Framework and method for manufacturing small-wire-diameter small-inner-diameter hollow frameless cemented coil

Abstract

The invention discloses a framework and a method for manufacturing a small-wire-diameter small-inner-diameter hollow frameless cemented coil. The framework comprises a circular main body, three fan-shaped bosses arranged on one surface of the main body and used for clamping a three-jaw chuck, and a left baffle used for providing a left side boundary for coil winding, wherein a circular hole used for mounting is formed in the center of the main body; the right baffle is opposite to the left baffle, has the same size as the left baffle and is used for providing a right side boundary for coil winding, and a round hole corresponding to the left baffle is formed in the middle of the right baffle; and the stepped shaft is mounted in interference fit with the two circular holes of the left baffle and the right baffle, protrudes out of one side of the right baffle and provides central support for coil winding. The method comprises the steps of S1, manufacturing of a water-soluble film, S2, manufacturing of a plasticizing film, S3, winding of the adhesive coil with the framework and S4, demolding. According to the method and the device, the coil can be easily demolded from the framework without high temperature or low temperature or strong force, and the manufactured coil is stable in performance.

Description

Technical Field

[0001] The invention relates to the field of frameless glue-fixed coils, and in particular to a frame and method for manufacturing hollow frameless glue-fixed coils with thin wire diameter and small inner diameter. Background Art

[0002] Pulse eddy current detection technology uses rectangular wave excitation. Under the condition of constant average power, it can achieve higher instantaneous power by changing the duty cycle and amplitude, generate a stronger magnetic field, and thus has a stronger penetration ability. It can detect metal defects through the covering layer. By reducing the outer diameter of the pulse eddy current probe to improve the spatial resolution, the detection accuracy of local defects can be effectively improved. Compared with magnetic sensitive elements, the glue-solid coil has the advantages of a large linear working range and no need for power supply. It can obtain the detection signal more completely and accurately. Therefore, the pulse eddy current probe generally uses a coaxially arranged excitation glue-solid coil and a receiving glue-solid coil to realize detection. In order to improve the detection accuracy, an air coil with better heat dissipation performance and smaller parasitic capacitance is required. The coreless frame-bonded coil is used as the excitation frame-bonded coil and the receiving frame-bonded coil to reduce the outer diameter of the pulse eddy current probe. Among them, the excitation frame-bonded coil is a small inner diameter frame-bonded coil, generally with an inner diameter less than or equal to 5mm, and is wound by an enameled wire with a wire diameter less than or equal to 1mm; the receiving frame-bonded coil is a fine wire diameter frame-bonded coil, generally made of thousands of turns of enameled wire with a wire diameter less than or equal to 0.1mm. In order to prevent the frame-bonded coil from being wrongly threaded during the winding process and to prevent the frame-bonded coil from being loose during use, quick-drying glue should be applied during the winding process, which makes it difficult to demould the frame-bonded coil from the frame. If brute force is used to demould the frame-bonded coil from the frame, the insulation layer of the enameled wire will be damaged, and even the enameled wire will break.

[0003] At present, the skeleton and method used to make skeleton-free glued coils are difficult to demould from the skeleton, or the glued coils are easily damaged during demoulding, which hinders the development of small outer diameter pulsed eddy current detection probes.

[0004] In view of this, Chinese invention patent ZL202110464875.7 accelerates the curing of the adhesive layer during the winding process of the glued coil by arranging air grooves and exhaust holes on the skeleton. However, in the implementation scheme of this invention patent, there is an adhesive layer between the glued coil and the skeleton. When the method is used to make a skeleton and method for making a thin wire diameter and small inner diameter hollow skeleton-free glued coil, it is easy for the glued coil or the skeleton to be damaged due to adhesion; Chinese invention patent ZL201711441513.6 uses the principle of thermal expansion and contraction to expand the combined shaft core axially and radially by heating before and during winding. After winding, the combined shaft core is cooled, and the combined shaft core shrinks radially and axially to separate from the glued coil, and the edges at both ends of the glued coil are not easy to collapse. However, in the implementation scheme of the invention patent, a heating device needs to be installed inside the combined shaft core, which makes the outer diameter of the combined shaft core larger and is not suitable for winding small inner diameter glue-bonded coils. In addition, in the implementation scheme of the invention patent, the temperature of the combined shaft core needs to be maintained at 200-300°C during the winding process, and the insulation material between the combined shaft core and the glue-bonded coil and the insulation grade temperature limit of the glue-bonded coil material are relatively high, and the scope of application is limited. Moreover, heating and cooling can easily lead to large residual stress in the glue-bonded coil, thereby affecting the performance of the glue-bonded coil.

[0005] Chinese invention patent ZL201822000390.9 uses 36 0.8 cm thick rectangular demolding sheets to form a structure similar to circular fins to eject the glue-fixed coil from the mold; Chinese invention patent ZL201921809229.4 removes the wound glue-fixed coil by disassembling the parting flat head screws on the circular mold; Chinese invention patent ZL202321559353.6 demolds the wound glue-fixed coil by electrically heating it and then ejecting it.

