Coil device and flow regulating valve having the same

Abstract

Provided is a coil device and a flow regulating valve provided with the same, which can eliminate the problems of long time required for forming of injection molding coil (problem point 1) and high cost of injection molding coil (problem point 2) by designing a cover. The device is provided with a bobbin (71), a coil (70a), a housing (72e), a cover (74) having a bottomed cylindrical portion (74a) and an injection inlet portion (74b) continuously formed with the bottomed cylindrical portion (74a), a sealing resin portion (75) for continuously and integrally sealing and bonding the bobbin (71), the coil (70a) and the housing (72e) received in the cover (74) with the same sealing resin to the cover (74), and an injection promoting unit for injecting sealing resin into the injection inlet portion (74b). At least a part of an injection inlet peripheral wall (74bw) of the injection inlet portion (74b) defined by the injection promoting unit is made of a material having softness.

Description

Technical Field

[0001] The present invention relates to a coil device having an injection promotion unit for injecting sealing resin into an injection port, and a flow regulating valve having the coil device. Background Technology

[0002] The coil assembly of solenoid valves and electric valves employs an electrical mounting component with a sealing resin covering the winding portion of the winding tube and the joint of the coil to ensure waterproof and drip-proof sealing. As one type, injection-molded coils, which are formed by injecting and curing sealing resins such as thermosetting resins, are widely used.

[0003] Here, for example, in patent document 1, such as Figure 15 As shown in (a), a coil device 1070 (hereinafter referred to as "conventional coil device 1") is described as an apparatus for forming injection molded coils. The coil device 1070 includes a winding tube 1071 on which a coil 1070a is wound, a housing 1072e fitted with the winding tube 1071, and a cover 1074 made of thermoplastic resin. In addition, Patent Document 1 describes that the winding tube 1071 with the housing 1072e fitted in it and the electrical mounting member 1073 are housed in the cover 1074, and a sealing resin is injected and cured to form a sealing resin part 1075.

[0004] In the conventional coil device 1, since equipment corresponding to the production quantity can be introduced, it is easy to handle from small-batch production to mass production. However, since the gap between the electrical mounting part 1073 and the cover 1074, and the gap between the outer shell 1072e and the cover 1074 are very small, there is a problem that the sealing resin is difficult to enter the filling space inside the cover 1074.

[0005] Ideally, the injection process would allow the air-free sealing resin to permeate the filling space in a short time, but it is difficult to avoid air mixing into the sealing resin. Therefore, in the conventional coil device 1, in order to suppress the residual air in the filled sealing resin, the injection is carried out gradually over time, in multiple injections, or vacuum degassing is performed after injection, all of which may require a relatively long time in the injection process. In addition, if the injection process time is forcibly shortened, there is a possibility that the sealing resin may overflow from the sealing resin cover 1074 or that more air may remain in the sealing resin, resulting in a decrease in the quality of the injection-molded coil (hereinafter referred to as "Conventional Problem 1 (Long molding time required for injection-molded coil)").

[0006] Furthermore, in order to shorten the degassing time of the sealing resin during the injection process, reducing the amount of sealing resin injected is considered. For example, in Patent Document 2, such as... Figure 15As shown in (b), a coil device 2070 (hereinafter referred to as "conventional coil device 2") is described, which includes a winding tube 2071 on which a coil 2070a is wound, a housing 2072e fitted with the winding tube 2071, and a cover 2074 made of soft synthetic resin. The winding tube 2071 with the housing 2072e fitted with the housing is injection molded using a molding material 2077 (a rigid synthetic resin of thermoplastic resin) to form the coil body 2070A. The coil body 2070A and the electrical mounting parts 2073 are housed in the cover 2074. Sealing resin is injected and cured to form a sealing resin part 2075.

[0007] Thus, in the conventional coil device 2, in the stage before forming the injection molded coil, injection molding, which can be performed in a short time, is used to pre-construct the coil body 2070A, which can occupy most of the volume inside the cover 2074. This reduces the filling space of the sealing resin, thereby eliminating the conventional problem 1 (the long time required for forming the injection molded coil).

[0008] However, in the conventional coil device 2, in addition to the injection molding machine used for insert molding with molding die, an auxiliary device is also required for filling with sealing resin, thus making it a large production device. As a result, even when the production quantity is small, the cost may be high (hereinafter referred to as "conventional problem 2 (high cost of injection molded coil)").

[0009] Existing technical documents

[0010] Patent Document 1: Japanese Patent Application Publication No. 2019-146299

[0011] Patent Document 2: Japanese Patent Application Publication No. 2001-343085 Summary of the Invention

[0012] The purpose of this invention is to provide a coil device and a flow regulating valve equipped with the coil device that can simultaneously eliminate both the previous problem 1 (long molding time required for injection molded coils) and the previous problem 2 (high cost of injection molded coils) by designing the cover.

[0013] To address the aforementioned issues, a coil device comprises: a winding tube having a generally cylindrical shape about an axis; a coil wound around the winding tube; a housing fitted into the winding tube; a cover having a bottomed cylindrical portion and an injection port, the bottomed cylindrical portion having a generally bottomed cylindrical shape, the injection port being continuously formed with the bottomed cylindrical portion; a sealing resin portion that continuously and integrally seals the winding tube, the coil, and the housing housed within the cover using the same sealing resin, and is bonded to the cover; and an injection facilitating unit that injects the sealing resin into the injection port, wherein at least a portion of the injection port peripheral wall defining the injection port of the injection facilitating unit is made of a flexible material.

[0014] Alternatively, in the above-described coil device, when viewed from the axial direction and / or a direction orthogonal to the axial direction, the injection facilitator may be an inclined surface disposed on at least a portion of the peripheral wall of the injection port.

[0015] Alternatively, in the above-described coil device, with regard to the injection promotion unit, the thickness of the peripheral wall of the injection port in the cover is thinner than the thickness of the cylindrical portion with a bottom.

[0016] Alternatively, in the above-described coil device, with regard to the injection promotion unit, the thickness of the peripheral wall of the injection port in the cover may be thinner than the thickness of the bottom of the bottomed cylindrical portion.

[0017] Alternatively, in the above-described coil device, the material of the cover, with regard to the injection promotion unit, may be any one of thermosetting elastomers, thermoplastic elastomers, and soft synthetic resins.

[0018] Alternatively, in the above-described coil device, the hardness of the cover, with respect to the injection promotion unit, may be 50 or more and 100 or less on the Shore A scale.

[0019] Alternatively, in the above-mentioned coil device, the cover of the injection promotion unit may be made of a variety of materials, and the peripheral wall of the injection port may be made of a material that is softer than the bottomed cylindrical portion.

[0020] Alternatively, it could be a flow regulating valve that includes the aforementioned coil device.

[0021] The effects of this invention are as follows.

[0022] According to the present invention, a coil device and a flow regulating valve having the coil device can be provided that can simultaneously eliminate both the previous problem 1 (long molding time required for injection molded coils) and the previous problem 2 (high cost of injection molded coils) by designing the cover. Attached Figure Description

[0023] Figure 1 A cross-sectional view of a flow regulating valve representing a first embodiment of the present invention is shown.

[0024] Figure 2 It shows from Figure 1 The diagram shows a cross-sectional view of the coil assembly removed from the flow regulating valve.

[0025] Figure 3 yes Figure 2 The diagram illustrates the assembly process of the coil assembly. Figure 3 (a) shows the stator assembly process. Figure 3 (b) shows the winding tube forming process.

[0026] Figure 4 It shows Figure 2 The diagram illustrates the winding tube assembly process in the assembly process of the coil device shown.

[0027] Figure 5 It shows Figure 2 The diagram illustrates the cover assembly process in the assembly process of the coil device shown.

[0028] Figure 6 It shows Figure 5 The diagram shown illustrates the completed winding tube assembly with the cover assembled.

