Coil device and flow adjustment valve provided with coil device

Abstract

The invention provides a coil device and a flow rate adjusting valve provided with the coil device. Even if the coil device is used in an environment with a great temperature change, a bonding wire part of a coil sealed by a sealing resin part can be prevented from being broken due to expansion and contraction of the sealing resin part, and reliability can be improved. The present invention is provided with: a sealing resin part (97) for sealing a flange part (94af) of a bobbin (94), a lap line part (93a1c) of a coil (93a), and a terminal (96a); and a lap line section breakage suppression means for suppressing breakage of the lap line section (93a1c), the lap line section breakage suppression means being provided with an adhesion strengthening means (Ar) for strengthening adhesion between the sealing resin section (97) and the flange section (94af) in an axially facing region (AF) of the flange section (94af), and the lap line section (93a1c) being disposed close to or in contact with the axially facing region (AF) of the flange section (94af). And the bobbin (94) has a linear expansion coefficient smaller than that of the sealing resin part (97).

Description

Technical Field

[0001] The present invention relates to a coil device having a sealing resin portion and a flow rate regulating valve including the coil device. Background Art

[0002] In coil devices, a sealing member made of a resin material (hereinafter referred to as a "sealing resin portion") is sometimes used in stator coils, electrical components, and the like as a dustproof and waterproof mechanism.

[0003] Specifically, if Figure 16 As shown, Patent Document 1 describes a coil device 1600 (hereinafter referred to as a "conventional coil device") comprising a stator yoke 1695; a bobbin 1694 made of a resin material and integrally formed with the stator yoke 1695; a coil 1693a wound around the outer periphery of the bobbin 1694; and a frame yoke 1695e and a cover 1696g fitted onto the outer periphery of the bobbin 1694. Patent Document 1 also describes a coil device comprising a terminal 1696a press-fitted into a flange 1694f of the bobbin 1694; and a lead wire 1696d connected to the terminal 1696a via a substrate 1696f. The bobbin 1694, coil 1693a, frame yoke 1695e, terminal 1696a, and the like are sealed by a sealing resin portion 1697.

[0004] Although not explicitly shown in Patent Document 1, both ends of the coil 1693 a wound around the bobbin 1694 have connecting wire portions (not shown) directly connected to the power supply terminals 1696 a , and these connecting wire portions are also sealed by the sealing resin portion 1697 .

[0005] In recent years, due to the expansion of applications, there has been a strong demand for coil devices to be used in environments with large temperature fluctuations between high and low temperatures (for example, a 160°C fluctuation from -40°C to 120°C in automotive coil devices).

[0006] In conventional coil device 1600, there is a significant difference in the linear expansion coefficient between the encapsulating resin portion 1697 and the coil 1693a, which is made of a metal material (e.g., soft copper). (Typically, the linear expansion coefficient of resin materials is several to approximately 10 times greater than that of metal materials.) Therefore, when conventional coil device 1600 is used in an environment subject to significant temperature fluctuations, the encapsulating resin portion 1697 repeatedly expands and contracts, and the overlapping wire portion of coil 1693a is tightly fixed to the encapsulating resin portion 1697, causing repeated tensile and compressive forces to be applied to the overlapping wire portion. The wire diameter of coil 1693a is generally small. Consequently, the overlapping wire portion of coil 1693a is also weak. Consequently, the overlapping wire portion cannot withstand the externally forced deformation caused by the expansion and contraction of the encapsulating resin portion 1697, leading to fatigue failure and the possibility of fracture (hereinafter referred to as the "conventional problem (fracture of the overlapping wire portion due to temperature fluctuations)").

[0007] In addition, in order to eliminate the existing problem (breakage of the overlapping wire part caused by temperature changes), consideration was given to changing the wire diameter of coil 1693a and setting a protective component at the overlapping wire part to increase the strength. However, this could not be adopted due to new issues such as high cost and failure to obtain the desired motor performance.

[0008] Prior art literature

[0009] Patent Literature

[0010] Patent Document 1: Japanese Patent Application Laid-Open No. 2006-20480 Summary of the Invention

[0011] Problems to be solved by the invention

[0012] The object of the present invention is to provide a coil device and a flow regulating valve equipped with the coil device, which can prevent the overlapping part of the coil sealed by the sealing resin part from breaking due to the expansion and contraction of the sealing resin part even when used in an environment with extremely large ambient temperature changes, thereby improving reliability.

[0013] Solutions to Problems

[0014] In order to solve the above-mentioned problems, a coil device is provided, comprising: a stator; a bobbin, which is made of resin material and has a bobbin body with a roughly cylindrical shape centered on an axis, and a flange portion extending radially outward from the bobbin body; a terminal for power supply, which is fixed to the above-mentioned flange portion; a coil, which is wound on the above-mentioned bobbin body and has a lap portion connected to the above-mentioned terminals at both ends; a sealing resin portion, which seals the above-mentioned bobbin including the above-mentioned flange portion, the above-mentioned coil including the above-mentioned lap portion, and the above-mentioned terminals; and a lap portion rupture suppression unit, which suppresses rupture of the above-mentioned lap portion, wherein the above-mentioned lap portion rupture suppression unit is provided with an axially opposing area of ​​the flange portion that is opposed to the above-mentioned lap portion in the axial direction to strengthen the adhesion between the above-mentioned sealing resin portion and the above-mentioned flange portion, so that the above-mentioned lap portion and the above-mentioned axially opposing area of ​​the flange portion are close to or abutted, and the above-mentioned bobbin has a smaller linear expansion coefficient than the above-mentioned sealing resin portion.

[0015] Furthermore, in the coil device, the contact reinforcing means may be a concave-convex portion or a surface modified portion provided in the axially opposing regions of the flange portion.

[0016] Furthermore, in the coil device described above, the concave-convex portion may extend in a direction intersecting the overlapped line portion when viewed in the axial direction.

[0017] In addition, in the above-mentioned coil device, the above-mentioned flange portion may have an axially orthogonal opposite area, and the axially orthogonal opposite area is opposite to the above-mentioned overlapped line portion in a direction orthogonal to the axis, and the above-mentioned overlapped line portion rupture suppression unit arranges the above-mentioned overlapped line portion in a non-contact state in the above-mentioned axially orthogonal opposite area of ​​the above-mentioned flange portion.

[0018] Furthermore, in the coil device, the jumper wire may include a winding portion wound around the terminal, and the jumper wire breakage suppression unit may fix only a front end of the winding portion to the terminal.

[0019] Furthermore, in the coil device, in the overlapped wire breakage suppression unit, the resin material forming the bobbin may be polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT) using glass fiber as a reinforcement or adding inorganic fillers to the glass fiber.

[0020] In addition, in the above-mentioned coil device, in the above-mentioned overlapped wire breakage suppression unit, when the resin material forming the above-mentioned bobbin and the resin material forming the above-mentioned sealing resin portion are the same material, the resin material forming the above-mentioned bobbin and the resin material forming the above-mentioned sealing resin portion may have a larger amount of the above-mentioned reinforcing agent added than the resin material forming the above-mentioned sealing resin portion.

[0021] Furthermore, in the coil device, the overlapped line breakage suppression unit may set a linear expansion coefficient of a resin material forming the bobbin so that a tension acting on the overlapped line at a use temperature is 40% or less of a breaking tension of the coil.

[0022] Furthermore, a flow rate regulating valve may include the coil device described above.

[0023] Effects of the Invention

[0024] According to the present invention, a coil device and a flow regulating valve equipped with the coil device can be provided, which can prevent the overlapping parts of the coil sealed by the sealing resin part from breaking due to expansion and contraction of the sealing resin part even when used in an environment with extremely large ambient temperature changes, thereby improving reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 A cross-sectional view of a flow rate regulating valve showing a first embodiment of the present invention is shown.

[0026] Figure 2 express Figure 1 The figure shows an explanatory diagram of the assembly process of the stator coil unit and the flow rate regulating valve body.

[0027] Figure 3 Indicates that Figure 1 The flow rate regulating valve is shown in a cross-sectional view in a state where it is mounted on a housing.

[0028] Figure 4 yes Figure 2 The illustrations show the bobbin forming process (lap wire breakage suppression unit (1)) in the assembly process of the coil device shown, where (a) is a top view of the first bobbin, (b) is a cross-sectional view of the first bobbin and the second bobbin, and (c) is a bottom view of the second bobbin.

[0029] Figure 5 express Figure 2 The figure shows an explanatory diagram of the bobbin assembly process (overlap wire breakage suppression unit (2)) in the assembly process of the coil device shown.

[0030] Figure 6 yes Figure 5 The illustrative diagram of the bobbin assembly shown, (a) is an upper perspective view, and (b) is a lower perspective view.

[0031] Figure 7 express Figure 2 The figure shows an explanatory diagram of the injection molding process (overlap wire breakage suppression unit (3)) in the assembly process of the coil device.

[0032] Figure 8 express Figure 21 and 2. The diagram shows an explanatory diagram of a connector sealing step and a stator assembly step in the assembly process of the coil device shown.

[0033] Figure 9 yes Figure 7 The enlarged view of the part shown, (a) shows the Figure 7 The region enclosed by the dotted line IXa shown in FIG. 1 shows the close contact reinforcing unit in Example 1 (b), and shows the close contact reinforcing unit in Example 2 (c).

[0034] Figure 10 A cross-sectional view of a flow rate regulating valve showing a second embodiment of the present invention is shown.

[0035] Figure 11 yes Figure 10 The illustrations of the coil device assembly process shown in the figure show a stator assembly process (a) and an injection molding process (overlap wire breakage suppression unit (1)).

[0036] Figure 12 express Figure 10 The figure shows an explanatory diagram of the bobbin assembly process (overlap wire breakage suppression unit (2)) in the assembly process of the coil device shown.

[0037] Figure 13 yes Figure 12 The illustrative diagram of the bobbin assembly shown, (a) is an upper perspective view, and (b) is a lower perspective view.

[0038] Figure 14 express Figure 10 1 and 2 are explanatory diagrams of a cover assembly process in the coil device assembly process shown.

[0039] Figure 15 yes Figure 10 The illustrations show an electrical component sealing step (bridging wire rupture suppression unit (3)) in the assembly process of the coil device shown, wherein (a) is an overall sectional view and (b) is an enlarged view of the area surrounded by the dotted line XVb shown in (a).

[0040] Figure 16 A cross-sectional view showing a conventional coil device.

