relative to the upper housing 11 and the lower housing 12.

  The lower end and the upper end of the first elastic body 19 formed of thick rubber are joined to the first elastic body support ring 14 and the first elastic body support boss 18 disposed on the axis L by vulcanization adhesion. Is done. A diaphragm support boss 20 is fixed to the upper surface of the first elastic body support boss 18 with bolts 21, and the outer peripheral portion of the diaphragm 22 joined to the diaphragm support boss 20 by vulcanization adhesion is added to the upper housing 11. Joined by sulfur adhesion. An engine mounting portion 20a integrally formed on the upper surface of the diaphragm support boss 20 is fixed to an engine (not shown). In addition, the vehicle body attachment portion 12b at the lower end of the lower housing 12 is fixed to a vehicle body frame (not shown).

  A flange portion 23a at the lower end of the stopper member 23 is coupled to the flange portion 11b at the upper end of the upper housing 11 with bolts 24 and nuts 25 and so on. The engine mounting portion 20a that protrudes from the upper surface of the upper and lower surfaces faces each other so as to be capable of contacting. When a large load is input to the active vibration isolating support device M, the engine mounting portion 20a abuts against the stopper rubber 26, thereby suppressing excessive displacement of the engine.

  The outer peripheral portion of the second elastic body 27 formed of a film-like rubber is joined to the second elastic body support ring 15 by vulcanization adhesion, and the movable member 28 is added so as to be embedded in the central portion of the second elastic body 27. Joined by sulfur adhesion. A disk-shaped partition wall member 29 is fixed between the upper surface of the second elastic body support ring 15 and the outer periphery of the first elastic body 19, and the first partition partitioned by the partition wall member 29 and the first elastic body 19. The liquid chamber 30 and the second liquid chamber 31 partitioned by the partition member 29 and the second elastic body 27 communicate with each other through a communication hole 29 a formed at the center of the partition member 29.

  An annular communication path 32 is formed between the first elastic body support ring 14 and the upper housing 11, and one end of the communication path 32 communicates with the first liquid chamber 30 through the communication hole 33. The other end communicates with the third liquid chamber 35 defined by the first elastic body 19 and the diaphragm 22 through the communication hole 34.

  Next, the structure of the electromagnetic actuator 41 that drives the movable member 28 will be described.

  A fixed core 42, a bobbinless coil assembly 43, and a yoke 44 are sequentially attached to the inside of the actuator case 13 from the bottom to the top. The bobbinless coil assembly 43 includes a bobbinless coil 46 disposed between the fixed core 42 and the yoke 44, and a coil molded with a synthetic resin so as to cover both end surfaces and the outer peripheral surface of the bobbinless coil 46 in the axis L direction. And a cover 47. The coil cover 47 is integrally formed with a connector 48 that extends through the openings 13b and 12c formed in the actuator case 13 and the lower housing 12 and extends to the outside.

  A seal member 49 is disposed between the upper surface of the coil cover 47 and the lower surface of the yoke 44, and a seal member 50 is disposed between the lower surface of the bobbinless coil 46 and the upper surface of the fixed core 42. These seal members 49 and 50 can prevent water and dust from entering the internal space 61 of the electromagnetic actuator 41 from the openings 13 b and 12 c formed in the actuator case 13 and the lower housing 12.

  A thin cylindrical bearing member 51 is fitted to the inner peripheral surface of the cylindrical portion 44a of the yoke 44 so as to be vertically slidable. An upper flange 51a bent radially inward is formed at the upper end of the bearing member 51. A lower flange 51b that is bent radially outward is formed at the lower end. A set spring 52 is disposed in a compressed state between the lower flange 51b and the lower end of the cylindrical portion 44a of the yoke 44. The elastic force of the set spring 52 causes the lower flange 51b to be fixed to the fixed core 42 via the elastic body 53. The bearing member 51 is supported by the yoke 44 by being pressed against the upper surface of the yoke 44.

  A substantially cylindrical movable core 54 is fitted to the inner peripheral surface of the bearing member 51 so as to be slidable up and down. A rod 55 extending downward from the center of the movable member 28 penetrates the center of the movable core 54 loosely, and a nut 56 is fastened to the lower end thereof. A set spring 58 in a compressed state is disposed between a spring seat 57 provided on the upper surface of the movable core 54 and the lower surface of the movable member 28, and the movable core 54 is pressed against the nut 56 by the elastic force of the set spring 58. Fixed. In this state, the lower surface of the movable core 54 and the upper surface of the fixed core 42 face each other via the conical air gap g. The rod 55 and the nut 56 are loosely fitted in an opening 42 a formed at the center of the fixed core 42, and the opening 42 a is closed by a plug 60 through a seal member 59.