[0006] However, these devices or methods are not suitable for demoulding the coils that need to be glued during the winding process. Therefore, it is necessary for those skilled in the art to provide a frame for making thin wire diameter, small inner diameter hollow frameless glued coils to solve the above technical problems. Summary of the invention

[0007] The present invention provides a frame and method for manufacturing a hollow frameless glue-fixed coil with a thin wire diameter and a small inner diameter, which solves the problem that the existing device or method is not suitable for demoulding the glue-fixed coil which needs to be smeared with glue during the winding process.

[0008] The frame used for making hollow frameless glue-fixed coils with thin wire diameter and small inner diameter is characterized by comprising:

[0009] The main body is circular, with a circular hole for installation in the center of the main body, three fan-shaped bosses for clamping by a three-jaw chuck on one surface of the main body, and a left baffle for providing a left boundary for coil winding;

[0010] A right baffle plate is arranged opposite to the left baffle plate and is of the same size as the left baffle plate, and is used to provide a right boundary for coil winding, and a circular right baffle plate is provided in the middle with a circular hole corresponding to the left baffle plate;

[0011] A stepped shaft is installed with interference fit with the two circular holes of the left baffle and the right baffle and protrudes from one side of the right baffle to provide central support for coil winding.

[0012] Preferably, both ends of the stepped shaft are connected with connecting rings, and the opposite sides of the left baffle plate and the right baffle plate are provided with annular grooves adapted to the connecting rings.

[0013] Preferably, the left baffle, the right baffle and the stepped shaft are all 3D printed parts made of special engineering resin.

[0014] Preferably, the left baffle plate, the right baffle plate and the stepped shaft are all provided with uniformly distributed through holes which are perpendicular to the contact surface of the wound coil and are convenient for demoulding by immersion in water.

[0015] Preferably, the diameter of the through hole is 1.4 mm.

[0016] The method for making a thin wire diameter and small inner diameter hollow frameless glue-fixed coil comprises the following steps:

[0017] S1. Preparation of water-soluble film;

[0018] S11, assembling the left baffle, the stepped shaft, and the right baffle into the framework by pressing;

[0019] S12, evenly spraying the propylene glycol aqueous solution on the left baffle, the stepped shaft, the adhesive coil contact surface of the right baffle, and the sides of the left baffle and the right baffle of the skeleton spliced ​​in S11 to form a water-soluble film;

[0020] S13, placing the skeleton in an air drying oven, setting the temperature in the air drying oven to 26° C. and the humidity to 45% for air drying;

[0021] S14, repeat S12 and S13 four times, wherein in S13, the frame is placed in an air drying box for air drying with the fan-shaped boss of the left baffle facing downward or upward alternately;

[0022] S2, production of plasticized film;

[0023] S21, spraying a spray film containing butyl acrylate evenly on the left baffle, the stepped shaft, the adhesive coil contact surface of the right baffle, and the sides of the left baffle and the right baffle of the skeleton described in S11 to form a plasticized film;

[0024] S22, repeat the operation of S11 at an interval of one minute until the total thickness of the formed water-soluble film and plasticized film is 0.8 mm;

[0025] S3, winding of the coil with frame glue;

[0026] S31, installing the skeleton with the plasticized film and the water-soluble film on the skeleton matching section of the auxiliary shaft, the fan-shaped boss of the left baffle of the skeleton is clamped by the three-jaw chuck of the winding machine, and a spring is provided between the annular boss of the right baffle of the skeleton and the shaft shoulder of the auxiliary shaft to prevent the left baffle, the stepped shaft and the right baffle of the skeleton from loosening in the axial direction;

[0027] S32, the three-claw chuck of the winding machine drives the frame to rotate and wind the enameled wire;

[0028] S33. During the winding process, evenly apply quick-drying glue to the enameled wire wound on the frame;

[0029] S34, after the winding is completed, the enameled wire is cut off after retaining the wire end, the three-claw chuck of the winding machine is loosened, and the auxiliary shaft is removed from the frame to obtain a frame-bonded coil;

[0030] S35, placing the coil with frame glue fixed thereon into an air drying box for air drying;

[0031] S4, demoulding;

[0032] S41, placing the wound skeleton glue-fixed coil into an ultrasonic cleaning machine, treating the skeleton glue-fixed coil with 35° C. distilled water and ultrasonic waves to cause the water-soluble film and the plasticized film to soften and dissolve in water, and the treatment time is 1 hour;

[0033] S42, removing the left baffle and the right baffle of the frame;

[0034] S43. After the left baffle and the right baffle are disassembled in S42, the stepped shaft is removed.

[0035] Preferably, the volume ratio of propylene glycol to water in S12 is 2:3.

[0036] Preferably, the air drying time of the water-soluble film in S13 is t1, Where C is a constant, its value is 5*10 4 J / m 2 , v is the wind speed, A is the surface area of ​​the water-soluble film, RH is the relative humidity of the air in the air-drying box (as a proportional value, ranging from 0 to 1), K is the air temperature in the air-drying box (Kelvin (K)), and H is the hardness of the water-soluble film after drying, and its value is 30.