[0041] In the picture:

[0042] 100a, 100b—flow regulating valve, 1a—valve port, 1b—side port, 2—valve chamber, 3—enclosed space, 10—flow regulating valve body, 20—support component, 21—fixed metal fitting, 21a—through hole, 23—threaded hole, 23a—internal threaded portion, 24—bearing hole, 25—sliding hole, 26—guide rail, 27—cylindrical portion, 30—connecting component, 30scm—external threaded screw-fitting portion, 40—valve body, 40scf—internal threaded screw-fitting portion, 40scm—external threaded screw-fitting portion, 41—insertion hole, 42—valve seat, 43—opening portion, 44—outer peripheral surface, 45—clamp engaging portion, 46—first annular groove, 47—second annular groove, 48—step portion, 50—drive shaft, 51—thread Part, 51a-external thread part, 52-guide part, 53-convex edge part, 60-valve core part, 61-valve frame, 61a-one end part, 61b-the other end part, 62-valve core, 63-gasket, 64-spring support, 65-compression coil spring, 70-coil component, 71-coil part, 72-claw part, 80-rotor unit, 81-shell part, 81a-recessed part, 82-magnetic rotor, 84-magnet part, 85-disc part, 86-metal fitting, 87-protrusion, 90, 90'-stator coil unit, 91-housing body, 91a-one end opening part, 91b-the other end opening part, 91c-seal component storage groove, 91e-cut part, 91f-storage space, 92-connector for control board, 93, 93'—coil device, 93a, 93a'—coil, 93a1, 93a1'—first coil (coil), 93a2, 93a2'—second coil (coil), 93a1c, 93a1c'—first lap portion, 93a1f, 93a1f'—first winding portion, 93a2c, 93a2c'—second lap portion, 93a2f, 93a2f'—second winding portion, 94, 94'—bobbin, 94a—first bobbin (bobbin), 94ab—first bobbin body (bobbin body), 94af—first flange portion (flange portion), 94af1—insertion hole, 94b—second bobbin (bobbin), 94bb—second bobbin body (bobbin body), 94bf—second flange portion (flange portion) ), 94bf1—insertion hole, 94f'—flange portion, 94f1'—insertion hole, 94f2'—insertion hole, 94'—bobbin, 94a'—bobbin body, 94Assy, 94'Assy—bobbin assembly, 95, 95'—stator, 95a, 95a'—first stator pole tooth portion, 95b, 95b'—second stator pole tooth portion, 95c, 95c'—first stator housing, 95d, 95d'—second stator housing, 95e'—third stator housing, 96a, 96a'—terminals, 96a1'—first terminal, 96a2'—second terminal, 96b—wire cover, 96c—connector, 96d—lead wire, 96e—connector resin portion, 96f'—substrate, 96g'—cover,96h—bracket, 96h1—convex portion, 97, 97'—sealing resin portion, 98—control substrate, 99—cover, AF—axially opposed regions, AOF—axially orthogonal opposed regions, Ar—adhesion reinforcement unit, Ar1, Ar2—concave and convex portions, E—longitudinal elastic modulus of the coil, Fp1—first flow path, Fp2—second flow path, G1—first receiving groove, G2—second receiving groove, G3—third receiving groove, H—housing, Hscf—internal thread Threaded portion, L—axis, Ly—length of the overlapped portion, O1—first shaft seal, O2—second shaft seal, Oc—housing body seal, Sc1—first threaded portion, Sc2—second threaded portion, Sh—threaded hole, T, T'—flange thickness, Ty—allowable tension of the coil, ΔLp—displacement of the bobbin due to temperature changes, ΔLty—displacement of the overlapped portion due to temperature changes, ΔLy—displacement of the overlapped portion when tension is allowed. DETAILED DESCRIPTION

[0043] Reference Figures 1 to 15 The embodiments of the present invention will be described in detail. However, the present invention is not limited to the embodiments of this invention. The following description uses an electric valve (electric flow control valve) as the flow control valve. However, the lap wire rupture suppression unit in the flow control valve of the present invention can also be applied to a solenoid valve (electromagnetic flow control valve, electromagnetic on-off valve, electromagnetic flow path switching valve) in place of the electric valve.

[0044] About Terminology

[0045] In this specification and claims, “left”, “right”, “upper” and “lower” mean Figures 1 to 3 、 Figure 4 (b) Figure 5 、 Figures 7 to 10 、 Figure 15In the direction shown. In this specification and claims, "one end" and "the other end" refer to the "lower end" and "upper end" in the figures. In this specification and claims, "axially opposing region" refers to the region of the flange portion that is axially opposing the overlapped portion, and refers to the region of the flange portion that at least overlaps with the overlapped portion when viewed axially. In this specification and claims, "arranging the overlapped portion and the axially opposing region of the flange portion so as to be close to or in contact with each other" means arranging the overlapped portion and the axially opposing region with a distance of 0 to less than approximately 0.2 mm. In this specification and claims, "axially orthogonally opposing region" refers to the region of the flange portion that is axially opposing the overlapped portion, and refers to the region of the flange portion that at least overlaps with the overlapped portion when viewed axially. In this specification and claims, "arranging the overlapped portion in a non-contact state in the axially orthogonally opposing region of the flange portion" means arranging the overlapped portion in a non-contact state with a gap therebetween in the axially orthogonally opposing region of the flange portion. In this specification and the claims, “pre-tension of the overlapped portion” means a tensile force generated in advance in the overlapped portion when the overlapped portion is connected to the terminal and when the sealing resin portion is molded and shrunk.

[0046] (First embodiment)

[0047] <About the structure of the flow control valve>

[0048] use Figure 1 as well as Figure 2 , the flow control valve 100a according to the first embodiment of the present invention will be described. Figure 2 As shown, the flow rate regulating valve 100a is composed of a flow rate regulating valve body 10 and a stator coil unit 90. Hereinafter, each structure of the flow rate regulating valve 100a will be described in sequence.

[0049] <About the flow control valve body>

[0050] First, if Figure 1 As shown, the flow control valve body 10 is mainly composed of a support member 20, a connecting member 30, a valve body 40, a drive shaft 50, a valve core 60, a coil member 70, and a rotor unit 80. Hereinafter, each structure of the flow control valve body 10 will be described in sequence.

[0051] Here, the details will be described later. In the first embodiment, by simultaneously adopting the overlapping line portion fracture suppression unit (1), the overlapping line portion fracture suppression unit (2), and the overlapping line portion fracture suppression unit (3), the conventional problem (the conventional problem (the fracture of the overlapping line portion due to temperature change)) can be eliminated and the reliability can be improved. In addition, as Figure 9As shown in (a), the overlapped line breakage suppression means (1) is provided with a close contact reinforcement means Ar in the axially opposed region AF of the flanges 94af and 94bf. Furthermore, the overlapped line breakage suppression means (2) is arranged so that the overlapped lines 93a1c and 93a2c are close to or in contact with the axially opposed region AF of the flanges 94af and 94bf. Furthermore, in the overlapped line breakage suppression means (3), the bobbin 94 has a smaller linear expansion coefficient than the sealing resin portion 97.

[0052] The support member 20 has a generally cylindrical shape and is constructed from a resin material such as polyphenylene sulfide (PPS). A fixing metal fitting 21 is integrally insert-molded into one end of the support member 20. The fixing metal fitting 21, constructed from a metal material such as stainless steel, has a circular ring shape with its inner periphery curved toward one end in the direction of the axis L. At least one through-hole 21a is defined in the region where the fixing metal fitting 21 is embedded within the support member 20. When the fixing metal fitting 21 is insert-molded into the support member 20, the resin material solidifies while filling the at least one through-hole 21a, thereby enhancing the joint strength.

[0053] In addition, the support member 20 is configured so that its axis overlaps with the axis L. In the center of the support member 20, a threaded hole 23, a bearing hole 24, and a sliding hole 25 are formed on concentric circles along the axis L in a manner that penetrates the support member 20. An internal threaded portion 23a is formed on the inner circumference of the threaded hole 23, and an external threaded portion 51a of the drive shaft 50 described later is threadedly engaged. The guide portion 52 of the drive shaft 50 described later can be slidably engaged with the inner circumference of the bearing hole 24. The sliding hole 25 is configured on one end side and is formed to have a larger diameter than the bearing hole 24. The valve core portion 60 described later can be slidably engaged with the sliding hole 25.

[0054] A guide rail 26 composed of spiral protrusions is integrally formed on the outer peripheral surface of the other end side of the support member 20. Adjacent winding portions of the guide rail 26 are arranged with intervals therebetween. The guide rail 26 is arranged so that its axis overlaps with the axis L, and the coil portion 71 of the coil member 70 described later is threadedly engaged, guiding each winding portion of the coil portion 71 from one side or both sides so that the coil member 70 can rotate in the circumferential direction.

[0055] Furthermore, a cylindrical portion 27 is integrally formed at one end of the support member 20. The outer circumference of the cylindrical portion 27 tapers toward one end in the direction of the axis L, allowing insertion into an insertion hole 41 of the valve body 40, described later. A portion of the outer circumference of the cylindrical portion 27 has a shape corresponding to the insertion hole 41 of the valve body 40.

[0056] The connecting member 30 has a generally cylindrical shape with its inner circumference tapering toward one end in the direction of the axis L. It is made of a metal material such as stainless steel, for example. An externally threaded portion 30scm, constituting a first threaded portion Sc1, is formed on the outer circumference of one end. This portion is threadedly secured to an internally threaded portion 40scf of the valve body 40, described later. Furthermore, the other inner circumferential end of the connecting member 30 is secured to the support member 20 via a fixing metal fitting 21 joined by arc welding or the like.

[0057] The valve body 40 is made of a metal material such as aluminum, and an insertion hole 41 and a valve port 1a are formed concentrically along the axis L in a manner penetrating the valve body 40. The insertion hole 41 and the valve port 1a define the valve chamber 2. A valve seat 42 is formed on the inner peripheral edge of the boundary between the insertion hole 41 and the valve port 1a. In addition, an opening 43 is formed on the side wall of the valve body 40, which defines the side port 1b and communicates with the valve chamber 2. Furthermore, the outer peripheral surface 44 of the valve body 40 is formed with: a clamp engaging portion 45 having a shape having two parallel surfaces or a hexagonal shape when viewed from the axis L and protruding radially outward; a first annular groove 46 that accommodates the first shaft seal component O1; an externally threaded screw portion 40scm that constitutes the second screw portion Sc2; and a second annular groove 47 that accommodates the second shaft seal component O2. Here, a female screwing portion 40scf constituting a first screwing portion Sc1 is formed on the inner circumference of the clamp engagement portion 45 and is screwed and fixed to the male screwing portion 30scm of the connection member 30. Thus, the valve body 40 is fixed to the support member 20 via the connection member 30.

[0058] The drive shaft 50 is formed into a cylindrical rod shape using a metal such as stainless steel as a material. A threaded portion 51, a guide portion 52, and a flange portion 53 arranged at one end of the guide portion 52 are formed side by side on the drive shaft 50 along the axis L direction. An external threaded portion 51a is formed on the threaded portion 51, and the external threaded portion 51a is threadedly engaged with the internal threaded portion 23a of the support member 20, so that the rotational motion of the drive shaft 50 is converted into linear motion. The guide portion 52 can be slidably engaged with the inner circumferential surface of the bearing hole 24, thereby guiding the movement of the drive shaft 50 along the axis L direction. The drive shaft 50 moves along the axis L direction by utilizing a thread feed action based on rotation. The flange portion 53 can rotatably lock the valve core portion 60 described later. In addition, in the first embodiment, the internal threaded portion 23a and the external threaded portion 51a are right-hand threads.