  The electronic control unit U, to which a crank pulse sensor Sa for detecting a crank pulse output with rotation of the crankshaft of the engine is connected, controls energization to the electromagnetic actuator 41 of the active vibration-proof support device M. The engine crank pulse is output 24 times per revolution of the crankshaft, that is, once every 15 ° of the crank angle.

  Next, a method for manufacturing the bobbinless coil assembly 43 will be described with reference to FIGS.

  First, in the bobbinless coil preparation step shown in FIG. 3, the bobbinless coil 46 is formed by winding a conducting wire 62 made of a self-bonding wire having a circular cross section into a cylindrical shape. The bobbinless coil 46 includes an inner peripheral surface 46a, an outer peripheral surface 46b, and a pair of end surfaces 46c, 46c.

  Subsequently, in the sealing surface forming step of FIG. 4, the synthetic resin is potted at a position closer to the radially inner side of the pair of end surfaces 46c, 46c of the bobbinless coil 46, that is, a position close to the inner peripheral surface 46a. The sealing surfaces 63, 63 are formed. The length of the sealing surfaces 63, 63 in the radial direction is, for example, the length of three layers of the wound conducting wire 62.

  A mold 71 used in the coil cover molding process shown in FIG. 5 includes a lower mold 72, an upper mold 73, and an auxiliary mold 74. The bobbinless coil 46 is fitted on the outer periphery of the cylindrical portion 72a of the lower mold 72. Held. When the upper die 73 is clamped with respect to the lower die 72 in this state, the cavity 75 is formed between the inner wall surfaces of the lower die 72 and the upper die 73 and the outer peripheral surface 46b and both end surfaces 46c, 46c of the bobbinless coil 46. It is formed. Molten resin is injected into the cavity 75 through a runner 73 a provided in the upper mold 73. The auxiliary die 74 moves in the horizontal direction with respect to the upper die 73 in order to release the connector 48 integrated with the coil cover 47.

  Next, the operation of the active vibration isolating support apparatus M having the above configuration will be described.

  When low-frequency engine shake vibration is generated while the vehicle is running, the first elastic body 19 is deformed by a load input from the engine via the diaphragm support boss 20 and the first elastic body support boss 18, and the first liquid When the volume of the chamber 30 changes, the liquid goes back and forth between the first liquid chamber 30 and the third liquid chamber 35 connected via the communication path 32. When the volume of the first liquid chamber 30 is enlarged / reduced, the volume of the third liquid chamber 35 is reduced / expanded accordingly, but the volume change of the third liquid chamber 35 is absorbed by the elastic deformation of the diaphragm 22. At this time, the shape and size of the communication path 32 and the spring constant of the first elastic body 19 are set so as to exhibit a low spring constant and a high damping force in the frequency region of the engine shake vibration. The vibration transmitted to can be effectively reduced.

  In the frequency region of the engine shake vibration, the electromagnetic actuator 41 is kept in an inoperative state.

  When vibration having a higher frequency than the engine shake vibration, that is, vibration during idling or vibration during cylinder deactivation caused by rotation of the crankshaft of the engine occurs, the first liquid chamber 30 and the third liquid chamber 35 are connected. Since the liquid in the communication path 32 is in a stick state and cannot exhibit the anti-vibration function, the electromagnetic actuator 41 is driven to exhibit the anti-vibration function.

  The electronic control unit U controls energization to the bobbinless coil 46 based on a signal from the crank pulse sensor Sa in order to operate the electromagnetic actuator 41 of the active vibration isolation support device M to exhibit the vibration isolation function.

That is, in the flowchart of FIG. 7, first, in step S1, a crank pulse output from the crank pulse sensor Sa every 15 ° of crank angle is read, and in step S2, the read crank pulse is used as a reference crank pulse (specific cylinder). And the time interval of the crank pulse is calculated. In the next step S3, the crank angular velocity ω is calculated by dividing the crank angle of 15 ° by the time interval of the crank pulse, and in step S4, the crank angular velocity ω is time-differentiated to calculate the crank angular acceleration dω / dt. In the following step S5, the torque Tq around the engine crankshaft is set as I, and the moment of inertia around the engine crankshaft is set as I.
Tq = I × dω / dt
Calculate by This torque Tq is zero assuming that the crankshaft is rotating at a constant angular velocity ω, but in the expansion stroke, the angular velocity ω increases due to acceleration of the piston, and in the compression stroke, the angular velocity ω decreases due to deceleration of the piston. Since the crank angular acceleration dω / dt is generated, a torque Tq proportional to the crank angular acceleration dω / dt is generated.

