Coil device and flow control valve including the same

Abstract

To provide a coil device capable of suppressing breakage of an across wire part of a coil sealed in a sealing resin part due to an expansion or a contraction of the sealing resin part even when the coil device is used in an environment in which a temperature change is extremely large, and improving reliability, and provide a flow control valve including the coil device.SOLUTION: A coil device includes: a sealing resin part 97 that seals each of a flange part 94af of a bobbin 94, an across wire part 93a1c of a coil 93a, and a terminal 96a; and across wire part breakage suppressing means of suppressing breakage of the across wire part 93a1c. The across wire part breakage suppressing means is to provide adhesion strengthening means Ar for strengthening adhesion between the sealing resin part 97 and the flange part 94af in an axial direction opposing region AF of the flange part 94af, to dispose the across wire part 93a1c close to or in contact with the axial direction opposing region AF of the flange part 94af, and to allow the bobbin 94 to have a smaller linear expansion coefficient than the sealing resin part 97.SELECTED DRAWING: Figure 9

Description

[Technical Field]

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

[0002] In a coil device, a sealing member (hereinafter referred to as "sealing resin portion") made of a resin material is sometimes used for the stator coil, electrical components, etc. as a dustproof and waterproof means.

[0003] 16, Patent Document 1 describes a coil device 1600 (hereinafter referred to as a "conventional coil device") that includes a stator yoke 1695, a bobbin 1694 made of a resin material and integrally molded 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 to the outer periphery of the bobbin 1694. Patent Document 1 also describes a coil device that further includes a terminal 1696a press-fitted into a flange portion 1694f of the bobbin 1694, and a lead wire 1696d connected to the terminal 1696a via a substrate 1696f, and that the bobbin 1694, the coil 1693a, the frame yoke 1695e, the terminal 1696a, etc. are sealed with a sealing resin portion 1697.

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

[0005] In recent years, as the range of applications for coil devices has expanded, there has been a demand for them to be used in environments where there is a large temperature change between high and low temperatures (for example, in the case of coil devices for vehicles, the temperature change is from -40°C to 120°C, a change of 160°C).

[0006] In conventional coil device 1600, there is a large difference between the linear expansion coefficient of sealing resin portion 1697 and the linear expansion coefficient of coil 1693a made of a metal material (e.g., annealed copper). (Generally, the linear expansion coefficient of resin material is several to ten times larger than that of metal material.) Therefore, when conventional coil device 1600 is used in an environment with extremely large temperature changes, sealing resin portion 1697 repeatedly expands and contracts. Furthermore, because the periphery of the crossover portion of coil 1693a is tightly fixed to sealing resin portion 1697, tensile and compressive forces are also repeatedly applied to the crossover portion. The wire diameter of coil 1693a is generally small. Therefore, the strength of the crossover portion of coil 1693a is also low. Therefore, the crossover wire portion may not be able to withstand the external forced deformation caused by the expansion and contraction of the sealing resin portion 1697, which may cause fatigue failure and lead to breakage (hereinafter referred to as "the conventional problem (breakage of the crossover wire portion due to temperature changes)").

[0007] In order to solve the previous problem (breakage of the crossover wire due to temperature changes), it is possible to change the wire diameter of coil 1693a or to add a protective member to the crossover wire to increase its strength, but this cannot be adopted because it would result in new issues such as increased costs and inability to achieve the desired motor performance. [Prior art documents] [Patent documents]

[0008] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-20480 Summary of the Invention [Problem to be solved by the invention]

[0009] The object of the present invention is to provide a coil device and a flow control valve equipped with the same that can prevent the cross wire portion of the coil sealed in the sealing resin portion from breaking due to expansion or contraction of the sealing resin portion, even when used in an environment with extremely large changes in ambient temperature, thereby improving reliability. [Means for solving the problem]

[0010] In order to solve the above problem, a coil device is provided which includes: a stator; a bobbin body made of a resin material and having a substantially cylindrical shape centered on the axis; and a bobbin having a flange portion extending radially outward from the bobbin body; a power supply terminal fixed to the flange portion; a coil wound around the bobbin body, the coil having crossover portions connected to the terminals at both ends; a sealing resin portion which seals the bobbin including the flange portion, the coil including the crossover portion, and the terminals; and a crossover portion breakage suppression means which suppresses breakage of the crossover portion, wherein the crossover portion breakage suppression means is provided in an axially opposing region of the flange portion which faces the crossover portion in the axial direction, with an adhesion strengthening means which strengthens the adhesion between the sealing resin portion and the flange portion; the crossover portion is positioned adjacent to or abutting the axially opposing region of the flange portion; and the bobbin has a smaller linear expansion coefficient than the sealing resin portion.