[0059] The valve body portion 60 includes a valve holder 61 , a valve body 62 , a washer 63 , a spring retainer 64 , and a compression coil spring 65 .

[0060] The valve holder 61 is formed in a cylindrical shape with an outer diameter substantially equal to the inner diameter of the sliding hole 25 of the support member 20. The valve holder 61 is engaged along the sliding hole 25 so as to be slidable in the axis L direction.

[0061] The valve core 62 has a frustoconical shape at one end, and the front end of the frustoconical shape is fixed to one end 61a of the valve frame 61 so as to face the valve port 1a. The valve core 62 adjusts the flow rate by increasing or decreasing the opening between the valve port 1a and the valve seat 42 from the maximum valve opening to the minimum valve opening (or fully closed state).

[0062] The flange 53 of the drive shaft 50 is rotatably secured to the other end 61b of the valve frame 61. Specifically, a washer 63 is sandwiched between the flange 53 of the drive shaft 50 and the other end 61b of the valve frame 61. The drive shaft 50 utilizes this flange 53 to rotatably engage the other end 61b of the valve frame 61. This engagement allows the valve frame 61 to be supported by the drive shaft 50 so that it can move along the axis L and rotate about the axis L. Furthermore, an opening is formed at the other end 61b of the valve frame 61 that is larger than the radial movable range of the drive shaft 50. Furthermore, a spring support 64 is provided within the valve frame 61 so that it can move along the axis L. A compression coil spring 65 is installed between this spring support 64 and the valve core 62 in a compressed state that applies a predetermined load. This biases the spring support 64 toward its other end, causing it to abut against one end of the drive shaft 50.

[0063] The coil component 70 integrally includes a coil portion 71 in the shape of a helical spring and a claw portion 72 that protrudes radially outward from one end of the coil portion 71. The coil portion 71 is screwed to the guide rail 26 of the support member 20 so as to be rotatable in the circumferential direction. The coil component 70 can be easily manufactured by forming a metal wire such as stainless steel.

[0064] The rotor unit 80 includes a housing 81 and a magnetic rotor 82 .

[0065] The shell 81 is made of a metal material such as stainless steel and has a generally bottomed cylindrical shape with its upper end blocked. The open end of one end of the shell 81 is airtightly joined to the other end of the outer periphery of the connecting member 30 by arc welding or the like, thereby defining the closed space 3. Figure 2 As shown, at least one recessed portion 81a recessed in the inner diameter direction is formed on the same circumference of the outer peripheral surface on one end side of the shell portion 81. This recessed portion 81a can engage with a protrusion 96h1 of the coil device 93 described later.

[0066] The magnetic rotor 82 integrally comprises a cylindrical magnet portion 84 with a multi-pole magnetized outer periphery, a disk portion 85 that closes its other end, and a protrusion 87. The magnetic rotor 82 is secured to the drive shaft 50 via a metal fitting 86 insert-molded into the center of the disk portion 85. Thus, the magnetic rotor 82 is rotatably disposed within the housing 81 about the axis L of the drive shaft 50. The protrusions 87 of the magnetic rotor 82 can abut against the claws 72 of the coil member 70. Rotation of the magnetic rotor 82 thereby pushes the coil member 70 circumferentially via the claws 72. This causes the coil member 70 to abut against an upper limit stopper (not shown) or a lower limit stopper (not shown), restricting the rotation of the coil member 70 and, consequently, the rotation of the magnetic rotor 82. This restricts movement of the valve core 60 beyond the maximum opening position or the minimum opening position (or closed valve state).

[0067] When the magnetic rotor 82 rotates, the drive shaft 50 rotates along with it. The threaded action created by the external thread 51a and the internal thread 23a causes the drive shaft 50 to move in the direction of the axis L, causing the valve core 60 to advance and retract relative to the valve port 1a. This changes the opening between the valve port 1a and the valve seat 42, controlling the flow rate of fluid flowing from the valve port 1a to the side port 1b (or vice versa).

[0068] <About the stator coil unit>

[0069] Then, if Figure 1 as well as Figure 2 As shown, the stator coil unit 90 mainly comprises a housing body 91, a control board connector 92, a coil device 93, a control board 98, and a cover 99. Hereinafter, each structure of the stator coil unit 90 will be described in sequence.

[0070] The housing body 91 is made of a resin material such as polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT). Figure 2 As shown, the flow control valve body 10 has a first opening 91a at one end, into which the flow control valve body 10 can be fitted, and a second opening 91b at the other end, which is sealed by a cover 99. The inner diameter increases along the axis L from the first opening 91a toward the second opening 91b. A seal member receiving groove 91c for receiving the housing body seal member Oc is provided on the inner circumference of one end of the first opening 91a. A notch 91e extending along the axis L is provided on the inner circumference of the other end of the first opening 91a.

[0071] The control board connector 92 is used as a power supply terminal for the control board 98 and is integrally formed by insert molding on the other end side of the housing body 91 .

[0072] like Figure 2As shown, the coil device 93 includes: a stator 95 having an annular shape; a bobbin 94 assembled to the stator 95; a coil 93a wound around the outer periphery of the bobbin 94; and a bobbin assembly 94Assy (see FIG. 1 ) which is assembled to the bobbin 94 and comprises a power supply terminal 96a connected to the coil 93a. Figure 6 ). In addition, the coil device 93 includes: a wire sheath 96b installed to protect the terminal 96a; a sealing resin portion 97 that seals the wire sheath 96b and the outer periphery of the bobbin assembly 94Assy; a connector 96c and a lead 96d installed on the terminal 96a; a connector resin portion 96e that seals the connector 96c; and a bracket 96h that protrudes to one end side. The stator 95 is made of a metal material such as SEC (electrogalvanized steel plate), and has a first stator pole tooth portion 95a, a second stator pole tooth portion 95b, a first stator housing 95c, and a second stator housing 95d, and the details will be described later. In addition, the bobbin 94 is made of a resin material such as polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT), and has a first bobbin 94a and a second bobbin 94b. The resin material forming the bobbin 94 may also be polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT) reinforced with glass fiber or with inorganic fillers added to the glass fiber. (Details will be described later.) This reduces the linear expansion coefficient of the bobbin 94 and reliably suppresses expansion and contraction caused by temperature changes in the sealing resin portion 97. Furthermore, the coil 93a is made of a metal material such as copper and includes a first coil 93a1 and a second coil 93a2. This coil device 93 rotates the magnetic rotor 82 in accordance with the number of pulses supplied by the external pulse signal.

[0073] In addition, if Figure 2 As shown, a protrusion 96h1 protruding in the inner radial direction is formed on a bracket 96h of the coil device 93. The bracket 96h engages with the cutout 91e of the housing body 91, thereby positioning the coil device 93 in the circumferential direction relative to the housing body 91.

[0074] The control substrate 98 is mounted with electronic components such as semiconductor elements, IC chips, etc. Figure 2 As shown, it is fixed to the housing body 91. The control board 98 is electrically connected to the coil 93a via the connector 96c and the lead wire 96d, and controls the driving signal.

[0075] The cover 99 is made of a resin material such as polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT). Figure 2 As shown, the coil assembly 93 is fitted and fixed to the other end opening 91b of the housing body 91. Thus, a storage space 91f is defined between the cover 99 and the coil assembly 93 in the housing body 91.

[0076] <Assembly process of the stator coil unit and the flow control valve body>

[0077] use Figure 2 , the assembly process of the stator coil unit 90 and the flow control valve body 10 will be described. By implementing the following assembly process, Figure 1 The flow regulating valve 100a is shown.

[0078] To assemble the stator coil unit 90 into the flow control valve body 10, the stator coil unit 90 is moved relative to the flow control valve body 10 toward the axis L, and the protrusion 96h1 of the bracket 96h of the coil assembly 93 is engaged with one of the plurality of recesses 81a provided on the same circumference of the outer circumference of the shell 81. Simultaneously, the housing body seal member Oc is sandwiched between the seal member receiving groove 91c of the one-end opening 91a and the outer circumference of the connecting member 30, thereby sealing the receiving space 91f from the external environment.

[0079] <About Mounting the Flow Control Valve to the Housing>

[0080] use Figure 3 , the process of mounting the flow regulating valve 100a to the housing H will be described.

[0081] <About the housing>

[0082] The housing H is made of a metal material such as aluminum, and has a through hole formed along the axis L with a plurality of annular steps that gradually decrease in diameter from the other end to the one end. The plurality of annular steps are formed in sequence with a first receiving groove G1, a second receiving groove G2, and a third receiving groove G3. Here, the third receiving groove G3 is formed with a side ( Figure 3 The first flow path Fp1 is connected to the left side of the second receiving groove G2, and a second flow path Fp2 is formed with the side ( Figure 3 In addition, on the side wall of the housing H ( Figure 3 A threaded hole Sh is formed in the left wall of the housing H close to the first flow path Fp1, and a first pipe (not shown) is installed in the threaded hole Sh via a sealing joint (not shown) and a fastening bolt (not shown), thereby connecting the first pipe to the first flow path Fp1. Figure 3 A threaded hole Sh is formed on the right wall of the second flow path Fp2 close to the second flow path, and a second pipe (not shown) is installed in the threaded hole Sh via a sealing joint (not shown) and a connecting bolt (not shown), thereby connecting the second pipe to the second flow path Fp2 fluid.

[0083] Furthermore, in the first embodiment, Figure 3The shape of the housing H shown in the figure has been described, but this is just an example, and the housing H may have any shape as long as it has an insertion hole and an outer shape that allows the flow regulating valve 100a to be inserted through the insertion hole.

[0084] <About the installation process>

[0085] The installation process of the flow control valve 100a into the housing H will be described. The valve body 40 of the flow control valve 100a is inserted into the first receiving groove G1 of the housing H along the axis L. Then, using a jig such as a wrench (not shown), the valve body 40 is engaged with the outer circumference of a jig engaging portion 45 having two parallel surfaces or a hexagonal shape. The valve body 40 is rotated, threading the externally threaded portion 40scm of the valve body 40 into the internally threaded portion Hscf of the housing H. The valve body 40 is then moved toward one end along the axis L until the step 48 of the valve body 40 abuts against the step between the first receiving groove G1 and the second receiving groove G2 in the housing H. In this installed state of the flow control valve 100a, the valve port 1a defined by the valve body 40 communicates with the first flow path Fp1, which introduces primary pressure, and the side port 1b defined by the valve body 40 communicates with the second flow path Fp2, which introduces secondary pressure. At this time, the second shaft sealing component O2 is clamped between the third receiving groove G3 and the second annular groove 47 of the valve body 40, the second receiving groove G2 and the third receiving groove G3 are sealed, and the first shaft sealing component O1 is clamped between the first receiving groove G1 and the first annular groove 46, and the first receiving groove G1 and the external environment are sealed.