  In the subsequent step S6, the maximum value and the minimum value of the temporally adjacent torque are determined, and in step S7, the active vibration isolation support device M that supports the engine as a deviation between the maximum value and the minimum value of the torque, that is, the amount of torque fluctuation. The amplitude at the position of is calculated. In step S8, the duty waveform and timing (phase) of the current applied to the bobbinless coil 46 of the electromagnetic actuator 41 are determined.

  Thus, when the engine moves downward with respect to the vehicle body frame and the first elastic body 19 is deformed downward and the volume of the first liquid chamber 30 is reduced, the bobbinless coil of the electromagnetic actuator 41 is synchronized with the timing. When 46 is excited, the movable core 54 moves downward toward the fixed core 42 by the adsorption force generated in the air gap g, and is pulled by the movable member 28 connected to the movable core 54 via the rod 55 to be second. The elastic body 27 is deformed downward. As a result, since the volume of the second liquid chamber 31 increases, the liquid in the first liquid chamber 30 compressed by the load from the engine flows into the second liquid chamber 31 through the communication hole 29a of the partition wall member 29. The load transmitted from the engine to the vehicle body frame can be reduced.

  Subsequently, when the engine moves upward with respect to the vehicle body frame and the first elastic body 19 is deformed upward to increase the volume of the first liquid chamber 30, the bobbinless coil 46 of the electromagnetic actuator 41 is synchronized with the timing. Is demagnetized, the attracting force generated in the air gap g disappears and the movable core 54 can move freely, so that the second elastic body 27 deformed downward is restored upward by its own elastic restoring force. As a result, since the volume of the second liquid chamber 31 decreases, the liquid in the second liquid chamber 31 passes through the communication hole 29a of the partition wall member 29 and flows into the first liquid chamber 30, and the engine is in contact with the vehicle body frame. It can be allowed to move upward.

  In this way, by exciting and demagnetizing the bobbinless coil 46 of the electromagnetic actuator 41 according to the period of vibration of the engine, an active damping force that prevents the vibration of the engine from being transmitted to the vehicle body frame is generated. be able to.

  In this embodiment, the use of the bobbinless coil 46 not only makes it possible to reduce the number of parts and cost by eliminating the bobbin, but also reduces the inner diameter of the bobbinless coil 46 by the amount of the bobbin. be able to. In addition, when the inner diameter of the bobbinless coil 46 is reduced, the length of the conducting wire 62 for securing the required number of turns can be shortened, the resistance and inductance of the bobbinless coil 46 are reduced, and the current response is improved.

  Further, when the coil cover 47 is molded by injecting molten resin from the runner 73a into the cavity 75 with the bobbinless coil 46 inserted into the mold 71, it is provided on both end faces 46c, 46c of the bobbinless coil 46. Since the sealing surfaces 63, 63 are brought into close contact with the lower die 72 and the upper die 73 to exert a sealing function, the molten resin is prevented from flowing from the cavity 75 to the inner peripheral surface 46a side of the bobbinless coil 46 by the injection pressure, It is possible to prevent the molten resin from adhering to the inner peripheral surface 46a or generating burrs. In addition, since the sealing surfaces 63 and 63 formed by potting have extremely high flatness, reliable sealing performance can be obtained.

  8 to 10 show a second embodiment of the present invention, FIG. 8 is a view showing a sealing surface forming step, FIG. 9 is a view showing a mold for molding a coil cover of a bobbinless coil, and FIG. FIG. 10 is an enlarged view of 10 parts in FIG. 9.

  The bobbinless coil 46 of the first embodiment has flat sealing surfaces 63, 63 formed by potting on both end faces 46c, 46c, whereas the bobbinless coil 46 of the second embodiment has both end faces 46c, The flat seal surfaces 63 and 63 are formed by pressing the lead wires 62 in a predetermined range (three rows in the embodiment) on the inner peripheral side of 46c in the direction of the axis L by the press arms 64 and 64. Also according to the second embodiment, the sealing surfaces 63, 63 provided on the both end faces 46c, 46 of the bobbinless coil 46 are brought into close contact with the lower mold 72 and the upper mold 73 to exert a sealing function. Therefore, it is possible to prevent the molten resin from leaking from the inner peripheral surface 46a of the bobbinless coil 46. In addition, since the sealing surfaces 63 and 63 are formed by pressing, the sealing surfaces 63 and 63 having high flatness can be easily obtained.