[0011] In the coil device, the adhesion strengthening means may be an uneven portion or a surface modified portion provided in the axially opposing region of the flange portion.

[0012] In the coil device, the uneven portion may extend in a direction intersecting the crossover portion when viewed from the axial direction.

[0013] In addition, in the above-mentioned coil device, the flange portion may have an axis-orthogonal facing region that faces the crossover portion in a direction perpendicular to the axis, and the crossover portion breakage prevention means may be configured to position the crossover portion in a non-contact state in the axis-orthogonal facing region of the flange portion.

[0014] In addition, in the above coil device, the crossover portion may have a winding portion that is wound around the terminal, and the crossover portion breakage prevention means may fix only the tip of the winding portion to the terminal.

[0015] In addition, in the above-mentioned coil device, the crossover wire breakage prevention means may be such that the resin material forming the bobbin is made of glass fiber as a reinforcing agent, or polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT) in which inorganic filler is added to glass fiber.

[0016] In addition, in the above-mentioned coil device, the cross wire portion breakage prevention means may be such that, when the resin material forming the bobbin and the resin material forming the sealing resin portion are the same material, the resin material forming the bobbin has a greater amount of the reinforcing agent added than the resin material forming the sealing resin portion.

[0017] In addition, in the above-mentioned coil device, the crossover wire breakage prevention means may set the linear expansion coefficient of the resin material forming the bobbin so that the tension acting on the crossover wire at the operating temperature is 40% or less of the breakage tension of the coil.

[0018] Furthermore, a flow rate adjusting valve may be provided with the above coil device. [Effects of the Invention]

[0019] According to the present invention, it is possible to provide a coil device and a flow control valve equipped with the same that can prevent the cross wire portion of the coil sealed in the sealing resin portion from breaking due to expansion or contraction of the sealing resin portion, even when used in an environment with extremely large changes in ambient temperature, thereby improving reliability. [Brief explanation of the drawings]

[0020] [Figure 1] 1 is a cross-sectional view showing a flow rate adjustment valve according to a first embodiment of the present invention. [Figure 2] 2 is an explanatory diagram of a process for assembling the stator coil unit and the flow rate adjustment valve main body shown in FIG. 1. [Figure 3]2 is a cross-sectional view showing the flow rate adjustment valve shown in FIG. 1 attached to a housing. [Figure 4] 3 is an explanatory diagram of the bobbin forming process (crossover wire breakage prevention means (1)) in the assembly process of the coil device shown in FIG. 2, 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. [Figure 5] 3 is an explanatory diagram of a bobbin assembling step (crossover wire breakage suppressing means (2)) in the assembling process of the coil device shown in FIG. 2. FIG. [Figure 6] 6A and 6B are explanatory views of the bobbin assembly shown in FIG. 5, in which (a) is a top perspective view and (b) is a bottom perspective view. [Figure 7] 3 is an explanatory diagram of an injection molding step (crossover wire breakage suppression means (3)) in the assembly process of the coil device shown in FIG. 2. FIG. [Figure 8] 3 is an explanatory diagram of a connector sealing step and a stator assembling step in the assembly process of the coil device shown in FIG. 2. FIG. [Figure 9] 8A and 8B are enlarged views of a portion shown in FIG. 7, in which (a) shows the area surrounded by dashed line IXa shown in FIG. 7, (b) shows the adhesion strengthening means in Example 1, and (c) shows the adhesion strengthening means in Example 2. [Figure 10] FIG. 4 is a cross-sectional view showing a flow rate adjustment valve according to a second embodiment of the present invention. [Figure 11] 11A and 11B are explanatory views of the assembly process of the coil device shown in FIG. 10, where (a) shows the stator assembly process, and (b) shows the injection molding process (crossover wire breakage suppression means (1)). [Figure 12] 11 is an explanatory diagram of a bobbin assembling step (crossover wire breakage suppressing means (2)) in the assembling process of the coil device shown in FIG. [Figure 13] 13A and 13B are explanatory views of the bobbin assembly shown in FIG. 12, in which (a) is a top perspective view and (b) is a bottom perspective view. [Figure 14] 11 is an explanatory diagram of a cover mounting step in the assembly process of the coil device shown in FIG. 10. FIG. [Figure 15] 11 is an explanatory diagram of the electrical component sealing process (crossover wire breakage prevention means (3)) in the assembly process of the coil device shown in FIG. 10, where (a) is an overall cross-sectional view, and (b) is an enlarged view of the area surrounded by the dashed line XVb shown in (a). [Figure 16] 1 shows a cross-sectional view of a coil device according to the prior art. DETAILED DESCRIPTION OF THE INVENTION