[0086] <Regarding the existing problem (breakage of the lap joint due to temperature changes)>

[0087] As mentioned above, in Figure 16 In the conventional coil device 1600 shown, when used in an environment with extremely large temperature changes, the sealing resin portion 1697 repeatedly expands and contracts, and the lap portion of the coil 1693a is tightly fixed to the sealing resin portion 1697, so that tensile and compressive forces are also repeatedly applied to the lap portion. The wire diameter of the coil 1693a is generally small. Therefore, the strength of the lap portion of the coil 1693a is also small. As a result, the lap portion cannot withstand the forced deformation from the outside caused by the expansion and contraction of the sealing resin portion 1697, and has existing problems (fracture of the lap portion due to temperature changes), so there is a concern about reduced reliability.

[0088] In contrast, in the first embodiment, the existing problem (fracture of the overlapped line caused by temperature change) is eliminated by simultaneously adopting a lapped line fracture suppression unit (1) (a tight-fitting reinforcement unit provided in the axially opposing area of ​​the flange portion), a lapped line fracture suppression unit (2) (arranging the lapped line portion and the axially opposing area of ​​the flange portion close to or in contact with each other), and a lapped line fracture suppression unit (3) (the linear expansion coefficient of the bobbin is smaller than that of the sealing resin portion).

[0089] <About the Coil Device Assembly Process>

[0090] Here, use Figures 4 to 8 The assembly process of the coil device 93 (the bobbin forming process, the bobbin assembly process, the injection molding process, the connector sealing process, and the stator assembly process) is described. The details will be described later. The overlapping wire breakage suppression unit (1) (a tightness reinforcement unit provided in the axially opposed region of the flange portion), the overlapping wire breakage suppression unit (2) (arrangement of the overlapping wire portion and the axially opposed region of the flange portion close to or in contact with each other), and the overlapping wire breakage suppression unit (3) (the linear expansion coefficient of the bobbin is smaller than that of the sealing resin portion) in the assembly process are described.

[0091] <About the bobbin forming process (overlap wire breakage suppression unit (1))>

[0092] use Figure 4 The bobbin forming process will be described. The bobbin 94 includes a first bobbin 94a and a second bobbin 94b, and is made of a resin material such as polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT), and is resin-molded.

[0093] like Figure 4 As shown in (a) and (b), the first bobbin 94a comprises: a first bobbin body 94ab having a substantially cylindrical shape and a pair of annular flanges at both ends in the direction of the axis L; and a first flange 94af extending radially from the flange at one end of the first bobbin body 94ab. The first flange 94af is provided with a terminal 96a (see Figure 5 ) is inserted into the first insertion hole 94af1 and has a flange portion thickness T.

[0094] Likewise, Figure 4 As shown in (b) and (c), the second bobbin 94b comprises: a second bobbin body 94bb having a substantially cylindrical shape and a pair of annular flanges at both ends in the direction of the axis L; and a second flange 94bf extending radially from the flange at the other end of the second bobbin body 94bb. A terminal 96a (see Figure 5) is inserted into the second insertion hole 94bf1 and has a flange portion thickness T.

[0095] Here, the details will be described later. As the overlap line fracture suppression unit (1), a close reinforcement unit Ar is provided on the other side of the first flange portion 94af and on one side of the second flange portion 94bf (see Figure 4 (a) and (c) of the dot pattern) (e.g., the concave and convex portion (see Figure 9 (b), (c)), surface modified portion, etc.).

[0096] The close contact reinforcement unit Ar is used in the injection molding process described later (see Figure 9 In (a)), the anchoring effect between the sealing resin portion 97 and the first flange portion 94af and the second flange portion 94bf is significantly improved, and the adhesion is strengthened, thereby suppressing the breakage of the first overlap line portion 93a1c and the second overlap line portion 93a2c.

[0097] <About the bobbin assembly process (lap wire breakage suppression unit (2))>

[0098] use Figure 5 First, insert the L-shaped terminal 96a (see FIG. 1 ) into the first insertion hole 94af1 of the first flange portion 94af and the second insertion hole 94bf1 of the second flange portion 94bf. Figure 5 Then, the first coil 93a1 and the second coil 93a2 are wound around the outer peripheries of the first bobbin body 94ab and the second bobbin body 94bb, respectively (see Figure 5 A2 in FIG. Furthermore, first and second jumper wires 93a1c, 93a2c at the ends of first and second coils 93a1, 93a2 are connected to terminal 96a via first and second windings 93a1f, 93a2f, respectively (e.g., soldered). Alternatively, the L-shaped bending of terminal 96a can be performed after inserting the flat terminal 96a into first and second insertion holes 94af1, 94bf1, and connecting first and second jumper wires 93a1c, 93a2c to terminal 96a.

[0099] Here, as will be described in detail later, as the overlap line portion breakage suppression means (2), the first overlap line portion 93a1c and the second overlap line portion 93a2c are respectively arranged close to or in contact with the other side surface of the first flange portion 94af and one side surface of the second flange portion 94bf. The positions where the first overlap line portion 93a1c and the second overlap line portion 93a2c are arranged become the positions in the injection molding process described later (refer to Figure 9In (a)), the anchoring effect of the sealing resin portion 97 is significantly enhanced by the overlapped line breakage suppression unit (1), thereby suppressing breakage of the first overlapped line 93a1c and the second overlapped line 93a2c.

[0100] Furthermore, if Figure 5 As shown, the first stator tooth portion 95a and the second stator tooth portion 95b are assembled on the first bobbin 94a and the second bobbin 94b, respectively, and the first flange portion 94af of the first bobbin 94a is joined to the second flange portion 94bf of the second bobbin 94b (see Figure 5 At this time, a portion of the first stator tooth portion 95a and the second stator tooth portion 95b is covered by the first bobbin body 94ab and the second bobbin body 94bb.

[0101] Therefore, if Figure 6 As shown, the bobbin assembly 94Assy is constituted. In the bobbin assembly 94Assy, as the overlapped line breakage suppression unit (1), a close-fitting reinforcement unit Ar is provided on the other side of the first flange portion 94af and on one side of the second flange portion 94bf (see Figure 6 (a) and (b) dot pattern). In addition, as the overlapped line breakage suppression means (2), the first overlapped line 93a1c and the second overlapped line 93a2c are arranged close to or in contact with the other side surface of the first flange portion 94af and the one side surface of the second flange portion 94bf. In addition, in the first embodiment, the first overlapped line 93a1c and the second overlapped line 93a2c are eight in total, and the terminal 96a has two universal terminals in the center, so the total number is six, but the number of overlapped lines and terminals is not limited to this.

[0102] <About the injection molding process (lap line fracture suppression unit (3))>

[0103] use Figure 7 First, in order to protect the terminal 96a of the bobbin assembly 94Assy, the wire sheath 96b is assembled to the terminal 96a (refer to Figure 7 Then, the bobbin assembly 94Assy equipped with the wire sheath 96b is injection molded by a molding die, and the outer periphery of the wire sheath 96b and the bobbin assembly 94Assy (see Figure 7 The sealing resin portion 97 is sealed by A5 in FIG. The sealing resin portion 97 is made of a thermoplastic resin material such as polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT). At this time, the peripheries of the first overlapped line portion 93a1c and the second overlapped line portion 93a2c are also simultaneously adhered and fixed to the sealing resin portion 97.

[0104] Here, the details will be described later. As a lap line breakage suppression unit (3), the linear expansion coefficients of the first bobbin 94a and the second bobbin 94b are set smaller than the linear expansion coefficient of the sealing resin portion 97, thereby suppressing the breakage of the first lap line portion 93a1c and the second lap line portion 93a2c.

[0105] Connector Sealing and Stator Assembly

[0106] use Figure 8 , the connector sealing process and the stator assembly process are described. First, the connector 96c and the lead wire 96d are assembled to the terminal 96a (refer to Figure 8 Next, a molding resin (e.g., a thermosetting resin material such as epoxy resin or polyurethane resin) is injected around the connector 96c and heated to cure, thereby providing the connector resin portion 96e (see arrow A6 in FIG). Figure 8 Then, the first stator housing 95c and the second stator housing 95d are assembled to the bobbin assembly 94Assy, and the mating portions of the first stator housing 95c and the second stator housing 95d are spot welded at multiple locations (see Figure 8 A8 arrow in the middle)

[0107] <About overlap line fracture suppression units (1) to (3)>

[0108] use Figure 9 (a) of the embodiment of the present invention will further describe the overlapping line fracture suppression units (1) to (3) in detail. First, the overlapping line fracture suppression unit (1) is provided with a bonding reinforcement unit Ar (see FIG. 1 ) for strengthening the bonding between the sealing resin portion 97 and the first flange portion 94af and the second flange portion 94bf in the axial direction opposing region AF which is opposed to the first overlapping line portion 93a1c and the second overlapping line portion 93a2c in the axial direction L direction. Figure 9 In addition, the overlap line rupture suppression means (2) makes the first overlap line 93a1c and the second overlap line 93a2c close to or in contact with the axially opposed regions AF of the first flange 94af and the second flange 94bf, respectively. Furthermore, the overlap line rupture suppression means (3) makes the linear expansion coefficients of the first bobbin 94a and the second bobbin 94b smaller than the linear expansion coefficient of the sealing resin portion 97.

[0109] Thus, in the first embodiment, as Figure 9As shown in (a), according to the overlapped line breakage suppression means (1) and (2), the anchoring effect of the sealing resin portion 97 to the axially opposed region AF of the first flange portion 94af and the second flange portion 94bf is significantly improved, and the first overlapped line portion 93a1c and the second overlapped line portion 93a2c are arranged in the region where the anchoring effect of the sealing resin portion 97 is significantly improved. In addition, at the same time, according to the overlapped line breakage suppression means (3), the expansion and contraction of the first flange portion 94af and the second flange portion 94bf due to temperature changes are smaller than those of the sealing resin portion 97. Therefore, even when the coil device 93 is used in an environment where the ambient temperature changes greatly, the sealing resin portion 97 tightly fixed to the first overlapped line portion 93a1c and the second overlapped line portion 93a2c is suppressed from expanding and contracting due to temperature changes due to the anchoring effect on the first flange portion 94af and the second flange portion 94bf. As a result, the first overlapping line portion 93a1c and the second overlapping line portion 93a2c that are closely fixed to the sealing resin portion 97 can be suppressed from being broken, thereby improving reliability.

[0110] As described above, in the first embodiment, by simultaneously adopting a lap line fracture suppression unit (1) (a tight-fitting reinforcement unit provided in the axially opposing area of ​​the flange portion), a lap line fracture suppression unit (2) (arranged so that the lap line portion and the axially opposing area of ​​the flange portion are close to or in contact with each other), and a lap line fracture suppression unit (3) (the linear expansion coefficient of the bobbin is smaller than that of the sealing resin portion), the existing problem point (fracture of the lap line portion caused by temperature change) can be eliminated and reliability can be improved.

[0111] Furthermore, the inventors have conducted diligent research and further studied the structures of the respective overlapping line breakage suppression units (1) to (3), attempting to further suppress the breakage of the first overlapping line 93a1c and the second overlapping line 93a2c.