  11 and 12 show a third embodiment of the present invention. FIG. 11 is a view showing a mold for molding a coil cover of a bobbinless coil, and FIG. 12 is an enlarged view of a portion 12 in FIG.

  The bobbinless coil 46 of the first and second embodiments uses a conducting wire 62 having a circular cross section, while the bobbinless coil 46 of the third embodiment uses a conducting wire 62 made of a self-bonding wire having a rectangular cross section. By using the conducting wire 62 made of a rectangular wire having a rectangular cross section, the sealing surfaces 63, 63 are automatically formed on both end faces 46c, 46c of the bobbinless coil 46. Therefore, as in the first and second embodiments. The effect of this can be achieved. In addition, a special member or process for forming the seal surfaces 63 and 63 is not necessary, and the processing cost is reduced.

  FIGS. 13 and 14 show a fourth embodiment of the present invention. FIG. 13 is a view showing a mold for molding a coil cover of a bobbinless coil, and FIG. 14 is an enlarged view of a portion 14 in FIG.

  In the fourth embodiment, the bobbinless coil 46 is configured by winding the conducting wire 62 using a suitable jig, and the first and second end surfaces in the axial direction of the bobbinless coil 46 removed from the jig, respectively. The plates 87 and 89 are fixed by means such as adhesion. When the bobbinless coil 46 having the first and second plates 87 and 89 is inserted into the mold 71, a part of the flat first and second plates 87 and 89 become the seal surfaces 63 and 63 and the upper mold. 73 and close contact with the lower mold 72, and it is possible to prevent the molten resin from leaking and flowing around to the inner peripheral surface 46a side of the bobbinless coil 46. In addition, by using the first and second plates 87 and 89 processed with high accuracy in advance, the seal surfaces 63 and 63 having high flatness can be easily obtained.

  15 to 18 show a fifth embodiment of the present invention. FIG. 15 shows the first and second plate preparation steps, FIG. 16 is a view in the direction of arrow 16 in FIG. 15, and FIG. The figure which shows a coil formation process and FIG. 18 are figures which show a coil cover mold process.

  As shown in FIGS. 15 and 16, the winding jig 81 for winding the bobbinless coil 46 used in the first and second plate preparation steps includes an upper jig half 82 and a lower jig half 83. In a state of being positioned by the collar 84 and the non-rotating pin 85, and is integrally coupled by a bolt 86. A first plate 87 is supported on the lower surface of the flange 82a of the upper jig half 82 in a state where the first plate 87 is positioned by a rotation stopper pin 88, and a second plate 89 is supported on the upper surface of the flange 83a of the lower jig half 83. It is supported in a state where it is positioned by the non-rotating pin 90.

  In the bobbinless coil forming step shown in FIG. 17, the cylindrical guide surfaces 82b and 83b of the upper jig half 82 and the lower jig half 83, the lower surface of the first plate 87, and the upper surface of the second plate 89 As a guide, the conducting wire 62 is wound into a cylindrical shape.

  Subsequently, in the coil cover molding step shown in FIG. 18, the bobbinless coil 46 integrally provided with the first and second plates 87 and 89 is inserted into the mold 71. At this time, the upper jig half 82 of the winding jig 81 constitutes a part of the upper die 73, and the lower jig half 83 of the winding jig 81 constitutes a part of the lower die 72. The flat upper surface of the first plate 87 and the flat lower surface of the second plate 89 function as the sealing surfaces 63 and 63, respectively, so that the molten resin leaking from the cavity 75 is moved to the inner peripheral surface 46a side of the bobbinless coil 46. It can be prevented from wrapping around.

  Thus, the fifth embodiment can achieve the same effects as those of the first to fourth embodiments described above. Moreover, since the bobbinless coil 46 is inserted into the mold 71 while being set on the winding jig 81, the winding is not unwound even if a normal conducting wire 62 which is not a self-bonding wire is used, which contributes to cost reduction. can do.

  In addition, since the coil cover 47 is molded by inserting the bobbinless coil 46 integrally provided with the first and second plates 87 and 89 into the mold 71, both the end faces 46c and 46c of the bobbinless coil 46 and the first, It is not necessary to fix the second plates 87 and 89 by means such as adhesion, thereby further reducing the cost.