[0021] An embodiment of the present invention will be described in detail with reference to Figures 1 to 15. However, the present invention is not limited to this embodiment. In the following description, a motor-operated valve (motor-operated flow control valve) is used as the flow control valve, but the crossover wire breakage suppression means in the flow control valve of the present invention can be applied to a solenoid valve (electromagnetic flow control valve, electromagnetic on-off valve, electromagnetic flow path switching valve) instead of the motor-operated valve.

[0022] <Terminology> In this specification and claims, the terms "left," "right," "upper," and "lower" refer to the directions shown in Figures 1 to 3, 4(b), 5, 7 to 10, and 15. In this specification and claims, the terms "one end" and "other end" refer to the "lower end" and "upper end" in the drawings. In this specification and claims, the term "axially opposing region" refers to the region of the flange that faces the crossover wire in the axial direction and at least the region of the flange that overlaps with the crossover wire when viewed from the axial direction. In this specification and claims, the term "disposing the crossover wire adjacent to or in contact with the axially opposing region of the flange" refers to disposing the crossover wire at a distance of 0 to less than approximately 0.2 mm from the axially opposing region. In this specification and claims, the term "axis-orthogonal facing region" refers to a region of the flange that faces the crossover wire in the axis-orthogonal direction, and refers to at least the region of the flange that overlaps with the crossover wire when viewed from the axis-orthogonal direction. In this specification and claims, "the crossover wire is arranged in a non-contacting manner in the axis-orthogonal facing region of the flange" refers to the crossover wire being arranged in a spaced, non-contacting manner in the axis-orthogonal facing region. In this specification and claims, the term "pre-tensioning force of the crossover wire" refers to the tensile force that occurs in advance in the crossover wire when the crossover wire is connected to the terminal and when the sealing resin shrinks during molding.

[0023] (First embodiment) <Configuration of flow control valve> A flow rate adjustment valve 100a according to a first embodiment of the present invention will be described using Figures 1 and 2. As shown in Figure 2, the flow rate adjustment valve 100a is composed of a flow rate adjustment valve main body 10 and a stator coil unit 90. Each component of the flow rate adjustment valve 100a will be described below in order.

[0024] <About the flow control valve body> 1, the flow control valve main body 10 is mainly composed of a support member 20, a connecting member 30, a valve body 40, a drive shaft 50, a valve body 60, a coil member 70, and a rotor unit 80. Below, each component of the flow control valve main body 10 will be described in order.

[0025] As will be described in detail later, in the first embodiment, by simultaneously employing crossover wire breakage suppression means (1), crossover wire breakage suppression means (2), and crossover wire breakage suppression means (3), it is possible to solve the conventional problem (crossover wire breakage due to temperature changes) and improve reliability. As shown in FIG. 9(a), crossover wire breakage suppression means (1) is to provide adhesion strengthening means Ar in the axially opposing region AF of the flange portions 94af, 94bf. Furthermore, crossover wire breakage suppression means (2) is to position the crossover wires 93a1c, 93a2c in proximity to or in contact with the axially opposing region AF of the flange portions 94af, 94bf. Furthermore, crossover wire breakage suppression means (3) is to have a linear expansion coefficient of the bobbin 94 smaller than that of the sealing resin portion 97.

[0026] The support member 20 has a substantially cylindrical shape and is made of a resin material such as polyphenylene sulfide (PPS), and the fixing bracket 21 is integrally insert-molded into one end of the support member 20. The fixing bracket 21 is made of a metal material such as stainless steel, and has a circular ring shape with its inner periphery curved toward one end in the direction of the axis L, and at least one through-hole 21a is provided in the area where the fixing bracket 21 is embedded in the support member 20. When the fixing bracket 21 is insert-molded into the support member 20, the resin material is solidified while filled in the at least one through-hole 21a, thereby improving the bonding strength between them.