[0112] <Study on the unit for suppressing the fracture of the overlapped line (1)>

[0113] Here, as a structure for concretizing the adhesion strengthening unit Ar in the overlap line fracture suppression unit (1), the overlap line fracture suppression unit (1-1) (concave-convex portion, surface modification portion) is shown, and as a structure for further improving the anchoring effect of the concave-convex portion, the overlap line fracture suppression unit (1-2) (the concave-convex portion and the overlap line intersect) is shown.

[0114] <About the Line Breakage Suppression Unit (1-1)>

[0115] The overlap line fracture suppression unit (1-1) is a structure that concretizes the adhesion strengthening unit Ar in the overlap line fracture suppression unit (1), and a concave-convex portion and a surface modification portion are provided in the axially opposing areas AF of the first flange portion 94af and the second flange portion 94bf as the adhesion strengthening unit Ar.

[0116] <Bridge breakage suppression unit (1-1) (concave-convex portion)>

[0117] like Figure 9 As shown in (b) and (c), the overlapped wire breakage suppression unit (1-1) (concave-convex portion) is a resin-molded bobbin 94 (refer to Figure 2 ) are formed by mechanical embossing on the other side of the first flange portion 94af and one side of the second flange portion 94bf to form a groove Ar1 with a V-shaped cross-sectional shape and a groove Ar2 with a U-shaped cross-sectional shape. In addition, as another example, although the overlapping line breakage suppression unit (1-1) (convex and concave portion) is omitted in the figure, it is a concave and convex portion formed as a resin molded product by performing pleating on the portion corresponding to the other side of the first flange portion 94af and one side of the second flange portion 94bf in the molding die of the resin-molded bobbin 94. In this way, as the adhesion reinforcement unit Ar in the overlapping line breakage suppression unit (1), by adopting the overlapping line breakage suppression unit (1-1) (convex and concave portion), there is no need to make a major process change in the assembly process of the coil device 93, and it can be handled by only incorporating an additional process for forming the concave and convex portion, thereby reducing the manufacturing cost.

[0118] Here, the concave-convex portion Ar1 having a V-shaped cross-sectional groove, the concave-convex portion Ar2 having a U-shaped cross-sectional groove, and the concave-convex portion formed by pleating the forming mold as the overlap line fracture suppression means (1-1) preferably have an average depth of 1% to 10% of the flange thickness T, or an arithmetic mean roughness Ra that satisfies the range of 5≤Ra≤400. Thus, even when the coil device 93 is used in an environment where the ambient temperature fluctuates greatly, excessive stress concentration and cracking caused by the concave-convex portion can be suppressed on the first flange portion 94af and the second flange portion 94bf. In addition, due to the anchoring effect generated by the concave-convex portion, expansion and contraction caused by temperature changes in the sealing resin portion 97 tightly fixed to the first overlap line portion 93a1c and the second overlap line portion 93a2c can be reliably suppressed.

[0119] In the first embodiment, in the overlapped line breakage suppression unit (1-1) (convex-concave portion), as the adhesion reinforcement unit Ar, a concave-convex portion Ar1 having a groove with a V-shaped cross-sectional shape, a concave-convex portion Ar2 having a groove with a U-shaped cross-sectional shape, and a concave-convex portion formed as a resin molded product by pleating the forming mold are used, but it is not limited to this. For example, a concave-convex portion having a groove with a different cross-sectional shape and a concave-convex portion formed by pleating the resin-molded bobbin 94 may also be used.

[0120] <Bridge fracture suppression unit (1-1) (surface modification unit)>

[0121] Furthermore, although not shown in the figure, the overlapped line breakage suppression unit (1-1) (surface modification unit) is a surface modification unit formed by irradiating the other side surface of the first flange portion 94af and one side surface of the second flange portion 94bf in the resin-molded bobbin 94 with ultraviolet light and applying a primer. Thus, by adopting the overlapped line breakage suppression unit (1-1) (surface modification unit) as the adhesion reinforcement unit Ar in the overlapped line breakage suppression unit (1), it is not necessary to make a major change in the assembly process of the coil device 93. This can be achieved by simply incorporating an additional process for forming the surface modification unit, thereby reducing manufacturing costs.

[0122] <About the overlapped line fracture suppression unit (1-2) (intersection of the concave-convex portion and the overlapped line)>

[0123] The overlap line fracture suppression unit (1-2) (the concave-convex portion intersects the overlap line) is configured such that the concave-convex portions Ar1 and Ar2 of the overlap line fracture suppression unit (1-1) (the concave-convex portion) extend in directions intersecting the first overlap line 93a1c and the second overlap line 93a2c, respectively, as viewed from the axis L. This further enhances the anchoring effect of the concave-convex portions Ar1 and Ar2 extending in the directions of the first overlap line 93a1c and the second overlap line 93a2c, thereby more reliably suppressing expansion and contraction caused by temperature changes in the sealing resin portion 97 that is tightly fixed to the periphery of the first overlap line 93a1c and the second overlap line 93a2c.

[0124] <Study on the unit for suppressing the fracture of the overlapped line (2)>

[0125] Here, in the jumper wire breakage suppression unit (2), when the first jumper wire 93a1c and the second jumper wire 93a2c are connected to the terminal 96a, in order to avoid applying pre-tension to the first jumper wire 93a1c and the second jumper wire 93a2c as much as possible, the processing and connection structure of the first jumper wire 93a1c and the second jumper wire 93a2c are studied, and a jumper wire breakage suppression unit (2-1) (the jumper wire is non-contactly arranged in the area opposite to the axis in the direction orthogonal to the axis) and a jumper wire breakage suppression unit (2-2) (only the front end of the winding portion of the jumper wire is fixed) are shown.

[0126] <About the overlapping line fracture suppression unit (2-1) (the overlapping line is arranged in a non-contact manner in the region facing each other in the direction perpendicular to the axis)>

[0127] like Figure 9 As shown in (a), the lap wire breakage suppression unit (2-1) (lap wires arranged in a non-contact manner in the area opposite to the axis) arranges the first lap wire 93a1c and the second lap wire 93a2c in a non-contact manner in the area opposite to the axis in the first flange 94af and the second flange 94bf in the area opposite to the axis AOF. As a result, the first lap wire 93a1c and the second lap wire 93a2c can be connected to the terminal 96a in a state of being bent in a direction perpendicular to the axis L. Therefore, when the first lap wire 93a1c and the second lap wire 93a2c are connected to the terminal 96a and in the injection molding process (refer to Figure 7 ) When the sealing resin portion 97 is molded and shrunk, it is possible to suppress the application of pretension to the first overlapping line portion 93a1c and the second overlapping line portion 93a2c.

[0128] <About the overlapped line breakage suppression unit (2-2) (fixing only the front end of the winding portion of the overlapped line)>

[0129] like Figure 9 As shown in (a), the lap wire breakage suppression unit (2-2) (fixing only the front end of the winding portion of the lap wire) fixes only the front end of the first winding portion 93a1f and the second winding portion 93a2f when connecting the first lap wire 93a1c and the second lap wire 93a2c to the terminal 96a. Figure 9 (a) only the right side of 93a1f and 93a2f), and the remaining winding portion is in a state that can be freely deformed in the direction perpendicular to the axis L. As a result, the first lap wire portion 93a1c and the second lap wire portion 93a2c can be connected to the terminal 96a in a state of being bent in the direction perpendicular to the axis L. Therefore, when the first lap wire portion 93a1c and the second lap wire portion 93a2c are connected to the terminal 96a and during the injection molding process (refer to Figure 7) When the sealing resin portion 97 is molded and shrunk, it is possible to suppress the application of pretension to the first overlapping line portion 93a1c and the second overlapping line portion 93a2c.

[0130] <Research on the unit for suppressing the fracture of the overlapped line (3)>

[0131] Here, in the overlapped wire portion rupture suppression unit (3), as a specific scheme for making the linear expansion coefficient of the bobbin 94 smaller than the linear expansion coefficient of the sealing resin portion 97, a overlapped wire portion rupture suppression unit (3-1) (adding a reinforcing agent to the bobbin), a overlapped wire portion rupture suppression unit (3-2) (the bobbin and the sealing resin portion are made of the same material, and more reinforcing agent is added to the bobbin than to the sealing resin portion), and a overlapped wire portion rupture suppression unit (3-3) (the linear expansion coefficient of the bobbin is less than 40% of the breaking tension of the coil) are shown.

[0132] Comparative evaluation of overlapped line fracture suppression units (3-1) and (3-2)

[0133] Here, in order to determine the quality of the overlapped line fracture suppression means (3-1) and (3-2) in preventing fractures in the overlapped line portions 93a1c and 93a2c, a comparative evaluation was conducted on the bobbin 94 and the sealing resin portion 97 in the coil device 93 shown in Table 1 based on the type of resin material, the presence or absence of a reinforcing agent (linear expansion coefficient), and the presence or absence of a close contact reinforcement means. Furthermore, under any of the conditions in Table 1, both the overlapped line fracture suppression means (2) (arranged so that the overlapped line portion and the axially opposed region of the flange portion are close to or in contact with each other) and the overlapped line fracture suppression means (3) (the linear expansion coefficient of the bobbin is smaller than that of the sealing resin portion) were present.

[0134] The following describes the description of Table 1. "Cu" and "α" in Table 1 represent "soft copper" and "linear expansion coefficient (×10 -5 / ℃)", and "PPS" and "PBT" respectively represent "polyphenylene sulfide" and "polybutylene terephthalate" as thermoplastic resin materials. In addition, "◎" in "Judgment of the quality of fracture" in Table 1 means that "no change in wire diameter and no fracture occurred" in the overlapped wire portions 93a1c and 93a2c when the coil device 93 was subjected to a temperature change of 160℃ (from -40℃ to 120℃) for 1000 times for one cycle (two hours). Similarly, "○", "△ (not recorded)" and "×" in "Judgment of the quality of fracture" in Table 1 respectively mean that the coil device 93 was subjected to a temperature change of 160℃ (from -40℃ to 120℃) for 500 times for one cycle (two hours). Regarding the overlapping wires 93a1c and 93a2c, the results of the following tests were obtained: "No change in wire diameter, no breakage", "Change in wire diameter, no breakage", and "breakage". Since it is difficult to directly measure the wire diameter of the overlapping wire, it is confirmed by the change in the resistance value of the coil (if the resistance value increases, the wire diameter decreases). For reference, the fifth and sixth rows of Table 1 (the portion surrounded by the black frame) show that the overlapping wires 93a1c and 93a2c broke when the overlapping wire breakage suppression unit (1) (the adhesion strengthening unit provided in the axially opposed region of the flange portion) was not provided, and the description thereof is omitted here.