[0029] Figure 7 yes Figure 6 The diagram shown illustrates the sealing process (insertion process) of the completed winding tube assembly. Figure 7 (a) shows an overall sectional view. Figure 7 (b) shows from Figure 7 The view shown in (a) is the view taken in the direction of arrow VIIb (leader lines omitted). Figure 7 (c) shows a top view.

[0030] Figure 8 yes Figure 7 The diagram illustrates the sealing process (injection port expansion process and injection process) of the completed winding tube assembly. Figure 8 (a) shows an overall sectional view. Figure 8 (b) shows from Figure 8 The view shown in (a) is the view taken in the direction of arrow VIIIb (leader lines omitted).

[0031] Figure 9 yes Figure 8 The diagram illustrates the sealing process (injection port expansion process) of the completed winding tube assembly. Figure 9 (a) shows the above three-dimensional view. Figure 9 (b) shows the 3D view below.

[0032] Figure 10 yes Figure 8 The diagram shown illustrates the sealing process (injection port restoration process) of the completed winding tube assembly. Figure 10 (a) shows an overall sectional view. Figure 10 (b) shows from Figure 10 The view shown in (a) is the view taken in the direction of arrow Xb (leader lines omitted).

[0033] Figure 11 This is an explanatory diagram of the sealing process (insertion process) in the assembly process of the coil device according to the second embodiment of the present invention. Figure 11 (a) shows the overall sectional view. Figure 7 (corresponding diagram of (a)). Figure 11 (b) shows from Figure 11 (a) shows the view taken in the direction of arrow XIb (leader lines omitted). Figure 7 (corresponding diagram of (b)). Figure 11 (c) shows a top view. Figure 7 (The corresponding diagram of (c)).

[0034] Figure 12 yes Figure 11 The diagram illustrates the sealing process (injection port expansion process and injection process) of the completed winding tube assembly. Figure 12 (a) shows the overall sectional view. Figure 8 (corresponding diagram of (a)). Figure 12 (b) shows a top view.

[0035] Figure 13 yes Figure 12 The diagram illustrates the sealing process (injection port expansion process) of the completed winding tube assembly. Figure 13 (a) shows the above three-dimensional view. Figure 13 (b) shows the 3D view below.

[0036] Figure 14 It shows Figure 12 The diagram illustrates the sealing process (injection port restoration process) of the completed winding tube assembly. Figure 10 (Corresponding diagram of (a)).

[0037] Figure 15 This is a cross-sectional view of a prior art coil device. Figure 15 (a) shows a conventional coil device 1. Figure 15 (b) shows a conventional coil device 2.

[0038] In the diagram: 1—First connector pipe, 2—Second connector pipe, 10—Valve body, 10a—Matching hole, 11—Valve chamber, 20—Valve seat, 20a—Valve port, 30—Support component, 31—Bracket, 32—Fixing part, 33—Threaded hole, 33a—Internal thread, 35—Sliding hole, 40—Drive shaft, 41—Threaded part, 41a—External thread, 43—Flange, 50—Valve core, 51—Valve bracket, 51a—Lower end, 51b—Upper end, 52—Valve core, 53—Washer, 55—Compression spiral spring Spring, 60—Stepper motor, 61—Housing, 62—Magnetic rotor, 64—Magnetic part, 65—Disc part, 66—Metal part, 67—Protrusion, 70—Coil assembly, 70a—Coil, 70a1—First coil, 70a1c—First connecting part, 70a1f—First winding part, 70a2—Second coil, 70a2c—Second connecting part, 70a2f—Second winding part, 71—Winding tube, 71a—Winding tube body, 71Assy—Winding tube assembly, 71f—Annular part, 71f1—First 71f2—Second insertion hole, 72—Stator, 72a—First stator pole tooth, 72b—Second stator pole tooth, 72c—First stator housing, 72d—Second stator housing, 72e—Third stator housing (outer shell), 73—Electrical mounting component, 73a—Terminal, 73a1—First terminal, 73a2—Second terminal, 73d—Lead wire, 73f—Substrate, 74—Cover, 74a—Bottomed cylindrical portion, 74ab—Bottom, 74ac—Cylindrical portion, 74b—Injection port, 74bw— Inlet peripheral wall, 74bwl—front end, 74bws—inclined surface, 75—sealing resin part, 76—bracket, 80—rotation limiting mechanism, 81—cylinder part, 82—guide component, 83—guide line body, 84—movable slider, 100—flow regulating valve, Ep—expansion pin, EpIn—expansion inflow nozzle, In—injection nozzle, L—axis, Lr1, Lr2—radial length of injection port, Lw1, Lw2—width of the front end of the injection port peripheral wall, PI—pressurized injection component, Si—injection port. Detailed Implementation

[0039] Reference Figures 1 to 14 The embodiments of the present invention will be described in detail. However, the present invention is not limited to the form of this embodiment. Hereinafter, an electric valve (electric flow control valve) will be used as a flow control valve using a coil device, but the injection promotion units 1 to 7 described later in the flow control valve of the present invention can also be applied to the coil device of a solenoid valve (electromagnetic flow control valve, electromagnetic on / off valve, electromagnetic flow path switching valve) that replaces the electric valve.

[0040] <Regarding terminology>

[0041] In the description of the scope of this specification and technical solution, "left", "right", "up", and "down" indicate... Figures 1 to 5 The directions shown. In the scope of this specification and technical solution, "one end" and "the other end" refer to the "lower end" and "upper end" in the accompanying drawings. In the scope of this specification and technical solution, "continuous and integral sealing with the same sealing resin" means "the same sealing resin, without boundaries, continuously and integrally sealing." In the scope of this specification and technical solution, "width of the front end of the injection port peripheral wall" means "the length in the width direction of the opening edge of the front end of the injection port peripheral wall." In the scope of this specification and technical solution, "width direction" means "the direction orthogonal to a straight line extending radially from the axis when viewed from the axial direction." In the scope of this specification and technical solution, "radial length of the injection port" means "the length of the injection port from the axis along the radial direction."

[0042] (First Implementation)

[0043] <About the structure of the flow regulating valve>

[0044] use Figure 1 The flow regulating valve 100 according to the first embodiment of the present invention will be described. The flow regulating valve 100 mainly consists of a valve body 10, a valve seat 20, a support member 30, a drive shaft 40, a valve core 50, a stepper motor 60, and a rotation limiting mechanism 80. Hereinafter, the structure of each component of the flow regulating valve 100 will be described in turn.

[0045] Here, the coil device 70 in the first embodiment, by employing an injection promotion unit 1 (the peripheral wall of the injection port is made of a flexible material) that injects sealing resin into the injection port 74b, can simultaneously eliminate both the previous problem 1 (long molding time required for injection molded coils) and the previous problem 2 (high cost of injection molded coils), as will be described in detail later.

[0046] The valve body 10 is made of a metal such as stainless steel and is formed into a cylindrical shape from a thin sheet by stamping. A fitting hole 10a is provided at the bottom of the valve body 10, and a valve seat portion 20, which is separate from the valve body 10, is installed to block this fitting hole 10a. Furthermore, a first connector pipe 1, serving as a flow path for fluids such as refrigerant, is connected to the outer peripheral side wall of the valve body 10. This first connector pipe 1 communicates with a valve chamber 11 formed within the internal space of the valve body 10. This first connector pipe 1 is made of a material such as copper or stainless steel, formed into a cylindrical shape from a thin sheet by stamping or the like, and fixed to the valve body 10 by brazing or the like.

[0047] The valve seat portion 20 is made of a metal such as stainless steel and extends along the axis L, with a valve port 20a at one end having an annular valve seat. This valve seat portion 20 is fitted into the fitting hole 10a of the valve body 10. Furthermore, a second connector tube 2 is fitted into the fitting hole 10a of the valve body 10 in a manner that abuts against one end face of the valve seat portion 20. This second connector tube 2 communicates with the valve chamber 11 via the valve port 20a. The second connector tube 2 is made of a material such as copper or stainless steel, formed from a thin sheet into a cylindrical shape by stamping or the like, and is fixed to the valve body 10 together with the valve seat portion 20 by brazing or the like.

