JPS5858715A - Manufacture of mold coil - Google Patents

Abstract

PURPOSE:To obtain a mold coil having stable quality by a method wherein the main body of a coil is fixed in a fiber reinforced plastic box providing a fixing seat and a hardening resin mortar material is poured in the box while vibrating the box. CONSTITUTION:A wrinkle 12 is provided at the inside of a fiber reinforced plastic box 11 so that the main body of a coil 5 may be fixed at a fixed position. This forms a fixing seat. A female mole 8 is fixed on a vibrator 7. Next, a box 11 mounting the main body of the coil 5 by using the wrinkle 12 is inserted in the inside of the female mold 8. Next, a hardening resin mortar material 6 is gradually poured in the box while vibrating the vibrator 7 and impregnation to the narrow surface section of the main body of the coil 5 and defoaming are promoted. After finishing hardening, a male mold 9 is released and a mold coil is obtained by releasing from the female mold 7.

Description

[Detailed description of the invention] The present invention relates to a method for manufacturing a molded coil.

More specifically, the present invention relates to a method for manufacturing a useful molded coil that has excellent one-dimensional accuracy, has a good magnetic effect, can be manufactured efficiently, and is especially suitable for use as a coil placed on the ground of a magnetically levitated train.

In recent years, maglev trains are expected to be able to run at ultra-high speeds of approximately 500 km/hr, and their development is progressing further. However, in order to achieve this, it is necessary to be able to efficiently manufacture a large number of ground-installed coils and to be economically advantageous.

Here, the ground installation coils are 1) a molded structure of a round levitation coil that levitates a train; 2) a molded structure of a guide coil to stabilize the train at a fixed position in the width direction of the track; This includes molded structures for propulsion coils used to propel trains.

Since these ground-mounted coils are used in all weather conditions, they are required to have excellent water resistance, weather resistance, and dust resistance, as well as mechanical strength and electrical insulation that can sufficiently withstand electromagnetic force.

Therefore, we decided to use fiber-reinforced plastic (hereinafter referred to as FR) for the coil body.
The formation of a protective layer for P (abbreviated as P) has been studied.

- Examples of FRP include sheet molding composite resin. Figure 1 is a perspective view of a molded coil, where 1 is a protective layer, 2 is a coil conductor, 3 is a rib, and 4 is a perspective view of a molded coil.
is a bolt hole. In order to effectively perform the repulsion and attraction functions between the ground-installed coil (4) and the on-board coil (B) of the magnetic levitation train, it is necessary to reduce the distance between the respective coil bodies of the above-mentioned coil (4) and (B). Regarding ground-mounted coils.

It is desirable to keep the thickness of the protective layer as constant and thin as possible.

When using the sheet molded composite, there are limits to this requirement due to water resistance of 1M, mechanical properties, and electrical insulation, and the thinnest part of the protective layer is generally 5 to 1M.
It is said to be 0■.

Also, the thickness of this protective layer for one molded coil is
It is desired to manufacture the product as close to the design value as possible and to minimize variations in mass production, but in order to improve this dimensional sheath layer, considerable skill in molding is required.

As methods for improving this, improvements in the method of wrapping the material in a method using a sheet molding conband, and a method of fixing using a pre-molded spacer made of the same material have been proposed. In the case of resin mortar materials, a method of positioning the coil body using support bins or spacers is also provided.

These improvement methods and the method of improving the dimensional accuracy of the protective layer through the skill of the mold operator require a large number of hands in the case of mass production, which is disadvantageous.

Machinery is also complex to automate. It is desired that molded coils with stable quality and excellent performance can be mass-produced with as simple a process as possible and in a short time.

The present invention satisfies such requirements.

In other words, the present invention has a fixing seat that supports the coil body on the inner surface, fixes the coil body in a fiber-reinforced plastic box, and vibrates the fiber-reinforced plastic box. The present invention relates to a method for manufacturing a molded coil, which involves injecting a curable resin mortar material between the coil body and impregnating, defoaming, and hardening.

The box made of fiber-reinforced plastic has an outer shape of a molded coil, and an inner surface with a fixed seat so that the coil body can be inserted and supported at a fixed position. Preferably, the fixed seat has a pleated shape. The material is so-called fiber reinforced plastic (FRP) and glass fiber.

It is a composite material that is reinforced with carbon fiber and uses unsaturated polyester resin, epoxy resin, etc. as the matrix resin. The molding method can be any of the molding methods such as dry-up, spray-up, cold press, SMC, BMC, etc., where the coil is injected and filled around the coil body installed at a fixed position in a box made of reinforced plastic. .

When the fiber-reinforced plastic box is vibrated, every detail of the internal coil body is impregnated and degassed, and hardens at room temperature, under normal pressure, under heat and pressure, etc. Stel resin, hardening agent, hardening accelerator, and aggregate and a filler.

There are no restrictions on unsaturated polyester resins.

Any unsaturated polyester resin can be used.

Methyl ethyl ketone peroxide is used as a hardening agent.

Cyclohexanone peroxide, cumene peroxide, benzoyl peroxide, etc. are used, and as curing accelerators, cobalt,
Salts of octenoic or naphthenic acids such as vanadium, vanadyl, manganese, iron, etc.

Salts of other organic acids, N,N dimethylaniline.

Organic amines such as N, N diethylaniline, etc., lucium, calcium sulfate, barium sulfate, melamine powder, plastic powder, glass powder, etc. are used. If necessary, a thermofusible low-shrinkage agent, short glass fibers, an internal spawner, a pigment, etc. may be added to the curable resin mortar material.

As the internal mold release agent, zinc stearate or the like is used.