[0135] Table 1

[0136]

[0137] First, in the third and fourth rows of Table 1, all of the overlapping line breakage suppression units (1) to (3) are present, and as overlapping line breakage suppression unit (3-1), a reinforcing agent is added to the resin material forming bobbin 94. As a result, the linear expansion coefficient of bobbin 94 is smaller than the linear expansion coefficient of sealing resin portion 97, and thus the breakage occurrence quality is judged as "0." Furthermore, in the first and second rows of Table 1, as overlapping line breakage suppression unit (3-2), bobbin 94 and sealing resin portion 97 are made of the same material, and the amount of reinforcing agent added to the resin material forming bobbin 94 is greater than that to the resin material forming sealing resin portion 97. As a result, the linear expansion coefficient of bobbin 94 is smaller than that of sealing resin portion 97 and is closer to that of coil 93a, and thus the breakage occurrence quality is judged as "◎." In this way, by adopting the overlapping line portion rupture suppression unit (3-1) and the overlapping line portion rupture suppression unit (3-2), the rupture of the overlapping line portions 93a1c and 93a2c can be further suppressed.

[0138] In the first embodiment, the linear expansion coefficients of bobbin 94 and sealing resin portion 97 are determined by making them of the same material and varying them depending on the presence or amount of a reinforcing agent. However, this is not limiting. Since the linear expansion coefficient of cross-linked polyphenylene sulfide is smaller than that of linear polyphenylene sulfide, for example, bobbin 94 and sealing resin portion 97 may be made of the same material (polyphenylene sulfide (PPS)), with cross-linked polyphenylene sulfide used for bobbin 94 and linear polyphenylene sulfide used for sealing resin portion 97.

[0139] <About the overlapped wire breakage suppression unit (3-3) (linear expansion coefficient of the bobbin of 40% or less of the breaking tension of the coil)>

[0140] The inventors set the linear expansion coefficient of bobbin 94 so that even when coil device 93 is used under extreme temperature fluctuations (160°C, ranging from -40°C to 120°C), 40% of the breaking tension of coil 93a remains a safe allowable tension (safety factor of 2.5) as a condition for ensuring that overlapping wires 93a1c and 93a2c do not break. The reason for this is that, firstly, the sealing resin portion 97, which is tightly fixed around overlapping wires 93a1c and 93a2c, acts as an anchor to bobbin 94, suppressing expansion and contraction caused by temperature fluctuations. Therefore, for example, when the temperature rises, the tensile force on coil 93a is exerted primarily by the elongation of bobbin 94, not by the sealing resin portion 97. Therefore, in the overlapped line breakage suppression means (3-3), the linear expansion coefficient of the bobbin 94 is set so that the tensile force acting on the overlapped lines 93a1c and 93a2c due to temperature changes is 40% or less of the breaking tension of the coil 93a. The following describes the calculation process of the linear expansion coefficient of the bobbin 94 in an example.

[0141] For example, in the case of the coil 93a with a wire diameter of 0.2 (mm) and a breaking tension of 7.4 (N), the allowable tension Ty is 3.0 (N) (= 7.4 × 0.4). The cross-sectional area A of the coil 93a is 0.1 × 0.1 × 3.14 = 0.0314 (mm). 2 Here, the length Ly of the overlapping wire portions 93a1c and 93a2c is set to 5 (mm). In addition, the longitudinal elastic modulus E of the coil 93a made of a general soft copper wire is 118×10 3 (N / mm 2 ).

[0142] Here, the mathematical formula representing the relationship between stress σ and strain ε is as follows (Formula 1), the stress σ when allowing tension is as follows (Formula 2), and the displacement per unit length, i.e., strain ε, is as follows (Formula 3).

[0143] σ=εE (Formula 1)

[0144] σ=Ty / A (Equation 2)

[0145] ε=ΔLy / Ly (Equation 3)

[0146] Therefore, by introducing (Formula 2) and (Formula 3) into (Formula 1), the following (Formula 4) can be calculated, and can be transformed into the following (Formula 5).

[0147] Ty / A=E×ΔLy / Ly (Equation 4)

[0148] ΔLy=Ty×Ly / (A×E) (Equation 5)

[0149] Here, if the above-mentioned known values ​​of the allowable tension Ty, the lengths Ly of the overlapped portions 93a1c and 93a2c, the cross-sectional area A of the coil 93a, and the longitudinal elastic modulus E of the coil 93a are introduced into (Equation 5), the displacement of the overlapped portion under the allowable tension becomes ΔLy = 3.0 (N) × 5 (mm) / (0.0314 (mm) 2 )×118×10 3 (N / mm 2 ))=0.004(mm).

[0150] The calculation results show that when the overlapping wire portions 93a1c and 93a2c have a wire diameter of 0.2 (mm) and a length of 5 (mm), and a tensile force is forcibly applied from the outside, when the stretching exceeds 0.004 (mm), the risk of breakage of the overlapping wire portions 93a1c and 93a2c increases because the allowable tension Ty is exceeded.

[0151] In the calculations up to this point, the elongation of the overlapping wires 93a1c and 93a2c due to temperature changes was not considered at all. Therefore, from this point on, the displacement ΔLty of the overlapping wires 93a1c and 93a2c due to temperature changes was studied. In addition, the linear expansion coefficient αy of a coil made of ordinary soft copper wire is 1.7×10 -5 ( / °C), and the temperature difference Δt is assumed to be within the temperature range of -40°C to 120°C, which is 160°C. Therefore, when the length Ly of the overlapping lines 93a1c and 93a2c is 5 mm, the displacement ΔLty due to a temperature change of 160°C is ΔLty = αy × Ly × Δt = 0.0136 mm. However, the displacement ΔLty due to the temperature change is caused by the temperature change of the overlapping lines 93a1c and 93a2c themselves, and therefore does not generate a tensile force.

[0152] Therefore, the displacement of the overlapping portions 93a1c and 93a2c when tension is allowed and the temperature changes by 160°C becomes 0.0176 (mm) by adding the displacement ΔLty (0.0136 (mm)) when the temperature changes to the displacement ΔLy (0.004 (mm)) when tension is allowed.

[0153] Therefore, it is assumed that the displacement ΔLy+ΔLty of the overlapping wire portions 93a1c and 93a2c when the temperature changes by 160°C under this allowable tension is caused by the anchoring effect of the sealing resin portion 97 and the adhesion reinforcement unit Ar, which causes the displacement ΔLp of the bobbin 94 when the temperature changes by 160°C.

[0154] If the linear expansion coefficient of the bobbin 94 is set to αp, the length of the bobbin 94 is set to Lp, and the temperature difference is set to Δt, then the displacement ΔLp of the bobbin 94 when the temperature changes by 160°C becomes the following (Formula 6). If the linear expansion coefficient αp of the bobbin 94 is sorted, it becomes the following (Formula 7).

[0155] ΔLp=αp×Lp×Δt (Formula 6)

[0156] αp=ΔLp / (Lp×Δt) (Equation 7)

[0157] Here, if the displacement amount ΔLp (=ΔLy+ΔLty) of the bobbin 94 due to the known temperature change, the length Lp (=Ly) of the bobbin 94, and the temperature difference Δt are introduced into (Equation 7), the result is:

[0158] αp=0.0176(mm) / (5(mm)×160(℃))=2.2×10 -5 ( / ℃).

[0159] Therefore, in this example, if the linear expansion coefficient of the resin material of the bobbin 94 is greater than 2.2×10 -5 A low linear expansion coefficient ensures that even if coil 93a elongates due to temperature fluctuations, the coil 93a can be kept within the safe allowable tension (safety factor 2.5) for use. As can be seen from Table 1, this allows the linear expansion coefficient of bobbin 94 to be even closer to that of coil 93a. Thus, by employing the overlapped wire breakage suppression unit (3-3), overlapped wires 93a1c and 93a2c are reliably prevented from breaking even when used under extreme temperature fluctuations, significantly improving the safety of coil device 93.

[0160] As described above, in the first embodiment, by simultaneously adopting the overlap line fracture suppression unit (1) (a tight-fitting reinforcement unit provided in the axially opposing area of ​​the flange portion), the overlap line fracture suppression unit (2) (arranging the overlap line portion and the axially opposing area of ​​the flange portion to be close to or in contact with each other), and the overlap line fracture suppression unit (3) (the linear expansion coefficient of the bobbin is smaller than that of the sealing resin portion), the existing problem point (fracture of the overlap line portion caused by temperature change) can be eliminated and reliability can be improved.

[0161] In the first embodiment, the overlapped line breakage suppression means (1) is studied. By adopting the overlapped line breakage suppression means (1-1) (concave-convex portion, surface modified portion), manufacturing costs can be reduced. Furthermore, by adopting the overlapped line breakage suppression means (1-2) (concave-convex portion intersecting with the overlapped line), the anchoring effect in the direction in which the overlapped lines 93a1c and 93a2c extend is further enhanced, and expansion and contraction caused by temperature changes in the sealing resin portion 97 can be more reliably suppressed.

[0162] Moreover, in the first embodiment, as a structure for studying the lap wire portion rupture suppression unit (2), by adopting the lap wire portion rupture suppression unit (2-1) (the lap wire portion is non-contactly arranged in the area opposite to the axis in the direction perpendicular to the axis) and / or the lap wire portion rupture suppression unit (2-2) (only the front end of the winding portion of the lap wire portion is fixed), it is possible to suppress the pre-tension applied to the lap wire portions 93a1c, 93a2c when the lap wire portions 93a1c, 93a2c are connected to the terminal 96a and when the sealing resin portion 97 is formed and shrunk.

[0163] Furthermore, in the first embodiment, as a scheme for suppressing the breakage of the overlapping wire portion (3), by adopting the overlapping wire portion suppressing breakage means (3-1) (adding a reinforcing agent to the bobbin) and the overlapping wire portion suppressing breakage means (3-2) (the bobbin and the sealing resin portion are made of the same material, and a larger amount of reinforcing agent is added to the bobbin than to the sealing resin portion), the breakage of the overlapping wire portions 93a1c and 93a2c can be further suppressed. In addition, by adopting the overlapping wire portion suppressing breakage means (3-3) (the linear expansion coefficient of the bobbin is 40% or less of the breaking tension of the coil), the safety of the coil device 93 during use can be greatly improved.

[0164] Furthermore, in the first embodiment, in addition to the overlapping line rupture suppression units (1) to (3), all of the overlapping line rupture suppression units (1-1), (1-2), (2-1), (2-2), (3-1), (3-2), and (3-3) are employed, but the present invention is not limited thereto. For example, as long as at least the overlapping line rupture suppression units (1) to (3) are employed simultaneously, any one of the overlapping line rupture suppression units (1-1), (1-2), (2-1), (2-2), (3-1), (3-2), and (3-3) may not be employed, and a combination including at least one of the overlapping line rupture suppression units (1-1), (1-2), (2-1), (2-2), (3-1), (3-2), and (3-3) may be employed.

[0165] (Second embodiment)

[0166] use Figure 10 as well as Figure 15 , the flow control valve 100b of the second embodiment is described. In the second embodiment, the structure of the coil assembly 93' and the overlapped wire breakage suppression unit (3-2') (a reinforcing agent is added to the bobbin and the sealing resin portion) differ mainly from the structure of the coil assembly 93 and the overlapped wire breakage suppression unit (3-2) of the first embodiment (the bobbin and the sealing resin portion are made of the same material, and a larger amount of reinforcing agent is added to the bobbin than to the sealing resin portion). The rest of the basic structure is substantially the same as that of the first embodiment. Here, the same reference numerals are given to the same components, and repeated descriptions are omitted.