[0048] The support member 30 includes, for example, a generally cylindrical support portion 31 made of a resin-based material such as polyphenylene sulfide (PPS), and a stainless steel fixing portion 32 integrally formed on the end of the support portion 31 near the valve body 10 by embedding. The support member 30 is welded to the valve body 10 via the fixing portion 32.

[0049] The support portion 31 is configured such that its axis overlaps with the axis L of the shaft passing through the valve port 20a. At the center of the support portion 31, a threaded hole 33 and a sliding hole 35, arranged in a continuous manner along the axis L, are formed on concentric circles. An internal thread portion 33a is formed on the inner circumferential surface of the threaded hole 33, which threadedly engages with the external thread portion 41a of the drive shaft 40, described later. The sliding hole 35 is positioned close to the valve port 20a and is formed with a diameter larger than that of the threaded hole 33. The valve core portion 50, described later, engages with the sliding hole 35 in a slidable manner.

[0050] The drive shaft 40 is formed into a cylindrical rod shape, for example, using a metal such as stainless steel. A threaded portion 41 arranged along the axis L and a flange portion 43 disposed at the end of the threaded portion 41 near the valve port 20a are formed on the drive shaft 40. An external threaded portion 41a is formed in the threaded portion 41a, which threadedly engages with the internal threaded portion 33a of the support portion 31. The rotational motion of the drive shaft 40 is converted into linear motion in the axis L direction by the threaded feed action. The flange portion 43 locks the valve core portion 50, which will be described later, into a rotatable position.

[0051] The valve core 50 includes a valve support 51, a valve core 52, a washer 53, a spring seat 54, and a compression coil spring 55.

[0052] The valve support 51 is formed into a cylindrical shape with an outer diameter that is approximately the same as the inner diameter of the sliding hole 35 of the support portion 31. The valve support 51 is engaged in a manner that allows it to slide along the sliding hole 35 in the direction of axis L.

[0053] The valve core 52 is formed in the shape of a needle and is fixed to the lower end 51a of the valve support 51 on the valve port 20a side with the front end of the needle facing the valve port 20a. The valve core 52 regulates the flow rate by increasing or decreasing the opening of the valve seat of the valve port 20a between the maximum opening degree of the valve and the minimum opening degree of the valve (or the fully closed state).

[0054] The flange 43 of the drive shaft 40 is rotatably engaged with the upper end 51b of the valve bracket 51 on the side opposite to the valve port 20a. Specifically, a washer 53 is inserted between the flange 43 of the drive shaft 40 and the upper end 51b of the valve bracket 51, and the drive shaft 40 is rotatably hooked onto the upper end 51b of the valve bracket 51 via the flange 43. Through this engagement, the valve bracket 51 is supported by the drive shaft 40 so that it can move along the axis L and rotate around the axis L. Furthermore, an opening larger than the radially movable range of the drive shaft 40 is formed in the upper end 51b of the valve bracket 51. In addition, a spring seat 54 is provided inside the valve bracket 51 so as to be movable along the axis L. A compression coil spring 55 is installed between the spring seat 54 and the valve core 52 in a compressed state with a predetermined load applied. As a result, the spring seat 54 is pressed toward the drive shaft 40 and comes into contact with the flange portion 43 of the drive shaft 40.

[0055] The stepper motor 60 includes a housing 61, a magnetic rotor 62, and a coil assembly 70.

[0056] The housing 61 is made of a metal such as stainless steel and is formed from a thin sheet by stamping into a generally cylindrical shape with the upper end blocked. The lower open end of the housing 61 is airtightly fixed to the upper end of the valve body 10 by welding or the like.

[0057] The magnetic rotor 62 integrally comprises a cylindrical magnetic section 64 with its outer periphery magnetized into multiple poles and a disk section 65 blocking the approximately central portion of the magnetic section 64. The magnetic rotor 62 is fixed to the drive shaft 40 via a metal piece 66 integrally formed in the center of the disk section 65. Thus, the magnetic rotor 62 is mounted within the housing 61 in a manner capable of rotating about the axis L of the drive shaft 40. The drive shaft 40 is the axis of rotation of the magnetic rotor 62. Additionally, protrusions 67 are formed on the magnetic rotor 62.

[0058] The coil device 70 is disposed on the outer peripheral surface of the housing 61. By giving the coil device 70 a pulse signal, the magnetic rotor 62 rotates according to the number of pulses.

[0059] The rotation limiting mechanism 80 includes a cylindrical portion 81 that hangs down from the inner top of the housing 61 and is cylindrical in shape; a guide member 82, disposed within the cylindrical portion 81 and cylindrical in shape, that guides the upper end of the drive shaft 40; a spiral guide line 83 fixed to the outer periphery of the cylindrical portion 81; and a movable slider 84 that is guided by the guide line 83 and is capable of rotation and vertical movement. Furthermore, as the magnetic rotor 62 rotates, the protrusions 67 of the magnetic rotor 62 press against and rotate the movable slider 84. As a result, the movable slider 84 abuts against the lower limit member (not shown) or upper limit member (not shown) of the rotation limiting mechanism 80, limiting the lowermost and uppermost positions of the drive shaft 40 (and the magnetic rotor 62). Therefore, it limits the movement of the valve core 50 beyond the position of maximum opening or minimum opening (or closed state).

[0060] <Regarding the operation of the flow regulating valve>

[0061] In the flow regulating valve 100, when the stepper motor 60 is driven, the magnetic rotor 62 and the drive shaft 40 rotate. Through a threaded feed mechanism consisting of an external threaded portion 41a and an internal threaded portion 33a, the drive shaft 40 moves forward and backward along the axis L. By moving forward and backward along the axis L, the valve core 52 and the valve support 51 move together. The valve core 52 changes the opening area, or opening degree, of the valve port 20a by moving forward and backward along the axis L at its front end. Furthermore, it controls the flow rate of fluid flowing from the first connector pipe 1 to the second connector pipe 2 (or from the second connector pipe 2 to the first connector pipe 1).

[0062] <About coil devices>

[0063] like Figure 2As shown, the coil assembly 70 includes a winding tube assembly 71Assy, which comprises a stator 72 having an annular shape, a winding tube 71 integrally disposed with the stator 72, a coil 70a wound around the outer periphery of the winding tube 71, and a power supply terminal 73a assembled on the winding tube 71 and connected to the coil 70a. Furthermore, the coil assembly 70 includes a substrate 73f and leads 73d connected to the terminal 73a, a cover 74 housing the winding tube assembly 71Assy on which the substrate 73f is mounted, and a sealing resin portion 75 sealing the cover 74 and the outer periphery of the winding tube assembly 71Assy. The stator 72 is made of a metal material such as SEC (electroplated galvanized steel sheet) and has a first stator pole tooth portion 72a, a second stator pole tooth portion 72b, a first stator housing 72c, a second stator housing 72d, and a third stator housing (outer shell) 72e, details of which will be described later. Furthermore, the winding tube 71 is made of resin materials such as polyphenylene sulfide (PPS) and polybutylene terephthalate (PBT). Moreover, the coil 70a is made of metal materials such as copper, and has a first coil 70a1 and a second coil 70a2.

[0064] <About the assembly process of the coil assembly>

[0065] Next, use Figures 3 to 10 The assembly process of the coil device 70 is explained below (stator assembly process, winding tube formation process, winding tube assembly process, cover assembly process, and sealing process). Furthermore, the sealing process consists of an insertion process, an injection port expansion process, an injection process, and an injection port restoration process.