[0037] Preferably, the temperature in the air drying box in S35 is set to 30° C. and the humidity is set to 35%, and the air drying time is determined according to the following formula:

[0038]

[0039] Where t2 is the time required for the coil with skeleton glue to air dry, and C is a constant, generally 5*10 3 s.m 2 K / kg, v is the wind speed, A is the surface area of ​​the glued coil, RH is the relative humidity in the air drying box (as a proportional value, ranging from 0 to 1), T is the air temperature in Kelvin (K), d is the thickness of each layer of glue on the glued coil, D is the average diameter of the enameled wire, and τ is the thickness of the glued coil.

[0040] Preferably, the outer diameter of the coil with skeleton glue in S3 is:

[0041]

[0042] in (Unit: mm) is the outer diameter of the glue-fixed coil, (Unit: mm) is the inner diameter of the glue-fixed coil, n is the actual number of turns required, h (unit: mm) is the height of the glue-fixed coil, and r is the diameter of the enameled wire.

[0043] In order to solve the above technical problems, the present invention provides a frame for making a thin wire diameter and small inner diameter hollow frameless glue-fixed coil, comprising:

[0044] A left baffle 1, a stepped shaft 2 is disposed on one side of the left baffle 1, and a right baffle 3 is disposed on one side of the stepped shaft 2;

[0045] An auxiliary shaft 4 is connected to one side of the right baffle 3. A plurality of fan-shaped bosses 9 are connected to the surface of the left baffle 1. A three-jaw chuck 6 is provided on the surface of the left baffle 1 and between the plurality of fan-shaped bosses 9. A spring 5 is sleeved on the surface of the auxiliary shaft 4.

[0046] Preferably, both ends of the stepped shaft 2 are connected with connecting rings 7 , and opposite sides of the left baffle 1 and the right baffle 3 are provided with annular grooves 8 matched with the connecting rings 7 .

[0047] Compared with the related art, the skeleton and method for making a thin wire diameter and small inner diameter hollow skeleton-free glue-fixed coil provided by the present invention have the following beneficial effects:

[0048] The present invention provides a frame for manufacturing a hollow frameless glue-fixed coil with a thin wire diameter and a small inner diameter. The frame is composed of only a left baffle, a stepped shaft, and a right baffle. The non-assembly surfaces of the left baffle, the stepped shaft, and the right baffle are covered with through holes with a diameter of 1.4 mm and a spacing of 2 mm, which are perpendicular to the contact surface of the glue-fixed coil. The frame is easy to manufacture using a light-curing 3D printing technology, and the manufacturing cost is low.

[0049] Water and ultrasonic waves pass through the through-holes perpendicular to the contact surface of the glue-fixed coil, which can dissolve the water-soluble film and facilitate the demoulding of the glue-fixed coil;

[0050] The plasticized film is in contact with the glue-solidified coil, which prevents the glue and enameled wire from invading the water-soluble film or even reaching the frame during the winding process. This not only avoids the irregular surface of the coil, which makes it difficult to assemble and use, but also prevents the enameled wire from sticking to the frame and breaking during demoulding.

[0051] After the water-soluble film in contact with the plasticized film is dissolved, the surface of the plasticized film becomes smooth. The smooth plasticized film is located on the inner surface, upper surface and lower surface of the glue-fixed coil, which is convenient for subsequent assembly and use. The quick-drying glue applied when the coil is wound has a solidifying effect, which can prevent the enameled wire from invading the interior of the coil during the winding process, resulting in the shape and size of the coil not meeting the requirements.

[0052] When the coil is energized, it will not only heat up, but also generate magnetic fields, which will cause stress. Compared with self-adhesive enameled wire, the coil wound by applying quick-drying glue has better heat resistance, mechanical strength, and dimensional stability. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Figure 1 A schematic structural diagram of a preferred embodiment of a skeleton for making a thin-wire, small-inner-diameter hollow skeleton-free glue-fixed coil provided by the present invention;

[0054] Figure 2 for Figure 1 A schematic diagram of the three-dimensional structure of the left baffle and the right baffle of the middle frame;

[0055] Figure 3 for Figure 1 A schematic diagram of the three-dimensional structure of the middle skeleton from the first perspective;

[0056] Figure 4 for Figure 1 A schematic diagram of the three-dimensional structure of the middle skeleton from a second perspective;

[0057] Figure 5 for Figure 1 A schematic diagram of the three-dimensional structure of the middle skeleton from a third-person perspective;

[0058] Figure 6 for Figure 1 Schematic diagram after the middle frame is installed;

[0059] Figure 7 A line graph showing the change in DC resistance of a wound glue-solidified coil over a twelve-month period;

[0060] Figure 8 The present invention is a flow chart of a method for making a thin-wire, small-inner-diameter hollow frameless glue-fixed coil.

[0061] Numbers in the figure: 1, left baffle; 2, stepped shaft; 3, right baffle; 4, auxiliary shaft; 5, spring; 6, three-jaw chuck; 7, connecting ring; 8, annular groove; 9, fan-shaped boss. DETAILED DESCRIPTION

[0062] The present invention will be further described below in conjunction with the accompanying drawings and implementation modes.