[0167] In addition, as will be described in detail later, in the second embodiment, similar to the first embodiment, by simultaneously adopting the overlapped line fracture suppression units (1) to (3), the existing problem (fracture of the overlapped line caused by temperature changes) can be eliminated and reliability can be improved.

[0168] <About coil devices>

[0169] like Figure 15 As shown, the coil device 93' comprises: a stator 95' having an annular shape; a bobbin 94' provided integrally with the stator 95'; a coil 93a' wound around the outer periphery of the bobbin 94'; and a bobbin assembly 94'Assy (see FIG. 1 ) which is assembled on the bobbin 94' and comprises a power supply terminal 96a' connected to the coil 93a'. Figure 13). In addition, the coil device 93' includes: a substrate 96f' and a lead 96d connected to the terminal 96a'; a cover 96g' that accommodates the bobbin assembly 94'Assy equipped with the substrate 96f'; and a sealing resin portion 97' that seals the cover 96g' and the outer periphery of the bobbin assembly 94'Assy. The details will be described later. The stator 95' is made of a metal material such as SEC (electrogalvanized steel plate), and has a first stator pole tooth portion 95a', a second stator pole tooth portion 95b', a first stator housing 95c', a second stator housing 95d', and a third stator housing 95e'. In addition, the bobbin 94' is made of a resin material such as polyphenylene sulfide (PPS) and polybutylene terephthalate (PBT). The resin material forming bobbin 94' can also be polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT) reinforced with glass fiber or with inorganic fillers added to the glass fiber. (Details will be described later.) This reduces the linear expansion coefficient of bobbin 94' and reliably suppresses expansion and contraction caused by temperature changes in sealing resin portion 97'. Similar to coil 93a of the first embodiment, coil 93a' is made of a metal material, such as copper, and includes a first coil 93a1' and a second coil 93a2'.

[0170] <About the Coil Device Assembly Process>

[0171] Start here, use Figures 11 to 15 The assembly process of the coil device 93' (stator assembly process, injection molding process, bobbin assembly process, cover assembly process, and electrical component sealing process) is described. The details will be described later. The overlapped wire breakage suppression unit (1) (a tightness reinforcement unit provided in the axially opposed area of ​​the flange part), the overlapped wire breakage suppression unit (2) (arrangement of the overlapped wire part and the axially opposed area of ​​the flange part close to or in contact with each other), and the overlapped wire breakage suppression unit (3) (the linear expansion coefficient of the bobbin part is smaller than that of the sealing resin part) in the assembly process are described.

[0172] <About the stator assembly process>

[0173] use Figure 11 (a) The stator assembly process is described. First, the first stator housing 95c' is assembled on the first stator pole tooth portion 95a', and the second stator housing 95d' is assembled on the second stator pole tooth portion 95b' (see Figure 11 A1' arrow in (a)

[0174] <About the injection molding process (lap line fracture suppression unit (1))>

[0175] use Figure 11(b) of the present invention will explain the injection molding process. Insert molding is performed in a state where the first stator pole tooth portion 95a', the second stator pole tooth portion 95b', the first stator housing 95c', and the second stator housing 95d' are assembled to form the bobbin 94' (see Figure 11 A2' in Figure 11 As shown in (b), the bobbin 94' comprises: a bobbin body 94a' having a substantially cylindrical shape, having annular flanges at both ends and in the center in the direction of the axis L; and a flange 94f' extending radially from the annular flange in the center of the bobbin body 94a'. In this case, the stator 95' (see Figure 15 A portion of (a)) is covered by the bobbin body 94a'. The flange portion 94f' is provided with a first terminal 96a1' and a second terminal 96a2' (see Figure 12 ) is inserted into the first insertion hole 94f1' and the second insertion hole 94f2', and has a flange portion thickness T'.

[0176] Here, the details will be described later. As the overlapped line fracture suppression unit (1), similar to the first embodiment, a close-fitting reinforcement unit Ar is provided on one side and the other side of the flange portion 94f' (see Figure 11 (b)) (for example, referring to the concave-convex portion ( Figure 9 (b), (c)), surface modified portion, etc.).

[0177] The adhesion strengthening unit Ar is used in the electrical component sealing step described later (see Figure 15 In (a) and (b)), the anchoring effect between the sealing resin portion 97' and the flange portion 94f' is significantly enhanced, and the close contact is strengthened, thereby suppressing the breakage of the first overlapping line portion 93a1c' and the second overlapping line portion 93a2c'.

[0178] <About the bobbin assembly process (lap wire breakage suppression unit (2))>

[0179] use Figure 12 as well as Figure 13 First, insert the first terminal 96a1' and the second terminal 96a2' into the first insertion hole 94f1' and the second insertion hole 94f2' of the flange portion 94f' (see Figure 12 Then, the first coil 93a1' and the second coil 93a2' are wound around the outer periphery of one end side and the other end side of the bobbin body 94a' (see Figure 12Then, the first and second connecting wires 93a1c' and 93a2c' at both ends of the first and second coils 93a1' and 93a2' are connected (for example, fixed by soldering) to the first and second terminals 96a1' and 96a2' via the first and second winding portions 93a1f' and 93a2f', respectively.

[0180] Here, the details will be described later. As the lap portion breakage suppression means (2), the first lap portion 93a1c' and the second lap portion 93a2c' are respectively arranged close to or in contact with one side surface and the other side surface of the flange portion 94f'. The positions where the first lap portion 93a1c' and the second lap portion 93a2c' are arranged become the positions in the electrical installation part sealing process described later (refer to Figure 15 In (b)), the anchoring effect of the sealing resin portion 97' is significantly enhanced by the overlapped line breakage suppression means (1), and thus the breakage of the first overlapped line 93a1c' and the second overlapped line 93a2c' can be suppressed.

[0181] Therefore, if Figure 13 As shown, a bobbin assembly 94'Assy is formed. In the bobbin assembly 94'Assy, as a lap portion breakage suppression unit (1), a close reinforcement unit Ar is provided on one side and the other side of the flange portion 94f' (see Figure 13 (a) and (b) of the drawings). In addition, as the overlapped line breakage suppression means (2), the first overlapped line 93a1c' and the second overlapped line 93a2c' are arranged close to or in contact with one side surface and the other side surface of the flange portion 94f'. In the second embodiment, the first overlapped line 93a1c' and the second overlapped line 93a2c' are eight in total, and the first terminal 96a1' and the second terminal 96a2' each have a universal terminal in the center, so there are six in total. However, the number of overlapped lines and terminals is not limited to this.

[0182] <About the cover assembly process>

[0183] use Figure 14 First, the terminal 96a' of the bobbin assembly 94'Assy is connected to the lead 96d via the substrate 96f' (for example, soldered) (see Figure 14 In addition, when viewed from the axis L, the third stator housing 95e' having a C-shape is fitted to the outer periphery of the bobbin assembly 94'Assy (see Figure 14 Furthermore, the cover 96g' made of resin material is fitted into the bobbin assembly 94'Assy from the axis L direction (see Figure 14Then, the spool assembly 94'Assy equipped with the cover 96g' is turned upside down (refer to Figure 14 A8' arrow in Figure 5).

[0184] <Regarding the sealing process of electrical components (unit for suppressing breakage of overlapping wires (3))>

[0185] use Figure 15 , the electrical installation parts sealing process (lap wire rupture suppression unit (3)) is described. Figures 11 to 14 Illustrations and Figure 15 The illustration is reversed upside down. A molding resin (for example, a thermosetting resin material such as epoxy resin or polyurethane resin) is injected into the space formed inside the cover 96g' and outside the bobbin assembly 94'Assy and heated and cured to form a sealing resin portion 97' (see Figure 15 At this time, the peripheries of the first overlapping line portion 93a1c' and the second overlapping line portion 93a2c' are tightly fixed to the sealing resin portion 97'.

[0186] Here, as will be described in detail later, as the overlapped line breakage suppression unit (3), the linear expansion coefficient of the bobbin 94' is set smaller than the linear expansion coefficient of the sealing resin portion 97', thereby suppressing the breakage of the first overlapped line portion 93a1c' and the second overlapped line portion 93a2c'.

[0187] <About overlap line fracture suppression units (1) to (3)>

[0188] use Figure 15 (b) of the present invention will explain the overlapping line breakage suppression units (1) to (3) in detail. First, the overlapping line breakage suppression unit (1) is provided with an adhesion reinforcement unit Ar (see FIG. 1 ) for reinforcing the adhesion between the sealing resin portion 97' and the flange portion 94f' in the axial direction opposing region AF which is opposed to the first overlapping line portion 93a1c' and the second overlapping line portion 93a2c' in the axial direction L direction. Figure 15 (b)). In addition, the overlap line rupture suppression means (2) arranges the first overlap line 93a1c' and the second overlap line 93a2c' to be close to or in contact with the axially opposed region AF of the flange portion 94f'. Furthermore, the overlap line rupture suppression means (3) arranges the linear expansion coefficient of the bobbin 94' to be smaller than the linear expansion coefficient of the sealing resin portion 97'.

[0189] Thus, in the second embodiment, as Figure 15As shown in (b), according to the overlapped line fracture suppression units (1) and (2), the anchoring effect of the sealing resin portion 97' to the axially opposed area AF of the flange portion 94f' is significantly improved, and the first overlapped line portion 93a1c' and the second overlapped line portion 93a2c' are arranged in the area where the anchoring effect of the sealing resin portion 97' is significantly improved. In addition, at the same time, according to the overlapped line fracture suppression unit (3), the expansion and contraction of the flange portion 94f' caused by temperature changes are smaller than those of the sealing resin portion 97'. Therefore, even when the coil device 93' is used in an environment where the ambient temperature changes greatly, the sealing resin portion 97' tightly fixed to the periphery of the first overlapped line portion 93a1c' and the second overlapped line portion 93a2c' is suppressed from expanding and contracting due to temperature changes due to the anchoring effect on the flange portion 94f', thereby suppressing the fracture of the first overlapped line portion 93a1c' and the second overlapped line portion 93a2c', thereby improving reliability.

[0190] As described above, in the second embodiment, similar to the first embodiment, by simultaneously adopting a lap line portion rupture suppression unit (1) (a tight-fitting reinforcement unit provided in the axially opposing area of ​​the flange portion), a lap line portion rupture suppression unit (2) (arranging the lap line portion and the axially opposing area of ​​the flange portion to be close to or in contact with each other), and a lap line portion rupture suppression unit (3) (the linear expansion coefficient of the bobbin is smaller than that of the sealing resin portion), the existing problem point (rupture of the lap line portion caused by temperature change) can be eliminated and reliability can be improved.

[0191] <Study on the overlapped line fracture suppression units (1) to (3)>

[0192] Regarding the study of the overlapped line fracture suppression units (1) to (3) in the second embodiment, since they are the same as those in the first embodiment, the following are used: Figure 15 (b) is briefly described below.