[0027] The support member 20 is also arranged so that its axis overlaps the axis L. A screw hole 23, a bearing hole 24, and a slide hole 25 are formed concentrically in the center of the support member 20 and aligned in the direction of the axis L so as to pass through the support member 20. A female thread portion 23a is formed on the inner peripheral surface of the screw hole 23, and a male thread portion 51a of the drive shaft 50, which will be described later, is threadedly engaged with the inner peripheral surface of the bearing hole 24. A guide portion 52 of the drive shaft 50, which will be described later, is slidably engaged with the inner peripheral surface of the bearing hole 24. The slide hole 25 is arranged on one end side and is formed with a diameter larger than that of the bearing hole 24. A valve body portion 60, which will be described later, is slidably engaged with the slide hole 25.

[0028] A guide rail 26 consisting of a spiral ridge is integrally formed on the outer peripheral surface of the other end of the support member 20. Adjacent winding portions of the guide rail 26 are arranged with a gap between them. The guide rail 26 is arranged so that its axis overlaps with the axis L, and guides each winding portion of the coil portion 71 from one or both sides so that the coil portion 71 of the coil member 70 (described later) is threadedly engaged with the guide rail 26 and can rotate in the circumferential direction.

[0029] Furthermore, a cylindrical portion 27 is integrally formed at one end of the support member 20. The outer circumferential surface of the cylindrical portion 27 has a diameter that decreases toward one end in the direction of the axis L, and the cylindrical portion 27 is insertable into an insertion hole 41 of the valve body 40, which will be described later. A portion of the outer circumferential surface of the cylindrical portion 27 has a shape that corresponds to the insertion hole 41 of the valve body 40.

[0030] The connecting member 30 has a generally cylindrical shape with an inner circumferential surface that tapers toward one end in the direction of the axis L, and is made of a metal material such as stainless steel, and a male threaded engagement portion 30scm that constitutes the first engagement portion Sc1 is formed on the outer circumferential surface at one end, and is threadedly fixed to a female threaded engagement portion 40scf of the valve body 40, which will be described later. The other inner end of the connecting member 30 is fixed to the support member 20 via a fixture 21 that is joined by arc welding or the like.

[0031] The valve body 40 is made of a metal material such as aluminum, and has an insertion hole 41 that defines the valve chamber 2 and a valve port 1a that are aligned concentrically along the axis L so as to penetrate the valve body 40. A valve seat 42 is formed on the inner circumferential edge at the boundary between the insertion hole 41 and the valve port 1a. An opening 43 that defines the side port 1b and communicates with the valve chamber 2 is formed in the side wall of the valve body 40. Furthermore, the outer circumferential surface 44 of the valve body 40 is formed with a jig engagement portion 45 that protrudes radially outward when viewed from the axis L, and has a shape such as two parallel sides or a hexagonal shape, a first annular groove 46 that accommodates the first shaft seal member O1, a male thread engagement portion 40scm that constitutes the second thread engagement portion Sc2, and a second annular groove 47 that accommodates the second shaft seal member O2. Here, a female threaded portion 40scf constituting the first threaded portion Sc1 is formed on the inner peripheral side of the jig engaging portion 45, and is threadably fixed to the male threaded portion 30scm of the connecting member 30. In this way, the valve body 40 is fixed to the support member 20 via the connecting member 30.

[0032] The drive shaft 50 is formed into a cylindrical rod shape using a metal such as stainless steel. The drive shaft 50 is formed with a threaded portion 51, a guide portion 52, and a flange portion 53 disposed at one end of the guide portion 52, which are aligned in the axial direction L. The threaded portion 51 is formed with a male threaded portion 51a, which is threadedly engaged with a female threaded portion 23a of the support member 20, thereby converting the rotational motion of the drive shaft 50 into linear motion. The guide portion 52 slidably engages with the inner circumferential surface of the bearing hole 24, thereby guiding the movement of the drive shaft 50 in the axial direction L. The drive shaft 50 is moved in the axial direction L by a screw feed action due to rotation. The flange portion 53 rotatably engages a valve body portion 60, which will be described later. In the first embodiment, the female threaded portion 23a and the male threaded portion 51a are right-handed threads.