[0063] Please refer to Figure 1-Figure 8 , used to make the skeleton of thin wire diameter and small inner diameter hollow skeleton-free glue-solidified coil, including:

[0064] The main body is circular, with a circular hole for installation in the center of the main body, three fan-shaped bosses 9 for clamping by a three-jaw chuck are provided on one surface of the main body, and a left baffle 1 is provided for providing a left boundary for coil winding;

[0065] A right baffle plate 3 is arranged opposite to the left baffle plate 1 and is of the same size as the left baffle plate 1, and is used to provide a right boundary for coil winding, and a circular right baffle plate 3 is provided in the middle with a circular hole corresponding to the left baffle plate 1;

[0066] The stepped shaft 2 is installed with interference fit with the two circular holes of the left baffle 1 and the right baffle 3 and protrudes from one side of the right baffle 3 to provide central support for coil winding.

[0067] Preferably, both ends of the stepped shaft 2 are connected with connecting rings 7 , and opposite sides of the left baffle 1 and the right baffle 3 are provided with annular grooves 8 matched with the connecting rings.

[0068] Preferably, the left baffle 1, the right baffle 3 and the stepped shaft 2 are all 3D printed parts made of special engineering resin.

[0069] Preferably, the left baffle plate 1, the right baffle plate 3 and the stepped shaft 2 are all provided with uniformly distributed through holes which are perpendicular to the contact surface of the wound coil and are convenient for demoulding by immersion in water.

[0070] Preferably, the diameter of the through hole is 1.4 mm.

[0071] The skeleton method for making a hollow skeleton-free glue-fixed coil with a thin wire diameter and a small inner diameter comprises the following steps:

[0072] S1. Preparation of water-soluble film;

[0073] S11, assembling the left baffle 1, the stepped shaft 2, and the right baffle 3 into the framework by pressing;

[0074] S12, evenly spraying the propylene glycol aqueous solution on the left baffle 1, the stepped shaft 2, the adhesive coil contact surface of the right baffle 3, and the side surfaces of the left baffle 1 and the right baffle 2 of the skeleton spliced ​​in S11 to form a water-soluble film;

[0075] S13, placing the skeleton in an air drying oven, setting the temperature in the air drying oven to 26° C. and the humidity to 45% for air drying;

[0076] The air drying time is determined according to the following formula:

[0077]

[0078] Where t1 is the time required for the water-soluble film to air dry, and C is a constant whose value is 5*10 4 J / m 2 , v is the wind speed, A is the surface area of ​​the water-soluble film, RH is the relative humidity of the air in the air-drying box (as a proportional value, ranging from 0 to 1), K is the air temperature in the air-drying box (Kelvin (K)), and H is the hardness of the water-soluble film after drying, and its value is 30.

[0079] S14, repeat S12 and S13 four times, wherein in S13, the frame is placed in an air drying box for air drying with the fan-shaped boss 9 of the left baffle 1 facing downward or upward alternately;

[0080] S2, production of plasticized film;

[0081] S21, uniformly spraying a spray film containing butyl acrylate on the glued coil contact surfaces of the left baffle 1, the stepped shaft 2, and the right baffle 3 of the skeleton described in S11, as well as the sides of the left baffle 1 and the right baffle 3 to form a plasticized film;

[0082] S22, repeat the operation of S11 at an interval of one minute until the total thickness of the formed water-soluble film and plasticized film is 0.8 mm;

[0083] S3, winding of the coil with frame glue;

[0084] S31, install the skeleton with plasticized film and water-soluble film on the skeleton matching section of the auxiliary shaft, the fan-shaped boss 9 of the left baffle plate 1 of the skeleton is clamped by the three-jaw chuck 6 of the winding machine, and a spring 5 is arranged between the annular boss of the right baffle plate 3 of the skeleton and the shaft shoulder of the auxiliary shaft 4 to prevent the left baffle plate 1, the stepped shaft 2, and the right baffle plate 3 of the skeleton from loosening in the axial direction;

[0085] S32, the three-claw chuck 6 of the winding machine drives the frame to rotate and wind the enameled wire;

[0086] S33. During the winding process, evenly apply quick-drying glue to the enameled wire wound on the frame;

[0087] S34, after the winding is completed, the enameled wire is cut off after retaining the wire end, the three-claw chuck 6 of the winding machine is loosened, and the auxiliary shaft 4 is removed from the frame to obtain a frame-bonded coil;

[0088] S35, placing the coil with frame glue fixed thereon into an air drying box for air drying;

[0089] S4, demoulding;

[0090] S41, placing the wound skeleton glue-fixed coil into an ultrasonic cleaning machine, treating the skeleton glue-fixed coil with 35° C. distilled water and ultrasonic waves to promote the softening of the water-soluble film and the dissolution of the plasticized film in water, and the treatment time is 1 hour;

[0091] S42, remove the left baffle 1 and the right baffle 3 of the frame;

[0092] S43, after the left baffle 1 and the right baffle 3 are disassembled in S42, the stepped shaft 2 is withdrawn;

[0093] The auxiliary shaft 4 is composed of a frame matching section, a shaft shoulder and a shaft neck.