[0193] In the second embodiment, as a structure that studies the overlap line fracture suppression means (1), the overlap line fracture suppression means (1-1) (concave-convex portion, surface modified portion) is adopted, thereby reducing manufacturing costs. In addition, by adopting the overlap line fracture suppression means (1-2) (the concave-convex portion intersecting with the overlap line), the anchoring effect in the direction in which the overlap lines 93a1c' and 93a2c' extend is further enhanced, and expansion and contraction caused by temperature changes in the sealing resin portion 97' can be more reliably suppressed.

[0194] Furthermore, in the second embodiment, as a structure for suppressing the rupture of the lap wire portion (2), by adopting a lap wire portion rupture suppression unit (2-1) (the lap wire portion is non-contactly arranged in the area opposite to the axis in the direction perpendicular to the axis) and / or a lap wire portion rupture suppression unit (2-2) (only the front end of the winding portion of the lap wire portion is fixed), the load pre-tension on the lap wire portions 93a1c', 93a2c' can be suppressed when the lap wire portions 93a1c', 93a2c' are connected to the terminal 96a' and when the sealing resin portion 97' is formed and shrunk.

[0195] Furthermore, in the second embodiment, as a method for studying the overlapped line breakage suppression means (3), by adopting the overlapped line breakage suppression means (3-1) (adding a reinforcing agent to the bobbin) and the overlapped line breakage suppression means (3-2') (adding a reinforcing agent to the bobbin and the sealing resin portion), the linear expansion coefficients of the bobbin 94' and the sealing resin portion 97' are further reduced relative to each other, thereby further suppressing the breakage of the overlapped lines 93a1c' and 93a2c'. Furthermore, by adopting the overlapped line breakage suppression means (3-3) (setting the linear expansion coefficient of the bobbin to 40% or less of the breaking tension of the coil), the safety of the coil device 93' during use can be greatly improved.

[0196] Comparative evaluation of overlapped line fracture suppression units (3-1) and (3-2')

[0197] Here, in order to judge the quality of the occurrence of fracture of the overlapping line portions 93a1c' and 93a2c' in the overlapping line portion fracture suppression means (3-1) and (3-2'), the comparative evaluation shown in Table 2 was performed in the same manner as in the first embodiment. In addition, under any of the conditions in Table 2, the overlapping line portion fracture suppression means (2) (the overlapping line portion and the axially opposed region of the flange portion are arranged close to or in contact with each other) and the overlapping line portion fracture suppression means (3) (the linear expansion coefficient of the bobbin is smaller than that of the sealing resin portion) are provided in the same manner as in Table 1.

[0198] The following description of Table 2 only describes the differences from Table 1. "EP" in Table 2 represents "epoxy resin," which is a thermosetting resin material. For reference, the fifth and sixth rows of Table 2 (the portions surrounded by black frames) show that fractures occurred in the overlapped line portions 93a1c' and 93a2c' without the overlapped line fracture suppression unit (1) (the adhesion reinforcement unit provided in the axially opposed region of the flange portion). The description here is omitted.

[0199] Here, polyurethane resin generally has a larger linear expansion coefficient than epoxy resin. Therefore, by adding a reinforcing agent to polyurethane resin, the linear expansion coefficient can be brought closer to that of epoxy resin without a reinforcing agent. Therefore, although not shown in Table 2, when polyurethane resin is used as the sealing resin portion 97', the addition of a reinforcing agent can achieve a "fracture occurrence quality judgment" equivalent to that of epoxy resin without a reinforcing agent.

[0200] Table 2

[0201]

[0202] First, in the third and fourth rows of Table 2, all of the overlapping line breakage suppression units (1) to (3) are present, and as overlapping line breakage suppression unit (3-1), a reinforcing agent is added to the resin material forming the bobbin 94'. As a result, the linear expansion coefficient of the bobbin 94' is smaller than the linear expansion coefficient of the sealing resin portion 97', and thus the breakage occurrence quality is judged as "0". Furthermore, in the first and second rows of Table 2, as overlapping line breakage suppression unit (3-2'), a reinforcing agent is added (in larger amounts) to the bobbin 94' and the sealing resin portion 97'. As a result, the linear expansion coefficients of the bobbin 94' and the sealing resin portion 97' further decrease relative to each other, approaching the linear expansion coefficient of the coil 93a', and thus the breakage occurrence quality is judged as "◎". Thus, by adopting the overlapping line breakage suppression units (3-1) and (3-2'), breakage of the overlapping lines 93a1c' and 93a2c' can be further suppressed.

[0203] <About the overlapped line breakage suppression means (3-3) (the linear expansion coefficient of the bobbin being 40% or less of the breaking tension of the coil)>

[0204] In the second embodiment, as in the first embodiment, by adopting the overlapped wire breakage suppression unit (3-3), the overlapped wires 93a1c' and 93a2c' are reliably prevented from breaking even when used under extreme temperature changes, thereby greatly improving the safety of the coil device 93' in use.

[0205] As described above, in the second embodiment, as in the first embodiment, a lap line fracture suppression unit (1) (a tight-fitting reinforcement unit provided in the axially opposing area of ​​the flange portion), a lap line fracture suppression unit (2) (arranges the lap line portion and the axially opposing area of ​​the flange portion to be close to or in contact with each other), and a lap line fracture suppression unit (3) (the linear expansion coefficient of the bobbin is smaller than that of the sealing resin portion) are simultaneously adopted, thereby eliminating the existing problem point (fracture of the lap line portion caused by temperature change) and improving reliability.

[0206] In the second embodiment, as in the first embodiment, a structure has been developed for the overlapped line fracture suppression means (1). By adopting the overlapped line fracture suppression means (1-1) (concave-convex portion, surface modified portion), manufacturing costs can be reduced. Furthermore, by adopting the overlapped line fracture suppression means (1-2) (concave-convex portion intersecting with the overlapped line), the anchoring effect in the direction in which the overlapped lines 93a1c' and 93a2c' extend is further enhanced, and expansion and contraction caused by temperature changes in the sealing resin portion 97' can be more reliably suppressed.

[0207] Moreover, in the second embodiment, as in the first embodiment, as a structure for studying the lap wire portion rupture suppression unit (2), by adopting the lap wire portion rupture suppression unit (2-1) (the lap wire portion is non-contactly arranged in the area opposite to the axis in the direction perpendicular to the axis) and / or the lap wire portion rupture suppression unit (2-2) (only the front end of the winding portion of the lap wire portion is fixed), the load pre-tension on the lap wire portions 93a1c', 93a2c' can be suppressed when the lap wire portions 93a1c', 93a2c' are connected to the terminal 96a' and when the sealing resin portion 97' is formed and shrunk.

[0208] Furthermore, in the second embodiment, as a scheme for studying the overlapped line breakage suppression means (3), by adopting the overlapped line breakage suppression means (3-1) (adding a reinforcing agent to the bobbin) and the overlapped line breakage suppression means (3-2') (adding a reinforcing agent to the bobbin and the sealing resin portion), it is possible to further suppress the breakage of the overlapped line portions 93a1c' and 93a2c'. In addition, by adopting the overlapped line breakage suppression means (3-3) (making the linear expansion coefficient of the bobbin less than 40% of the breaking tension of the coil), it is possible to greatly improve the safety of the coil device 93' during use.

[0209] Furthermore, in the second embodiment, in addition to the overlapped line fracture suppression units (1) to (3), all of the overlapped line fracture suppression units (1-1), (1-2), (2-1), (2-2), (3-1), (3-2'), and (3-3) are also employed, but the present invention is not limited thereto. For example, as long as at least the overlapped line fracture suppression units (1) to (3) are employed simultaneously, none of the overlapped line fracture suppression units (1-1), (1-2), (2-1), (2-2), (3-1), (3-2'), and (3-3) may be employed, or a combination including at least one of the overlapped line fracture suppression units (1-1), (1-2), (2-1), (2-2), (3-1), (3-2'), and (3-3) may be employed.

[0210] <Other>

[0211] Flow control valves 100a and 100b equipped with coil assemblies 93 and 93' according to this embodiment can maintain high reliability even when used in environments with significant ambient temperature fluctuations. Therefore, it goes without saying that they can be applied to all fluid devices and fluid circuits, including refrigeration cycles. Furthermore, the present invention is not limited to the aforementioned embodiments; appropriate changes and modifications can be made without departing from the technical spirit of the present invention.

Claims

1. A coil device, characterized in that: have: stator; A bobbin made of a resin material, comprising a bobbin body having a substantially cylindrical shape centered on an axis, and a flange portion extending radially outward from the bobbin body; a terminal for power supply, fixed to the flange portion; a coil wound around the bobbin body and having a lap portion at both ends connected to the terminals; a sealing resin portion that seals the bobbin including the flange portion, the coil including the lap wire portion, and the terminal; and a lap portion fracture suppression unit for suppressing fracture of the lap portion; The above-mentioned lap line breakage suppression unit is provided with a adhesion reinforcement unit for reinforcing the adhesion between the above-mentioned sealing resin part and the above-mentioned flange part in the axial direction opposing area of ​​the above-mentioned flange part which is opposite to the above-mentioned lap line part in the axial direction, so that the above-mentioned lap line part and the above-mentioned axial direction opposing area of ​​the above-mentioned flange part are close to or abutted, and the above-mentioned bobbin has a smaller linear expansion coefficient than the above-mentioned sealing resin part.

2. The coil device according to claim 1, wherein The contact reinforcing means is a concave-convex portion or a surface modified portion provided in the axially opposed regions of the flange portion.

3. The coil device according to claim 2, characterized in that The concave-convex portion extends in a direction intersecting the overlapped line portion when viewed from the axial direction.

4. The coil device according to claim 1, wherein The flange portion has an axis-orthogonal direction opposing region, and the axis-orthogonal direction opposing region is opposed to the overlapped portion in a direction orthogonal to the axis. The overlapped line breakage suppression unit arranges the overlapped line in a non-contact state in the axially orthogonal facing region of the flange portion.

5. The coil device according to claim 4, characterized in that The above-mentioned bridge portion has a winding portion wound around the above-mentioned terminal, The bridge line breakage suppression unit fixes only the front end of the wound portion to the terminal.

6. The coil device according to claim 1, wherein In the overlapped line breakage suppression unit, the resin material forming the bobbin is polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT) using glass fiber as a reinforcement or adding an inorganic filler to the glass fiber.

7. The coil device according to claim 6, characterized in that Regarding the overlap line breakage suppression unit, when the resin material forming the bobbin and the resin material forming the sealing resin portion are the same material, the amount of the reinforcing agent added to the bobbin is greater than that to the sealing resin portion.

8. The coil device according to claim 1, wherein The overlapped line breakage suppression unit sets a linear expansion coefficient of a resin material forming the bobbin so that tension acting on the overlapped line at a use temperature is 40% or less of a breaking tension of the coil.

9. A flow regulating valve, characterized in that: A coil device according to any one of claims 1 to 8 is provided.

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