[0066] As part of the sealing process, the injection port 74b (see reference) Figure 5 The injection facilitator unit for injecting sealing resin indicates the injection port peripheral wall 74bw (refer to...) Figure 5 The injection promotion unit (injection promotion unit 1) designed with the material of the injection port and the injection promotion unit (injection promotion unit 2) designed with the shape of the injection port peripheral wall 74bw will be described in detail later.

[0067] <Regarding the stator assembly process>

[0068] use Figure 3 (a) describes the stator assembly process. First, the first stator housing 72c is installed into the first stator pole tooth portion 72a, and the second stator housing 72d is installed into the second stator pole tooth portion 72b (see reference). Figure 3 Arrow A1 in (a).

[0069] <About the winding tube forming process>

[0070] use Figure 3(b) describes the winding tube forming process. With the first stator pole tooth portion 72a, the second stator pole tooth portion 72b, the first stator housing 72c, and the second stator housing 72d inserted, insertion forming is performed to form the winding tube 71 (see reference). Figure 3 (b) A2). Figure 3 As shown in (b), the winding tube 71 includes: a winding tube body 71a having a generally cylindrical shape and annular flanges at both ends and the center in the axial direction L; and an annular portion 71f extending further radially from the annular flanges at the center of the winding tube body 71a. At this time, a portion of the stator 72 is covered by the winding tube body 71a. The annular portion 71f is provided with first terminals 73a1 and second terminals 73a2, which are respectively configured as a plurality of terminals (see reference 1). Figure 4 The first insertion hole 71f1 and the second insertion hole 71f2 are inserted.

[0071] <About the winding tube assembly process>

[0072] use Figure 4 The assembly process of the winding tube is described below. First, insert the first terminal 73a1 and the second terminal 73a2 into the first insertion hole 71f1 and the second insertion hole 71f2 of the annular portion 71f, respectively (refer to...). Figure 4 (See arrow A3 in the diagram). Next, the first coil 70a1 and the second coil 70a2 are wound around the outer periphery of one end and the other end of the winding tube body 71a, respectively (refer to...). Figure 4 (A4 in the text). Furthermore, the first wire-connecting portion 70a1c and the second wire-connecting portion 70a2c located at both ends of the first coil 70a1 and the second coil 70a2 are respectively connected (for example, welded) to the first terminal 73a1 and the second terminal 73a2 via the first winding portion 70a1f and the second winding portion 70a2f. Thus, the winding tube assembly 71Assy is constituted.

[0073] <Regarding the cover assembly process>

[0074] use Figure 5 and Figure 6 The assembly process of the cover is explained. First, in order to form the electrical mounting component 73, the lead wire 73d is connected to the terminal 73a of the winding tube assembly 71Assy via the substrate 73f by welding or the like (see reference). Figure 5 (Arrow A5 in the image). Additionally, the third stator housing 72e, which has a C-shape when viewed from the L-axis, is fitted into the outer periphery of the winding tube assembly 71Assy (see reference). Figure 5 (Arrow A6 in the image). Furthermore, the cover 74 is fitted into the winding tube assembly 71Assy from the axis L direction (see reference). Figure 5(See arrow A7 in the image). Furthermore, the winding tube assembly 71Assy, fitted with cover 74, is reversed vertically (see reference). Figure 5 (Arrow A8 in the diagram). Here, the cover 74 has: a bottomed cylindrical portion 74a having a generally bottomed cylindrical shape; and an inlet portion 74b continuously formed with the bottomed cylindrical portion 74a. Furthermore, the bottomed cylindrical portion 74a has a bottom 74ab and a cylindrical portion 74ac. Moreover, the inlet portion 74b has an inlet peripheral wall 74bw formed by an inclined surface 74bws and a front end portion 74bwl. Thus, it constitutes... Figure 6 The shown is the completed winding tube assembly 71Assy, with cover 74 assembled.

[0075] <About the sealing process>

[0076] Next, use Figures 6 to 10 The following describes the insertion step, injection port expansion step, injection step, and injection port restoration step in the sealing process in sequence. In this sealing process, an injection nozzle In (see reference...) is used. Figure 7 , Figure 8 and Figure 10 ) and a pair of expansion pins Ep (refer to Figure 7 , Figure 8 and Figure 10 In addition, in Figure 7 of (b) Figure 8 (b) and Figure 10 In (b), for ease of explanation, the diagram of lead 73d is omitted, and... Figure 9 For ease of explanation, the illustrations of the injection nozzle In and the pair of expansion pins Ep are omitted.

[0077] <Regarding previous issue 1 and previous issue 2>

[0078] Here, as Figure 6 As shown, in the coil assembly 71Assy after the cover 74 is assembled, an injection port Si that can be accessed from the outside is defined at the injection port 74b of the cover 74. However, since electrical mounting components 73 (terminals 73a, substrate 73f, leads 73d) are sandwiched in this injection port Si, when the injection process is performed through the injection port Si in this state, it is difficult for the sealing resin to enter the filling space inside the cover 74, and it also becomes difficult to expel the air mixed in with the sealing resin, resulting in the conventional problem 1 (long molding time required for injection molded coils). In addition, in the coil assembly 71Assy after the cover 74 is assembled, if the filling space of the sealing resin is reduced in advance by injection molding, a new conventional problem 2 (high cost of injection molded coils) occurs.

[0079] <About Injection Facilitation Unit 1>

[0080] In contrast, in the coil device 70 of this embodiment, the injection promotion unit 1 (with a flexible material for the injection port peripheral wall) is designed to inject sealing resin into the injection port 74b during the sealing process. This design ensures that at least a portion of the injection port peripheral wall 74bw defining the injection port 74b is made of a flexible material. Therefore, in the injection port expansion process of the sealing process (see...),... Figure 8 In this process, the movement of a pair of expansion pins Ep (see reference) Figure 8 (A10 in (b)) The peripheral wall 74bw of the injection port is actively expanded, which increases the area of ​​the injection port Si as observed from the axis L, as detailed later. Thus, in the injection process of the sealing process (refer to...) Figure 8 In (a), by increasing the flow path area, the sealing resin can be smoothly impregnated into the filling space within the cover 74, and air mixed into the sealing resin can be expelled. Furthermore, in the injection port restoration process of the sealing process (see...), Figure 9 In this process, the movement of a pair of expansion pins Ep (see reference) Figure 10 (As indicated by arrow A12-2), the peripheral wall 74bw of the injection port independently contracts inward, and the shape of the injection port 74b is restored to its state before the injection port expansion process.

[0081] Thus, in the coil device 70 of this embodiment, by employing the injection promotion unit 1 (the injection port peripheral wall is made of a flexible material), both the previous problem 1 (long molding time required for injection molded coils) and the previous problem 2 (high cost of injection molded coils) can be eliminated simultaneously.

[0082] <About Injection Promotion Unit 2>

[0083] Here, the inventors further studied in depth whether the injection port peripheral wall 74bw could be deformed and restored more reliably by designing the shape of the injection port peripheral wall 74bw, and found that in addition to using injection promotion unit 1 (the injection port peripheral wall is made of a flexible material), they also used injection promotion unit 2 (an inclined surface is configured on a part of the injection port peripheral wall).

[0084] The injection promoting unit 2 (with an inclined surface disposed on a portion of the injection port peripheral wall) is an injection promoting unit in which an inclined surface 74bws is provided on at least a portion of the injection port peripheral wall 74bw when viewed from the direction of axis L and / or a direction orthogonal to axis L. Therefore, in the following description, as an example, the coil device 70 of this embodiment employs both the injection promoting unit 1 (with an injection port peripheral wall made of a flexible material) and the injection promoting unit 2 (with an inclined surface disposed on a portion of the injection port peripheral wall). Here, in Figure 7 (b), (c) Figure 8 of (b) Figure 9 and Figure 10 In (b), thick dots are marked in the area representing the inclined surface 74bws of the injection port peripheral wall 74bw. Furthermore, in the coil device 70 of this embodiment, the injection promotion unit 1 (the injection port peripheral wall is made of a flexible material) is a necessary structure, while the injection promotion unit 2 (an inclined surface is disposed on a part of the injection port peripheral wall) is not a necessary structure.