[0094] The temperature in the air drying box is set to 30°C and the humidity is 35%. The air drying time is determined according to the following formula:

[0095]

[0096] Where t2 is the time required for the coil with skeleton glue to air dry, and C is a constant, generally 5*10 3 s.m 2 K / kg, v is the wind speed, A is the surface area of ​​the glued coil, RH is the relative humidity in the air drying box (as a proportional value, ranging from 0 to 1), T is the air temperature in Kelvin (K), d is the thickness of each layer of glue on the glued coil, D is the average diameter of the enameled wire, and τ is the thickness of the glued coil.

[0097] The outer diameter of the glue-solidified coil to be wound is calculated by the following formula:

[0098]

[0099] in (Unit: mm) is the outer diameter of the glue-fixed coil, (Unit: mm) is the inner diameter of the glue-fixed coil, n is the actual number of turns required, h (unit: mm) is the height of the glue-fixed coil, and r is the diameter of the enameled wire.

[0100] Skeleton: It is composed of multiple components and is used to support the glue coil and maintain its shape during winding.

[0101] Removable connection method: The detachable plug-in connection method is adopted, so that the components of each skeleton can be easily disassembled and installed, which is convenient for replacement or upgrading.

[0102] Reusability: Due to the detachable connection method and the through holes on the surface, the assembled glue-solidified coil skeleton can be separated from the glue-solidified coil at a certain temperature and reduce the risk of skeleton damage, thereby improving resource utilization efficiency.

[0103] High-strength material: The frame is made of wear-resistant and high-strength special engineering resin to ensure structural stability and glue-solidified coil support function.

[0104] The composition and characteristics of the skeleton. The skeleton consists of a left baffle, a stepped shaft, and a right baffle. On the non-assembly surfaces of the left baffle, the stepped shaft, and the right baffle, a 2mm gap is retained between the holes to ensure the strength of the glued coil skeleton. The direction of the through hole is perpendicular to the surface in contact with the glued coil.

[0105] like Figure 3 As shown, the contact surface between the left baffle and the glue-fixed coil has a through hole with a diameter of 1.4mm, which is convenient for later demoulding by immersion in water, and has a 1mm chamfered corner on the periphery to prevent the enameled wire from being cut during the winding process; the other side is a fan-shaped boss 9, the size of which matches the three-jaw chuck 6 used to fix the glue-fixed coil skeleton. Like the left baffle 1, the contact surface between the right baffle 3 and the glue-fixed coil also has a through hole with a diameter of 1.4mm, which is convenient for later demoulding by immersion in water, and has a 1mm chamfered corner on the periphery to prevent the thin enameled wire from being cut during the winding process; the other side is a ring-shaped boss ( Figure 3 Left side, Figure 6 The right side of the right baffle 3 described in the figure) is used to tighten the glued coil skeleton with the spring 4 to prevent the glued coil skeleton from being bounced off due to the tension of the enameled wire during the winding process. There is a 1.4mm stepped hole (through hole) perpendicular to the surface on the stepped shaft to facilitate water immersion and demoulding in the later stage.

[0106] The assembly of various parts of the skeleton is an interference fit. Since the 0.1mm enameled wire is wound, the diameter of the wire is too small, and each assembly part must not have small cracks to prevent the glued coil from breaking due to the glued coil skeleton being stuck during the demoulding process; there is a through hole in the middle of the entire skeleton, which is used together with the auxiliary shaft 4 to fix the glued coil skeleton to prevent the skeleton from shaking in the up, down, left and right directions during the winding process.

[0107] method:

[0108] The design of the skeleton and the size of the skeleton are designed according to actual needs. The height of the step axis of the glue-solidified coil skeleton is consistent with the height of the wound glue-solidified coil. The inner diameter of the skeleton (outer diameter of the step axis) is 0.8mm smaller than the inner diameter of the glue-solidified coil. The step axis of the glue-solidified coil skeleton is 1.6mm higher than the target glue-solidified coil height to leave a thickness interval for spraying the water-soluble film liquid later. The outer diameter calculation formula of the glue-solidified coil is as follows:

[0109]

[0110] in is the outer diameter of the glued coil, The inner diameter of the glue coil, n is the actual number of turns required, h is the height of the glue coil, and r is the diameter of the enameled wire. The diameter of the skeleton can be about 3mm larger than the actual required diameter of the glue coil.

[0111] The skeleton is manufactured by 3D printing. After multiple comparative tests, black special engineering resin is selected for printing. The finished product has the best effect and precision. After printing, the material has ultra-high hardness, high toughness and no cracking. The hardness of the skeleton after molding can reach 85D (Shore Hardness D), the bending strength can reach 27~45MPa, and it is not easy to shrink, which ensures the accuracy of the skeleton. Some printing parameters are as follows: exposure time 2.5s, layer thickness 0.05mm, bottom exposure time 25s, lifting speed 160mm / min, and the skeleton is cured after printing.

[0112] Spray the water-soluble film liquid on the surface where the assembled skeleton contacts the enameled wire. The front surface of the glued coil skeleton (the surface in contact with the glued coil) also needs to be sprayed with the water-soluble film liquid to prevent the glued coil from being easily removed from the glued coil skeleton due to the quick-drying glue leaking to the front surface of the glued coil skeleton during the winding process. After each spraying of the water-soluble film liquid, place the skeleton upright or upside down in the air drying box, keep the temperature at 26 degrees and the humidity at 45%, and air dry for one hour.