  The embodiments of the present invention have been described above, but various design changes can be made without departing from the scope of the present invention.

  For example, in the embodiment, the bobbinless coil 46 of the active vibration isolating support device M is illustrated, but the bobbinless coil of the present invention can be applied to any other application.

1 is a longitudinal sectional view of an active vibration isolating support device according to a first embodiment. 2 enlarged view of FIG. Diagram showing bobbinless coil preparation process The figure which shows the seal surface formation process Diagram showing coil cover molding process 6 is an enlarged view of FIG. Flow chart explaining operation Explanatory drawing of the press process of the bobbin-less coil which concerns on 2nd Example The figure which shows the metal mold | die which molds the coil cover of a bobbin less coil 9 enlarged view of FIG. The figure which shows the metal mold | die which molds the coil cover of the bobbinless coil which concerns on 3rd Example. 12 enlarged view of FIG. The figure which shows the metal mold | die which molds the coil cover of the bobbin less coil which concerns on 4th Example. 14 enlarged view of FIG. The figure which shows the 1st, 2nd plate preparation process concerning 5th Example 16 direction arrow view of FIG. Diagram showing bobbinless coil forming process Diagram showing coil cover molding process

41 Electromagnetic actuator 43 Bobbinless coil assembly 46 Bobbinless coil 46a Inner peripheral surface 46b Outer peripheral surface 46c End surface 47 Coil cover 62 Conductive wire 63 Seal surface 71 Mold 75 Cavity
81 winding jig 87 first plate 89 second plate

Claims (9)

A coil cover (47) was molded using a die (71) on both axial end surfaces (46c) and outer peripheral surface (46b) of a bobbinless coil (46) configured by winding a conducting wire (62) in a cylindrical shape. A bobbinless coil assembly,
The coil cover (47) has an outer peripheral surface (46b) of the bobbinless coil (46) in a state where the inner peripheral surface (46a) of the bobbinless coil (46) is disposed on the outer periphery of the mold (71). And molten resin is injected into the cavity (75) defined by the axial end faces (46c) and the mold (71), and molded.
At least in part adjacent to the inner peripheral surface (46a) of said axial end surfaces (46c) of said bobbin-less coil (46), a flat where the molten resin is prevented from flowing to the inner peripheral surface (46a) A bobbinless coil assembly, wherein a sealing surface (63) is formed.   The bobbinless coil assembly according to claim 1, wherein the sealing surface (63) is made of a potting material.   The bobbinless coil assembly according to claim 1, characterized in that the sealing surface (63) is formed by a press surface.   The bobbinless coil assembly according to claim 1, wherein the sealing surface (63) is formed by the conducting wire (62) made of a rectangular wire.   The said sealing surface (63) was formed with the 1st, 2nd plate (87, 89) provided in the axial direction both end surface (46c) of the said bobbin less coil (46), The said 1st characterized by the above-mentioned. Bobbinless coil assembly.   The bobbinless coil assembly according to claim 1, wherein the bobbinless coil assembly (43) is used as a drive source of an electromagnetic actuator (41). A method for manufacturing a bobbinless coil assembly (43) according to any one of claims 1 to 6,
Winding the conductive wire (62) to prepare the bobbinless coil (46);
Forming the sealing surface (63) on the bobbinless coil (46);
The bobbinless coil (46) has a cavity (75) facing the outer peripheral surface (46b) and both axial end surfaces (46c) of the bobbinless coil (46), and the bobbinless coil (71) is in close contact with the seal surface (63). Inserting a coil (46);
Injecting molten resin into the cavity (75) to mold the coil cover (47);
The manufacturing method of the bobbin-less coil assembly characterized by including these. A method for manufacturing a bobbinless coil assembly (43) according to claim 5,
Preparing the first and second plates (87, 89);
Winding the lead wire (62) between the first and second plates (87, 89) to form the bobbinless coil (46);
The bobbinless coil (46) has a cavity (75) facing the outer peripheral surface (46b) and both axial end surfaces (46c) of the bobbinless coil (46), and the bobbinless coil (71) is in close contact with the seal surface (63). Inserting a coil (46);
Injecting molten resin into the cavity (75) to mold the coil cover (47);
The manufacturing method of the bobbin-less coil assembly characterized by including these. The bobbin-less according to claim 7 or 8, wherein a winding jig (81) for winding the conducting wire (62) constitutes at least a part of the mold (71). A method for manufacturing a coil assembly.

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