[0085] <Regarding the sealing process (insertion process)>

[0086] use Figure 7 The sealing process (insertion process) is described below. In this sealing process (insertion process), as follows... Figure 7 As shown, the injection nozzle In and a pair of expansion pins Ep are inserted into the cover 74 through the injection port Si of the injection port 74b until a predetermined depth is reached (see reference). Figure 7 (See arrows A9-1 and A9-2 in the diagram). Here, the injection nozzle In is configured in a suction tube shape, and is connected to the pressurized injection element PI (see...). Figure 8 The (a) connection is a nozzle used to inject sealing resin into the cover 74, and a pair of expansion pins Ep are used to physically expand the injection port Si of the injection port 74b. Furthermore, the insertion depth of the injection nozzle In is set at a position where the lower end of the injection nozzle In is away from the cover 74 in a manner that does not abut against the cover 74. On the other hand, the insertion depth of the pair of expansion pins Ep can also be the depth to which the lower ends of the pair of expansion pins Ep abut against the cover 74.

[0087] In addition, such as Figure 7 As shown in (c), when viewed from the axis L, the insertion position of the injection nozzle In is located inside the front end 74bwl near the peripheral wall 74bw of the injection port, and the insertion positions of the pair of expansion pins Ep are respectively located inside the inclined surfaces 74bws near the peripheral wall 74bw of the injection port. Furthermore, Figure 7 In (b) and (c), the width Lw1 of the front end of the injection port peripheral wall during non-expansion is, for example, 15 mm. Here, "width of the front end of the injection port peripheral wall" means "the length in the width direction of the opening edge of the front end 74bwl of the injection port peripheral wall 74bw". In the scope of this specification and technical solution, "width direction" means "the direction orthogonal to a straight line extending radially from the axis when viewed from the axial direction".

[0088] <Regarding the sealing process (injection port expansion process)>

[0089] use Figure 8 and Figure 9 The sealing process (injection port expansion process) will be described. In this sealing process (injection port expansion process), as follows... Figure 8 As shown in (b), a pair of expansion pins Ep are moved away from each other while in contact with the inner surface of the inclined surface 74bws of the injection port peripheral wall 74bw (see reference). Figure 8 (arrow A10 in (b)). Here, in this embodiment, as the injection promotion unit 1 (the injection port peripheral wall is made of a flexible material), at least a portion of the injection port peripheral wall 74bw is made of a flexible material. Therefore, by moving a pair of expansion pins Ep, the injection port peripheral wall 74bw actively expands outward, thereby increasing the area of ​​the injection port Si as observed from the axis L direction. Furthermore, Figure 8 In (b), the width of the front end of the injection port peripheral wall during expansion, Lw2, is, for example, 20 mm, which is, for example, about 1.3 times the width of the front end of the injection port peripheral wall during non-expansion.

[0090] In addition, such as Figure 9 As shown, in this embodiment, by employing the injection promotion unit 2 (with an inclined surface disposed on a portion of the injection port peripheral wall), an inclined surface 74bws is provided on at least a portion of the injection port peripheral wall 74bw when viewed from the axis L direction and / or a direction orthogonal to the axis L. Specifically, the inclined surface 74bws is provided in the region between the cylindrical portion 74ac and the front end portion 74bwl in the injection port peripheral wall 74bw of the cover 74. Therefore, by providing the inclined surface 74bws, compared to the method of connecting the cylindrical portion 74ac and the front end portion 74bwl with the shortest distance (when viewed from the axis L direction, the injection port peripheral wall 74bw has a U-shape), the connection distance can be extended, that is, by the movement of a pair of expansion pins Ep (see reference...). Figure 9 Arrow A10 in (a) and (b) enables the peripheral wall 74bw of the injection port to expand further outward.

[0091] Furthermore, since it is not necessary to use the injection promotion unit 2 (which has an inclined surface disposed on a part of the injection port peripheral wall), for example, when viewed from the axis L direction, if the injection port peripheral wall 74bw has a U-shape composed of a pair of planes and a front end 74bwl, the pair of expansion pins Ep can be moved away from each other in a state of contact with the inner surfaces of the pair of planes.

[0092] <Regarding the sealing process (injection process)>

[0093] use Figure 8 (a) describes the sealing process (injection process). In this sealing process (injection process), as follows: Figure 8As shown in (a), with the injection port peripheral wall 74bw expanded outward by a pair of expansion pins Ep, sealing resin is injected into the filling space containing the injection port Si within the cover 74 via the injection flow path of the injection nozzle In. At this time, by expanding the area of ​​the injection port Si, i.e., expanding the flow path area of ​​the inflow path, the sealing resin can smoothly penetrate into the filling space within the cover 74 and expel any air mixed into the sealing resin. Therefore, by employing the injection promotion unit 1 (the injection port peripheral wall is made of a flexible material), both the previous problem 1 (long molding time required for the injection molding coil) and the previous problem 2 (high cost of the injection molding coil) can be eliminated simultaneously. Furthermore, in the sealing process (injection port restoration process) described later, when the area of ​​the injection port Si is restored to its state before the injection port expansion process, the sealing resin injected into the filling space is injected in a predetermined amount adjusted by the pressurized injection member PI in a manner appropriate for the filling space.

[0094] <Sealing process (injection port restoration process)>

[0095] use Figure 10 The sealing process (injection port restoration process) will be described. In this sealing process (injection port restoration process), the injection nozzle In and the pair of expansion pins Ep move in the opposite direction to those in the sealing process (injection port expansion process) and the sealing process (insertion process). That is, firstly, the pair of expansion pins Ep are moved toward each other, and the injection nozzle In and the pair of expansion pins Ep are moved upward (see reference). Figure 10 (See arrows A12-1 and A12-2 in the diagram), removed from the injection port Si outwards. At this time, due to the restoring force of the expanded injection port peripheral wall 74bw, the injection port peripheral wall 74bw independently contracts inwards by the movement of the pair of expansion pins Ep (see...). Figure 10 Arrow A13 in (b) restores the shape of the injection port 74b to its state before the injection port expansion process. Thus, by continuously and integrally sealing the winding tube assembly 71Assy, coil 70a, and third stator housing 72e housed within the cover 74 using the same sealing resin and then heat-curing it, a sealing resin portion 75 bonded to the cover 74 is formed. Finally, the bracket 76 is moved along the axis L (refer to...). Figure 10 Arrow A14 in (a) is inserted between the winding tube assembly 71Assy and the cover 74. Thus, the coil device 70 is formed.

[0096] Furthermore, in the sealing process (injection port restoration process) of this embodiment, after the pair of expansion pins Ep are moved toward each other in a direction of approaching each other, they are taken out from the injection port Si to the outside. However, this is not the only possibility. For example, the pair of expansion pins Ep may not be moved toward each other in a direction of approaching each other, but may be moved upward and taken out from the injection port Si to the outside.

[0097] As described above, in the first embodiment, by employing injection facilitator 1 (the injection port peripheral wall is made of a flexible material), both the previous problem 1 (long molding time required for the injection mold coil) and the previous problem 2 (high cost of the injection mold coil) can be eliminated simultaneously. Furthermore, in the first embodiment, in addition to employing injection facilitator 1 (the injection port peripheral wall is made of a flexible material), injection facilitator 2 (a portion of the injection port peripheral wall is provided with an inclined surface) is also employed, thereby enabling the injection port peripheral wall 74bw to deform and recover more reliably.

[0098] <Design of the shape of the injection port periphery>

[0099] Furthermore, the inventors attempted to make the injection port peripheral wall 74bw deform and recover more reliably by designing the shape of the injection port peripheral wall 74bw in a different unit than the injection promoting unit 2 (which has an inclined surface configured on a part of the injection port peripheral wall). Thus, the inventors discovered that in the first embodiment, in addition to using the injection promoting unit 1 (which has a flexible material for the injection port peripheral wall), injection promoting unit 3 and / or injection promoting unit 4 are also used.