[0113] If the film is too hard (the longer the air-drying time, the harder the water-soluble film and plasticized film will be, and it will take longer to process the demoulding), it will make it difficult to handle the impurities in the later stage, and it will not be conducive to demoulding. This step should be repeated 4 times, and the film should be placed alternately upside down and upside down. Under the action of gravity, the right-angled edges formed by the assembly between the stepped shaft and the left and right baffles will form a fillet of about 1mm. This fillet is just tangent to the innermost circular through holes of the left and right baffles. The formation of the fillet is helpful for the later demoulding and the assembly and use of the glue-fixed coil. After four times of air-drying upside down and upside down, spray a film containing butyl acrylate on the surface of the glue-fixed coil skeleton at intervals of one minute to make the surface of the glue-fixed coil skeleton smooth and flat to prevent the surface of the wound glue-fixed coil from being uneven. After spraying, put it in the air-drying box for air-drying; after 5 times of air-drying, the thickness between the surface of the water-soluble film and the left and right baffles is 0.8mm.

[0114] During winding, the auxiliary shaft 4 is inserted into the through hole in the middle of the frame, the left baffle 1 with the fan-shaped boss 9 is fixed to the winding machine, and the right baffle 3 with the circular boss cooperates with the spring 5 to tighten the frame. The first circle of the enameled wire is tightly wound onto the surface of the stepped shaft, and a 5cm length of thread ends is reserved. During the winding process, quick-drying glue is evenly applied. After each layer is wound, quick-drying glue is evenly applied to prevent the glued coil from spreading. During the winding process, attention is always paid to the uniformity of the glued coil, and the winding process is manually intervened when necessary to ensure the regularity of the glued coil. After the winding is completed, a 5cm thread end is also reserved at the tail. After the quick-drying glue on the surface of the glued coil is air-dried, the last layer of enameled wire is fixed to the surface of the glued coil, and finally the wound glued coil frame is removed from the winding machine.

[0115] Air-dry, put the wound frame into the air-drying box for air-drying, so that the quick-drying glue can be air-dried to fix the coil, and put it in an environment with a temperature of 30 degrees for air-drying.

[0116] Demoulding:

[0117] Put the wound skeleton glued coil into an ultrasonic cleaning machine, and treat the skeleton glued coil with 35°C distilled water and ultrasonic waves to soften the water-soluble film and dissolve the plasticized film in water. The treatment time is 1 hour. When demolding, the left baffle and the right baffle should be removed first, and then the stepped shaft should be removed from the glued coil. Be careful during the demolding process to prevent the thread ends from being torn off.

[0118] Post-demolding treatment:

[0119] After the glued coil is demoulded, use distilled water to wash off the water-soluble film on the surface of the glued coil, wipe off the water stains on the surface of the glued coil with paper, and depaint the wire ends of the glued coil. Put the front 2 cm of the wire ends in the paint stripper and soak for about 1 minute. Use paper to wipe off the paint stripper on the surface. The wire ends are successfully depainted. Then use a multimeter to check whether it is qualified and the resistance of the glued coil. Adjust the multimeter to the ohm position. When the multimeter has a resistance indication, it means that the glued coil is successfully wound and the current resistance is recorded. Otherwise, the winding fails.

[0120] like Figure 7 As shown, the resistance of different coils is relatively stable within 12 months, indicating that the quality of the coils wound using this frame and method is relatively stable and reliable.

[0121] The stepped shaft 2 and the right baffle 3 are connected in a detachable manner to facilitate quick disassembly and assembly of the glued coil.

[0122] The connection mode between the stepped shaft 2 and the left baffle 1 is a disassembly connection mode.

[0123] The stepped shaft 2 has the characteristic of being able to change its length to accommodate glue coils of different heights.

[0124] The left baffle plate 1 and the right baffle plate 3 have the characteristic of being able to change their sizes so as to adapt to the glue coils of different sizes.

[0125] The left baffle 1, the stepped shaft 2 and the right baffle 3 have thermal deformation properties to facilitate the removal of the glued coil.

[0126] The left baffle 1, the stepped shaft 2 and the right baffle 3 have thermal conductivity to promote heat dissipation and temperature control of the skeleton.

[0127] The left baffle plate 1, the stepped shaft 2 and the right baffle plate 3 have circular holes of the same size on their surfaces to facilitate the separation of the frame from the glued coil.

[0128] The left baffle 1, the stepped shaft 2 and the right baffle 3 have corrosion-resistant and wear-resistant properties to extend the service life of the glued coil.

[0129] The left baffle plate 1, the stepped shaft 2 and the right baffle plate 3 have dustproof and waterproof properties to protect the glued coil from dust and moisture.

[0130] The surfaces of the left baffle plate 1, the stepped shaft 2 and the right baffle plate 3 that are in contact with the glue-fixed coil are evenly distributed with through holes with a diameter of 1.4 mm, and the center distance between the holes is 2 mm.