Linear molecules having a molecular weight of approximately 10,000 to 500,000 such as vinyl acetate, polyacrylate, and polyterephthabarate may be used, but modified low-shrinkage imparting agents shown in Japanese Patent Nos. 882,089 and 894,113 may also be used. Further, short glass fibers may be mixed with this curable resin mortar material.

Although the raw material composition of the curable resin mortar material is not limited, the generally preferred range is as shown in Table 1.

Unsaturated polyester resin 20~40 hardening agent
0.5-10 curing accelerator
0.1~5 Filler 5~80 Aggregate 5~80 Thermoplastic low shrinkage agent θ~20 Internal release agent
0-10 Pigment Others
The θ~10 curable curable resistor mortar material and curing time are not limited either, but generally preferred ranges are as shown in Table 2.

Viscosity* (25℃ poise) 5-30 curing time
(25℃ min) 30-300*: JIS K
Measured according to 6901.

For mixing hardenable resin mortar materials.

Commonly used kneaders, mixers, and the like are used, and a concrete vibrator or the like is used as a vibrator for pouring.

The fiber-reinforced plastic box may be fixed inside W, but it is not necessarily necessary to use a mold. If necessary, spacers, support pins, etc. may be used inside the box made of fiber-reinforced plastic.

The materials used for the mold include metal, plastic, wood, and cement concrete.

An embodiment of the present invention will be described below with reference to FIGS. 4, 5, 6, and 7.

FIG. 4 is a sectional view of a box 11 made of fiber-reinforced plastic (hereinafter simply referred to as a box). The inside of the box 11 is provided with a pleat 12, which serves as a fixation seat, so that the coil body 5 can be fixed in a fixed position. FIG. 5 is a sectional view showing the coil body 5 installed in the folds 12 of the box 11.

First, place the lower W8 (outer circumference 1 of the mold part) on the vibrator 7 (Mikasa Sangyo ■ concrete vibrator 200 type).
0001EIIX100O■, a in Figure 6 □, 5 Qv
na, b, 5 Qwm) are fixed, and the coil body 5 is installed inside the lower tweeter W8 using the pleats 12, and the box 11 is fitted therein.

Next, the curable resin mortar material 6 shown in Table 3 was gradually injected into the box while vibrating the vibrator 7 to promote impregnation into the fine details of the surface of the coil body 5 and defoaming.

Table 3 Resin mortar materials (parts by weight) ' Methyl ethyl peroxide z5 Cobalt octenoate solution 1.3 Calcium carbonate
10 sand
60 Zinc Stearate 5
After injecting the curable resin mortar material 6 into the lower part and fully defoaming, as shown in Fig. 6, the upper mold 9 (C0 in Fig. 6) is removed.
10)). When the curing of the curable resin mortar material 6 is completed, the upper mold 9 is removed and removed from the lower mold 7.
Obtain the molded coil shown in the figure.

Comparative Example As a comparative example, a molded coil was obtained by the method shown in FIG.

The lower mold 8 was fixed on the same vibrator 7 as in Example 1.

Next, the required number of spacers 10° spacers 13 and 14 are measured at predetermined positions inside the lower swing 8, and the coil body 5 is placed on top of them and fixed.

Next, the curable resin mortar material 6 shown in Table 1 was gradually injected while the vibrator 7 was vibrating.

Impregnation into the surface details of the coil body 5 and defoaming were promoted. After all the resin mortar material 6 has been poured and the air has been sufficiently degassed, the upper W9 is attached. After the resin mortar material 6 had completely hardened, the upper mold 9 was removed and the lower mold 8 was removed to obtain a molded coil as shown in FIG. 3.

In the comparative example, a predetermined spacer is manufactured in advance and then carefully set in a fixed position on the lower mold. Place the coil body on top of this spacer and position it accurately.
After checking, it must be carefully pressurized and heated to avoid any defects, and each operation is time-consuming and requires skill.

Also, when using this molded coil.

There is also a concern that the spacer part may have poor adhesion and water may enter through the gap.

According to the present invention, it is possible to obtain a molded coil with almost no voids or blemishes obtained by filling with a vibrator or the like at normal pressure without any special operations such as pressurization at temperatures below 100°C. can. Since the molded coil obtained by the manufacturing method of the present invention is integrally molded into a box made of fiber-reinforced plastic using a fixed seat, it has good dimensional accuracy and excellent weather resistance.

[Brief explanation of drawings]

Figure 1s1 is a perspective view showing a ground-installed coil, Figure 2 is a cross-sectional view showing the manufacturing method of the molded coil before improvement, Figure 3 is a cross-sectional view of the molded coil before improvement, and Figure 4 is used in the present invention. Figure 5 shows an example of a box made of fiber-reinforced plastic snacks, Figure 5 is a diagram with a coil body installed in it, Figure 6 is a diagram showing a method for manufacturing a molded coil according to an embodiment of the present invention, and Figure 7 is a diagram showing a method of manufacturing a molded coil according to an embodiment of the present invention.
The figure is a cross-sectional view of a molded coil obtained by the manufacturing method of the present invention. Explanation of symbols l...Retention layer 2...Coil conductor 3...
Lip 4... Bolt hole 5... Coil body 6... Hardening resin mortar material 7... Vibrator 8... Lower mold 9... Upper mold 1
0...Spacer 11...Fibre-reinforced plastic box 12...Fold χ° diagram Figure 4

Claims (1)

[Claims] 1. A fixed seat is provided on the inner surface to support the coil body, and the coil body is fixed in a box made of fiber-reinforced plastic.
A method for manufacturing a molded coil, which comprises injecting a hardening resin mortar material between the fiber-reinforced plastic box and the coil body, impregnating, degassing, and hardening the fiber-reinforced plastic box while vibrating the fiber-reinforced plastic box.