[0100] <Regarding Injection Promotion Unit 3 and Injection Promotion Unit 4>

[0101] like Figure 5 As shown, the injection promotion unit 3 (the thickness of the injection port peripheral wall is thinner than the thickness of the cylindrical portion) is an injection promotion unit in which the thickness T1 of the injection port peripheral wall 74bw in the cover 74 is thinner than the thickness T2 of the cylindrical portion 74ac of the bottomed cylindrical portion 74a. Additionally, as... Figure 5 As shown, injection promoting unit 4 (the thickness of the injection port peripheral wall is thinner than the thickness of the bottom) is an injection promoting unit in which the thickness T1 of the injection port peripheral wall 74bw in the cover 74 is thinner than the thickness T3 of the bottom 74ab of the bottomed cylindrical portion 74a. In this way, by using injection promoting unit 3 (the thickness of the injection port peripheral wall is thinner than the thickness of the cylindrical portion) and / or injection promoting unit 4 (the thickness of the injection port peripheral wall is thinner than the thickness of the bottom), the thickness of the injection port peripheral wall 74bw is made thinner than that of the cylindrical portion 74ac and / or the bottom 74ab. Thus, with only a slight design change, it is possible to reliably deform and recover the injection port peripheral wall 74bw while maintaining the rigidity of the cylindrical portion 74ac and / or the bottom 74ab.

[0102] <Design of the material for the periphery of the injection port>

[0103] Furthermore, in order to make the periphery wall 74bw of the injection port deform and recover more reliably, the inventors explored a more specific structure for the injection promoting unit 1 (the periphery wall of the injection port is made of a flexible material), and discovered that in addition to using the injection promoting unit 1 (the periphery wall of the injection port is made of a flexible material), at least one of the injection promoting unit 5, injection promoting unit 6 and injection promoting unit 7 is also used.

[0104] <Regarding Injection Promotion Unit 5>

[0105] As for the injection promotion unit 5 (the specific material of the cover including the injection port peripheral wall), by selecting an injection promotion unit made of a material selected from thermosetting elastomers, thermoplastic elastomers, and soft synthetic resins that constitutes the cover 74 including the injection port peripheral wall 74bw, the injection port peripheral wall 74bw can be deformed and restored more reliably. Here, thermosetting elastomers, such as polyurethane, have excellent heat resistance, chemical resistance, and mechanical properties, but their manufacturing cost is relatively high. In addition, thermoplastic elastomers, such as urethane-based, olefin-based, and polyester-based elastomers, have performance inferior to thermosetting elastomers, but their manufacturing cost is lower. Furthermore, soft synthetic resins, such as low-density polyethylene and polyvinyl chloride, have poor elasticity and durability compared to thermosetting and thermoplastic elastomers, but their manufacturing cost can be kept relatively low. Therefore, the material of the cover 74 including the injection port peripheral wall 74bw can be selected according to the application of the coil device 70.

[0106] <Regarding concerns (insulation failure caused by delamination of the interface between the sealing resin and the cover)>

[0107] In the coil device 70 of this embodiment, the sealing resin part 75 is bonded to the cover 74. However, for example, when the sealing resin part 75 returns to room temperature after being heated and cured, or in the case of repeated high and low temperature use, there is a concern that the interface between the sealing resin part 75 and the cover 74 may peel off, the surface of the sealing resin part 75 may crack, and moisture may enter the coil device 70, resulting in poor insulation (hereinafter referred to as "concern (insulation failure caused by interface peeling between the sealing resin part and the cover)").

[0108] In contrast, in the first embodiment, when an injection promoting unit 5 (a material specifically for a cover including the periphery of the injection port) is used in addition to the injection promoting unit 1 (a material with a flexible material for the injection port periphery), the hardness of the cover 74 is set to be less than or equal to the hardness of the sealing resin portion 75. Therefore, the flexibility of the cover 74 can be reliably improved compared to the sealing resin portion 75. Consequently, when the sealing resin portion 75 returns to room temperature after heat curing, and under repeated high and low temperature operating conditions, the cover 74 can deform in a way that follows the thermal expansion and contraction of the sealing resin portion 75 while maintaining an adhesive state, thus eliminating concerns about poor insulation caused by the interface peeling between the sealing resin portion and the cover.

[0109] Specifically, the material of the cover 74 is selected from any one of thermosetting elastomers (e.g., urethane elastomers), thermoplastic elastomers (e.g., urethane elastomers, olefin elastomers, and polyester elastomers), and soft synthetic resins (e.g., low-density polyethylene, polyvinyl chloride, etc.), and the material of the sealing resin part 75 is selected from thermosetting resins (urethane elastomers, epoxy resins, etc.). By adding additives respectively, the hardness can be adjusted to the desired value.

[0110] <Regarding Injection Promotion Unit 6>

[0111] As the injection facilitator unit 6 (hardness of the cover), an injection facilitator unit is adopted with a hardness of 50 or more and 100 or less on the Shore A hardness scale, including the peripheral wall 74bw of the injection port. By setting the hardness of the cover 74 within this range, the peripheral wall 74bw of the injection port can be deformed and restored more reliably. Furthermore, when the hardness of the cover 74 is less than 50, the rigidity of the cover 74 decreases, and the elastic modulus of the cover 74 decreases. Therefore, during the injection port restoration process, the restoration force in the cover 74 is less than the desired restoration force, and some residual deformation may remain in the cover 74, as will be described in detail later. On the other hand, if the hardness of the cover 74 exceeds 100, the elastic force of the cover 74 increases. Therefore, during the injection port expansion process, a greater external force is required to expand the peripheral wall 74bw of the injection port.

[0112] Furthermore, the hardness of Cover 74 was determined according to JIS K 6253-3. As a hardness test piece, a sheet with a thickness of 2 mm and a smooth, uniform surface was prepared, and the test was conducted at room temperature (23±2℃). During the test, a Type A hardness tester was used under the conditions specified in JIS K 6253-3, and the measurement time was recorded according to the material of Cover 74 (3 seconds for vulcanized rubber as a thermosetting elastomer and 15 seconds for thermoplastic rubber as a thermoplastic elastomer).

[0113] <Regarding Injection Promotion Unit 7>

[0114] As the injection facilitator unit 7 (the injection port peripheral wall is made of a material that is more flexible than the bottomed cylindrical portion), the cover 74 is made of various materials, i.e., materials with different hardness, and the injection port peripheral wall 74bw is made of a material that is softer than the bottomed cylindrical portion 74a. As a result, the degree of freedom in selecting the injection port peripheral wall 74bw from a material that is easy to deform and recover can be increased without reducing the rigidity of the bottomed cylindrical portion 74a, and the injection port peripheral wall 74bw can be deformed and recovered more reliably.

[0115] Furthermore, in the injection promotion unit 7 (where the material of the injection port peripheral wall is more flexible than that of the bottomed cylindrical portion), when selecting the materials of the injection port peripheral wall 74bw and the bottomed cylindrical portion 74a, it is set that "the hardness of the injection port peripheral wall 74bw is less than the hardness of the bottomed cylindrical portion 74a". Here, for example, when the cover 74 is two-color molded using resin materials with different hardnesses by injection molding, the materials of the injection port peripheral wall 74bw and the bottomed cylindrical portion 74a can be selected from any one of polyurethane, olefin-based, and polyester-based thermoplastic elastomers. By adding additives, the hardness can be adjusted to the desired value. In this case, it is preferable that the materials of the injection port peripheral wall 74bw and the bottomed cylindrical portion 74a are both made of the same thermoplastic elastomer, as the adhesion is higher. However, this is not a limitation; for example, the materials of the injection port peripheral wall 74bw and the bottomed cylindrical portion 74a can also be made of different thermoplastic elastomers.