[0131] The left baffle 1 has a through hole on its central axis, the stepped shaft 2 has a through hole on its central axis, and the right baffle 3 has a through hole on its central axis. The diameters of these three through holes form a transition fit with the outer diameter of the auxiliary shaft selected during winding.

[0132] The left baffle plate 1, the stepped shaft 2, and the right baffle plate 3 are interferingly fitted.

[0133] The stepped shaft 2 consists of a left assembly section, a glue-fixed coil winding section, and a right assembly section, wherein the length of the glue-fixed coil winding section is 1.6 mm longer than the length of the glue-fixed coil to be wound, and the outer diameter of the glue-fixed coil winding section is 1.6 mm smaller than the inner diameter of the glue-fixed coil to be wound. The lengths of the left and right assembly sections are 3 mm, and the outer diameters are 4 mm smaller than the outer diameter of the glue-fixed coil winding section.

[0134] The left baffle 1 is 10mm long and has an outer diameter that is 4-6mm larger than the outer diameter of the glue-fixed coil to be wound. The outer edge of the glue-fixed coil contact surface has a fillet with a radius of 1mm, and the back of the surface is evenly distributed with three fan-shaped bosses with an angle of 60° and a height of 5mm. The inner edge of the glue-fixed coil contact surface has a hole with a depth of 4mm and a diameter that is interference fit with the left assembly section of the stepped shaft.

[0135] The right baffle 3 has a length of 4 mm and an outer diameter consistent with that of the left baffle 1. The outer edge of the contact surface of the glued coil has a fillet with a radius of 1 mm, and the back of the surface has a circular boss with an outer diameter of 15 mm.

[0136] The dimensions of the left baffle 1, the stepped shaft 2 and the right baffle 3 are not less than 0.5 mm. The bending strength of the material used after molding at room temperature is 27-45 MPa and the surface hardness is 85D (Shore Hardness D).

[0137] The left baffle 1, the stepped shaft 2, and the right baffle 3 are printed using an LCD light-curing printer. The material used is black, and the non-cured coil contact surface is used as the bottom surface for printing. The printing parameters are: bottom layer exposure time 25s, single layer thickness 0.05mm, single layer exposure time 2.5s, and lifting speed 160mm / min.

[0138] Compared with the prior art, the present invention has the following beneficial effects:

[0139] The present invention provides a frame and method for manufacturing a hollow frameless glue-fixed coil with a thin wire diameter and a small inner diameter. The frame is composed of only a left baffle, a stepped shaft, and a right baffle. The non-assembly surfaces of the left baffle, the stepped shaft, and the right baffle are covered with through holes with a diameter of 1.4 mm and a spacing of 2 mm, which are perpendicular to the contact surface of the glue-fixed coil. It is relatively easy to manufacture using a light-curing 3D printing technology.

[0140] Water and ultrasonic waves pass through the through-holes perpendicular to the contact surface of the glue-fixed coil, which can dissolve the water-soluble film and facilitate the demoulding of the glue-fixed coil;

[0141] The plasticized film is in contact with the glue-solidified coil, which prevents the glue and enameled wire from invading the water-soluble film or even reaching the frame during the winding process. This not only avoids the irregular surface of the coil, which makes it difficult to assemble and use, but also prevents the enameled wire from sticking to the frame and breaking during demoulding.

[0142] After the water-soluble film in contact with the plasticized film is dissolved, the surface of the plasticized film becomes smooth. The smooth plasticized film is located on the inner surface, upper surface and lower surface of the glued coil, which is convenient for subsequent assembly and use.

[0143] The quick-drying glue applied when the coil is wound has a solidifying effect, which can prevent the enameled wire from invading the inside of the coil during the winding process, causing the coil shape and size to not meet the requirements;

[0144] When the coil is energized, it will not only heat up, but also generate magnetic fields, which will cause stress. Compared with self-adhesive enameled wire, the coil wound by applying quick-drying glue has better heat resistance, mechanical strength, and dimensional stability.

[0145] The inner sides of the left baffle plate 1 and the right baffle plate 3 of the recycled glue-fixed coil skeleton have a rounded corner to prevent the enameled wire from being torn off during winding.

[0146] The outer sides of the left baffle plate 1 and the right baffle plate 3 of the circulating glue-fixed coil skeleton are provided with fan-shaped bosses 9 to facilitate the fixing of the skeleton.

[0147] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification and drawings, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A skeleton for making thin wire diameter, small inner diameter hollow skeleton-free glue-solidified coils, characterized in that: include: The main body is circular, with a circular hole for installation in the center of the main body, three fan-shaped bosses for clamping by a three-jaw chuck on one surface of the main body, and a left baffle for providing a left boundary for coil winding; A right baffle plate is arranged opposite to the left baffle plate and is of the same size as the left baffle plate, and is used to provide a right boundary for coil winding, and a circular right baffle plate is provided in the middle with a circular hole corresponding to the left baffle plate; A stepped shaft is installed with interference fit with the two circular holes of the left baffle and the right baffle and protrudes from one side of the right baffle to provide central support for coil winding.

2. The frame for making a thin wire diameter and small inner diameter hollow frameless glue-fixed coil according to claim 1, characterized in that: Both ends of the stepped shaft are connected with connecting rings, and the opposite sides of the left baffle plate and the right baffle plate are provided with annular grooves matched with the connecting rings.