[0116] As described above, in the first embodiment, by employing the injection promotion unit 1 (the injection port peripheral wall is made of a flexible material), both the previous problem 1 (long molding time required for injection mold coils) and the previous problem 2 (high cost of injection mold coils) can be eliminated simultaneously.

[0117] In addition, in the first embodiment, besides using injection promoting unit 1 (the injection port peripheral wall is made of a flexible material), at least one of the following units designed to shape the injection port peripheral wall is also used: injection promoting unit 2 (an inclined surface is provided on a part of the injection port peripheral wall), injection promoting unit 3 (the thickness of the injection port peripheral wall is thinner than the thickness of the cylindrical part), and injection promoting unit 4 (the thickness of the injection port peripheral wall is thinner than the thickness of the bottom part), thereby enabling the injection port peripheral wall 74bw to deform and recover more reliably.

[0118] Furthermore, in the first embodiment, in addition to using injection promotion unit 1 (the injection port peripheral wall is made of a soft material), at least one of the following units designed for the material of the injection port peripheral wall is used: injection promotion unit 5 (containing the specific material of the cover of the injection port peripheral wall), injection promotion unit 6 (the hardness of the cover), and injection promotion unit 7 (the injection port peripheral wall is made of a material that is softer than the bottomed cylindrical portion), thereby enabling the injection port peripheral wall 74bw to deform and recover more reliably.

[0119] In the first embodiment, when injection promotion unit 5 (a material containing a cover for the periphery of the injection port) is used in addition to injection promotion unit 1 (a material with a soft material for the injection port periphery), concerns about poor insulation caused by the interface peeling between the sealing resin part and the cover can be eliminated by setting "the hardness of the cover 74 ≤ the hardness of the sealing resin part 75".

[0120] (Second Implementation)

[0121] use Figure 11 and Figure 14 The flow regulating valve 100 of the second embodiment will be described. In the sealing process of the second embodiment, the difference from the sealing process of the first embodiment lies in the use of an expansion inflow nozzle EpIn instead of an injection nozzle In and a pair of expansion pins Ep, but the flow regulating valve 100, which includes other coil devices 70, is the same as in the first embodiment. Here, the same reference numerals are used to refer to the same structures, and repeated descriptions are omitted.

[0122] Furthermore, although detailed descriptions are omitted, in the second embodiment, similar to the first embodiment, by employing injection facilitator 1 (the injection port peripheral wall is made of a flexible material), both the previous problem 1 (long molding time required for the injection mold coil) and the previous problem 2 (high cost of the injection mold coil) can be eliminated simultaneously. Additionally, in the second embodiment, by employing at least one of injection facilitator 2 to 7 in addition to injection facilitator 1 (the injection port peripheral wall is made of a flexible material), the injection port peripheral wall 74bw can be deformed and restored more reliably.

[0123] <Regarding concerns (the sealing process is complex)>

[0124] like Figures 7 to 10 As shown, in the sealing process (insertion process, injection port expansion process, injection process, and injection port restoration process) of the first embodiment, an injection nozzle In and a pair of expansion pins Ep are used respectively, and actions including movement are performed. Therefore, in the sealing process of the first embodiment, it is necessary to operate the injection nozzle In and the pair of expansion pins Ep separately, which raises concerns that the operation becomes complicated (hereinafter referred to as "concern (complex operation of the sealing process)").

[0125] In contrast, in the sealing process of the second embodiment, instead of the injection nozzle In and the pair of expansion pins Ep in the sealing process of the first embodiment, an expansion inflow nozzle EpIn that combines the injection nozzle In and the pair of expansion pins Ep is used. Therefore, in the sealing process, the action object can be only the expansion inflow nozzle EpIn, thus eliminating concerns about the complexity of the sealing process. Therefore, the sealing process (insertion process, injection port expansion process, injection process, and injection port restoration process) will be briefly described below.

[0126] <About the sealing process>

[0127] Next, use Figures 11 to 14 The following describes the insertion step, injection port expansion step, injection step, and injection port restoration step in the sealing process in sequence. In this sealing process, an expansion inflow nozzle EpIn ( Figure 11 , Figure 12 as well as Figure 14 In addition, in Figure 11 In (b), for ease of explanation, the diagram of lead 73d is omitted, and... Figure 13 For ease of explanation, the illustration of the expansion inflow nozzle EpIn is omitted. In addition, the injection promotion unit 1 (the peripheral wall of the injection port is made of a flexible material) and the injection promotion unit 2 (an inclined surface is provided on a part of the peripheral wall of the injection port) will be described, but the description of injection promotion units 3 to 7 will be omitted.

[0128] <Regarding the sealing process (insertion process)>

[0129] use Figure 11 The sealing process (insertion process) is described below. In this sealing process (insertion process), as follows... Figure 11 As shown, the expansion nozzle EpIn is inserted into the cover 74 through the injection port Si of the injection port 74b until a predetermined depth is reached (see reference). Figure 11 (See arrow A9' in the image). The expansion inlet nozzle EpIn has a generally flat shape extending along the axis L (see reference). Figure 11 (b) When viewed from the axis L direction, it has a generally rectangular cross-sectional shape extending in the direction along the front end 74bwl of the inlet peripheral wall 74bw (see reference). Figure 11 (c) is used to physically expand the injection port Si of the injection port 74b. Furthermore, when viewed from the axis L direction, the expansion inflow nozzle EpIn has an injection flow path extending along the axis L direction at its center (see reference). Figure 11 (a) and (c)), the injection flow path is connected to the pressurized injection element PI (refer to...). Figure 12The (a) connection is used to inject sealing resin into the cover 74. Moreover, the insertion depth of the expansion inflow nozzle EpIn is set at a position away from the cover 74 at the lower end of the expansion inflow nozzle EpIn so as not to come into contact with the cover 74.

[0130] In addition, such as Figure 11 As shown in (c), when viewed from the axis L direction, the insertion position of the expansion inflow nozzle EpIn is positioned inside the front end 74bwl near the peripheral wall 74bw of the injection port. Furthermore, Figure 11 In (a), the radial length Lr1 of the injection port in the non-expansion direction is, for example, 10 mm. Here, "radial length of injection port" means "the length of the injection port 74b along the radial direction from the axis L".

[0131] <Regarding the sealing process (injection port expansion process)>

[0132] use Figure 12 and Figure 13 The sealing process (injection port expansion process) will be described. In this sealing process (injection port expansion process), as follows... Figure 12 As shown in (b), the expansion nozzle EpIn is moved in a radial direction away from the axis L while in contact with the inner surface of the front end 74bwl of the injection port peripheral wall 74bw (refer to...). Figure 12 (b) and Figure 13 (See arrow A10' in (a) and (b)). In this embodiment, as the injection promotion unit 1 (the injection port peripheral wall is made of a flexible material), at least a portion of the injection port peripheral wall 74bw is made of a flexible material. Furthermore, the expansion inflow nozzle EpIn is configured as a flat shape extending along the axis L, thus, unlike the suction-shaped injection nozzle In of the first embodiment, it can achieve very high rigidity. Therefore, by moving the expansion inflow nozzle EpIn, the injection port peripheral wall 74bw can be actively expanded outwards, increasing the area of ​​the injection port Si as observed from the axis L. Moreover, Figure 12 In (a), the radial length Lr2 of the injection port during expansion is, for example, 14 mm, which is about 1.4 times larger than the radial length Lr1 of the injection port during non-expansion.

[0133] In addition, such as Figure 13As shown, in this embodiment, by employing the injection promotion unit 2 (with an inclined surface disposed on a portion of the injection port peripheral wall), an inclined surface 74bws is provided on at least a portion of the injection port peripheral wall 74bw when viewed from the axis L direction and / or a direction orthogonal to the axis L. By providing this inclined surface 74bws, compared to the method of connecting the cylindrical portion 74ac and the front end portion 74bwl with the shortest distance (when viewed from the axis L direction, the injection port peripheral wall 74bw has a U-shape), the connection distance can be extended, that is, by expanding the movement of the inflow nozzle EpIn (see reference). Figure 12 Arrow A10' in (a) and (b) enables the peripheral wall 74bw of the injection port to expand further outward.

[0134] Furthermore, since it is not necessary to use the injection promotion unit 2 (which has an inclined surface disposed on a part of the injection port peripheral wall), for example, when viewed from the axis L direction, if the injection port peripheral wall 74bw has a U-shape composed of a pair of planes and a front end portion 74bwl, the expansion inflow nozzle EpIn is moved in a radial direction away from the axis L while in contact with the inner surface of the front end portion 74bwl.

[0135] <Regarding the sealing process (injection process)>

[0136] use Figure 12 (a) describes the sealing process (injection process). In this sealing process (injection process), as follows: Figure 12 As shown in (a), with the injection port peripheral wall 74bw expanded outward using the expansion inflow nozzle EpIn, sealing resin is injected into the filling space containing the injection port Si within the cover 74 via the injection flow path of the expansion inflow nozzle EpIn. At this time, by expanding the area of ​​the injection port Si, i.e., expanding the flow path area of ​​the inflow path, the sealing resin can smoothly penetrate into the filling space within the cover 74, and air mixed into the sealing resin can be expelled. Therefore, by using the injection promotion unit 1 (the injection port peripheral wall is made of a flexible material), both the previous problem 1 (long molding time required for injection molding coils) and the previous problem 2 (high cost of injection molding coils) can be eliminated simultaneously.

[0137] <Regarding the sealing process (injection port restoration process)>

[0138] use Figure 14 The sealing process (injection port restoration process) will be described. In this sealing process (injection port restoration process), movement is performed in the opposite direction to that of the expansion nozzle EpIn in both the sealing process (injection port expansion process) and the sealing process (insertion process). Specifically, first, the expansion nozzle EpIn is moved radially toward axis L and upwards (see reference). Figure 14 (See arrow A12' in the image) it is removed from the injection port Si outwards. At this time, due to the restoring force of the expanded injection port peripheral wall 74bw, the injection port peripheral wall 74bw independently contracts inwards by the movement of the expansion into the nozzle EpIn (see reference). Figure 14 (See arrow A13' in the image) The shape of the injection port 74b is restored to its state before the injection port expansion process. Thus, by using the same sealing resin to continuously and integrally seal and heat-cure the winding tube assembly 71Assy, coil 70a, and housing 72e housed within the cover 74, a sealing resin portion 75 bonded to the cover 74 is formed. Finally, the bracket 76 is moved along the axis L (refer to...). Figure 14 Arrow A14 in the diagram is inserted between the winding tube assembly 71Assy and the cover 74. Thus, the coil device 70 is formed.

[0139] Furthermore, in the sealing process (injection port restoration process) of this embodiment, after the expansion inflow nozzle EpIn is moved toward the axis L in the radial direction, it is taken out from the injection port Si. However, it is not limited to this. For example, the expansion inflow nozzle EpIn may not be moved toward the axis L in the radial direction, but may be moved upward and taken out from the injection port Si.

[0140] As described above, in the second embodiment, similar to the first embodiment, by employing the injection promotion unit 1 (the injection port peripheral wall is made of a flexible material), both the previous problem 1 (long molding time required for injection mold coils) and the previous problem 2 (high cost of injection mold coils) can be eliminated simultaneously.

[0141] In addition, in the second embodiment, similar to the first embodiment, in addition to using injection promoting unit 1 (the injection port peripheral wall is made of a flexible material), at least one of the following injection promoting units designed with the shape of the injection port peripheral wall, namely injection promoting unit 2 (an inclined surface is provided on a part of the injection port peripheral wall), injection promoting unit 3 (the thickness of the injection port peripheral wall is thinner than the thickness of the cylindrical part) and injection promoting unit 4 (the thickness of the injection port peripheral wall is thinner than the thickness of the bottom), is used, thereby enabling the injection port peripheral wall 74bw to deform and recover more reliably.

[0142] Furthermore, in the second embodiment, similar to the first embodiment, in addition to using injection promotion unit 1 (the injection port peripheral wall is made of a soft material), at least one of the following injection promotion units designed for the material of the injection port peripheral wall, namely injection promotion unit 5 (including the specific material of the cover of the injection port peripheral wall), injection promotion unit 6 (the hardness of the cover), and injection promotion unit 7 (the injection port peripheral wall is made of a material that is softer than the bottomed cylindrical portion), can be used to make the injection port peripheral wall 74bw deform and recover more reliably.

[0143] Here, in the second embodiment, similar to the first embodiment, when the injection promoting unit 5 (including the specific material of the cover of the injection port peripheral wall) is used in addition to the injection promoting unit 1 (the material of the injection port peripheral wall), the concern (insulation failure caused by the interface peeling between the sealing resin part and the cover) can be eliminated by setting "the hardness of the cover 74 ≤ the hardness of the sealing resin part 75".

[0144] Furthermore, in the second embodiment, by employing an expansion inflow nozzle EpIn, the action target in the sealing process can be limited to the expansion inflow nozzle EpIn, thus eliminating concerns about the complexity of the sealing process.

[0145] <Other>

[0146] In the injection port expansion process, a pair of expansion pins Ep are used in the first embodiment, while an expansion inflow nozzle EpIn is used in the second embodiment. Alternatively, in the injection port expansion process, the pair of expansion pins Ep in the first embodiment and the expansion inflow nozzle EpIn in the second embodiment can be used simultaneously to expand the injection port 74b further.

[0147] The flow regulating valve 100 equipped with the coil device 70 of this embodiment can of course be applied to all fluid devices and fluid circuits, including refrigeration cycles. Moreover, the present invention is not limited to the embodiments described above, and appropriate changes and modifications can be made without departing from the technical concept of the present invention.

Claims

1. A coil device, characterized in that, have: A winding tube, which has a roughly cylindrical shape with its axis as the center; A coil wound around the winding tube; The outer casing, which fits into the winding tube; The cover has a bottomed cylindrical portion and an injection port, the bottomed cylindrical portion having a generally bottomed cylindrical shape, and the injection port being continuously formed with the bottomed cylindrical portion; A sealing resin section is used to continuously and integrally seal the winding tube, the coil, and the housing housed inside the cover using the same sealing resin, and is bonded to the cover. as well as An injection facilitator unit injects the sealing resin into the injection port. At least a portion of the peripheral wall of the injection port of the injection promotion unit, which defines the injection port, is made of a soft material.

2. The coil device according to claim 1, characterized in that, When viewed from the axial direction and / or a direction orthogonal to the axial direction, the injection facilitating unit is an inclined surface disposed on at least a portion of the peripheral wall of the injection port.

3. The coil device according to claim 1, characterized in that, Regarding the injection promotion unit, in the shroud, the thickness of the peripheral wall of the injection port is thinner than the thickness of the cylindrical portion with a bottom.

4. The coil device according to claim 1, characterized in that, Regarding the injection facilitator unit, within the shroud, the thickness of the peripheral wall of the injection port is thinner than the thickness of the bottom of the bottomed cylindrical portion.

5. The coil device according to claim 1, characterized in that, Regarding the injection promotion unit, the material of the cover is composed of any one of thermosetting elastomers, thermoplastic elastomers, and soft synthetic resins.

6. The coil device according to claim 1, characterized in that, Regarding the injection promotion unit, the hardness of the cover is 50 or higher and 100 or lower on the Shore A scale.

7. The coil device according to claim 1, characterized in that, Regarding the injection promotion unit, the cover is made of a variety of materials, and the peripheral wall of the injection port is made of a material that is softer than the bottomed cylindrical portion.

8. A flow regulating valve, characterized in that, A coil device comprising any one of claims 1 to 7.

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