3. The frame for making a thin wire diameter and small inner diameter hollow frameless glue-fixed coil according to claim 2, characterized in that: The left baffle, the right baffle and the stepped shaft are all 3D printed parts made of special engineering resin.

4. The frame for making a thin wire diameter and small inner diameter hollow frameless glue-fixed coil according to claim 2, characterized in that: The left baffle plate, the right baffle plate and the stepped shaft are all provided with uniformly distributed through holes which are perpendicular to the contact surface of the wound coil and are convenient for demoulding by immersion in water.

5. The frame for making a thin wire diameter and small inner diameter hollow frameless glue-fixed coil according to claim 3, characterized in that: The diameter of the through hole is 1.4 mm.

6. A method for making a thin wire diameter, small inner diameter, hollow, frameless, glue-fixed coil, characterized in that: The following steps are involved: S1. Preparation of water-soluble film; S11, assembling the left baffle, the stepped shaft, and the right baffle into the framework by pressing; S12, evenly spraying the propylene glycol aqueous solution on the left baffle, the stepped shaft, the adhesive coil contact surface of the right baffle, and the sides of the left baffle and the right baffle of the skeleton spliced ​​in S11 to form a water-soluble film; S13, placing the skeleton in an air drying oven, setting the temperature in the air drying oven to 26° C. and the humidity to 45% for air drying; S14, repeat S12 and S13 four times, wherein in S13, the frame is placed in an air drying box for air drying with the fan-shaped boss of the left baffle facing downward or upward alternately; S2, production of plasticized film; S21, spraying a spray film containing butyl acrylate evenly on the left baffle, the stepped shaft, the adhesive coil contact surface of the right baffle, and the sides of the left baffle and the right baffle of the skeleton described in S11 to form a plasticized film; S22, repeat the operation of S11 at an interval of one minute until the total thickness of the formed water-soluble film and plasticized film is 0.8 mm; S3, winding of the coil with frame glue; S31, installing the skeleton with the plasticized film and the water-soluble film on the skeleton matching section of the auxiliary shaft, the fan-shaped boss of the left baffle of the skeleton is clamped by the three-jaw chuck of the winding machine, and a spring is provided between the annular boss of the right baffle of the skeleton and the shaft shoulder of the auxiliary shaft to prevent the left baffle, the stepped shaft and the right baffle of the skeleton from loosening in the axial direction; S32, the three-claw chuck of the winding machine drives the frame to rotate and wind the enameled wire; S33. During the winding process, evenly apply quick-drying glue to the enameled wire wound on the frame; S34, after the winding is completed, the enameled wire is cut off after retaining the wire end, the three-claw chuck of the winding machine is loosened, and the auxiliary shaft is removed from the frame to obtain a frame-bonded coil; S35, placing the coil with frame glue fixed thereon into an air drying box for air drying; S4, demoulding; S41, placing the wound skeleton glue-fixed coil into an ultrasonic cleaning machine, treating the skeleton glue-fixed coil with 35° C. distilled water and ultrasonic waves to cause the water-soluble film and the plasticized film to soften and dissolve in water, and the treatment time is 1 hour; S42, removing the left baffle and the right baffle of the frame; S43. After the left baffle and the right baffle are disassembled in S42, the stepped shaft is removed.

7. The method for making a thin wire diameter and small inner diameter hollow frameless glue-fixed coil according to claim 6, characterized in that: The volume ratio of propylene glycol to water in S12 is 2:

3.

8. The method for making a thin wire diameter and small inner diameter hollow frameless glue-fixed coil according to claim 6, characterized in that: The air drying time of the water-soluble film in S13 is t1. Where C is a constant, its value is 5*10 4 J / m 2 , v is the wind speed, A is the surface area of ​​the water-soluble film, RH is the relative humidity of the air in the air-drying box (as a proportional value, ranging from 0 to 1), K is the air temperature in the air-drying box (Kelvin (K)), and H is the hardness of the water-soluble film after drying, and its value is 30.

9. The method for making a thin wire diameter and small inner diameter hollow frameless glue-fixed coil according to claim 6, characterized in that: The temperature in the air drying box in S35 is set to 30°C and the humidity is set to 35%. The air drying time is determined according to the following formula: Where t2 is the time required for the coil with skeleton glue to air dry, and C is a constant, generally 5*10 3 s.m 2 K / kg, v is the wind speed, A is the surface area of ​​the glued coil, RH is the relative humidity in the air drying box (as a proportional value, ranging from 0 to 1), T is the air temperature in Kelvin (K), d is the thickness of each layer of glue on the glued coil, D is the average diameter of the enameled wire, and τ is the thickness of the glued coil.

10. The method for making a thin wire diameter and small inner diameter hollow frameless glue-fixed coil according to claim 6, characterized in that: The outer diameter of the coil with skeleton glue in S3 is: in (Unit: mm) is the outer diameter of the glue-fixed coil, (Unit: mm) is the inner diameter of the glue-fixed coil, n is the actual number of turns required, h (unit: mm) is the height of the glue-fixed coil, and r is the diameter of the enameled wire.

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