[0033] The valve body portion 60 includes a valve holder 61 , a valve body 62 , a washer 63 , a spring bearing 64 , and a compression coil spring 65 .

[0034] The valve holder 61 is formed in a cylindrical shape with an outer diameter that is approximately the same as the inner diameter of the slide hole 25 of the support member 20. The valve holder 61 is engaged with the slide hole 25 so as to be slidable in the axial direction L along the slide hole 25.

[0035] The valve element 62 has a truncated cone shape on one end, and the tip of this truncated cone is fixed to one end 61a of the valve holder 61 so that it faces the valve port 1a. The valve element 62 adjusts the flow rate by adjusting the opening of the valve port 1a relative to the valve seat 42 between the maximum opening and the minimum opening (or fully closed state) of the valve.

[0036] The flange 53 of the drive shaft 50 is rotatably engaged with the other end 61b of the valve holder 61. Specifically, a washer 63 is sandwiched between the flange 53 of the drive shaft 50 and the other end 61b of the valve holder 61, and the drive shaft 50 is rotatably engaged with the other end 61b of the valve holder 61 via the flange 53. Due to this engagement, the valve holder 61 is supported by the drive shaft 50 so as to be movable in the direction of the axis L and rotatable about the axis L. An opening larger than the radial movement range of the drive shaft 50 is formed in the other end 61b of the valve holder 61. A spring retainer 64 is provided within the valve holder 61 so as to be movable in the direction of the axis L. A compression coil spring 65 is attached between the spring retainer 64 and the valve body 62 in a compressed state with a predetermined load applied. As a result, the spring receiver 64 is biased toward the other end and comes into contact with one end of the drive shaft 50 .

[0037] The coil member 70 integrally includes a coil spring-shaped coil portion 71 and a claw portion 72 that protrudes radially outward from one end of the coil portion 71. The coil portion 71 is threadedly engaged with the guide rail 26 of the support member 20 so as to be rotatable in the circumferential direction. The coil member 70 can be easily manufactured by forming a metal wire such as stainless steel.

[0038] The rotor unit 80 includes a can 81 and a magnet rotor 82 .

[0039] The can 81 is made of a metal material such as stainless steel and has a generally cylindrical shape with a closed top end. One open end of the can 81 is airtightly joined to the other outer peripheral end of the connecting member 30 by arc welding or the like, thereby defining the sealed space 3. As shown in Fig. 2, at least one recess 81a recessed in the inward radial direction is formed on the same circumference on the outer peripheral surface of the one end of the can 81, and this recess 81a is engageable with a protrusion 96h1 of the coil device 93 described below.

[0040] The magnet rotor 82 integrally includes a cylindrical magnet portion 84 whose outer periphery is magnetized with multiple poles, a disk portion 85 that closes the other end, and a protrusion 87. The magnet rotor 82 is fixed to the drive shaft 50 via a metal fitting 86 insert-molded into the center of the disk portion 85. This allows the magnet rotor 82 to rotate around the axis L of the drive shaft 50 within the can 81. The protrusion 87 of the magnet rotor 82 can abut against the claw portions 72 of the coil member 70. Thus, rotation of the magnet rotor 82 pushes and rotates the coil member 70 in the circumferential direction via the claw portions 72. This causes the coil member 70 to strike an upper limit stopper (not shown) or a lower limit stopper (not shown), restricting the rotation of the coil member 70 and the magnet rotor 82. This restricts the valve body 60 from moving beyond the maximum or minimum opening position (or the valve closed state).

[0041] When the magnet rotor 82 rotates, the drive shaft 50 rotates together with the magnet rotor 82, and the screw feed action of the male thread portion 51a and the female thread portion 23a causes the drive shaft 50 to move in the direction of the axis L, moving the valve body portion 60 forward and backward relative to the valve port 1a. This changes the opening of the valve port 1a relative to the valve seat 42, and controls the flow rate of the fluid flowing from the valve port 1a to the side port 1b (or from the side port 1b to the valve port 1a).

[0042] <About the stator coil unit> 1 and 2, the stator coil unit 90 is mainly composed of a case body 91, a control board connector 92, a coil device 93, a control board 98, and a lid 99. Each component of the stator coil unit 90 will be described below in order.

[0043] The case body 91 is made of a resin material such as polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT), and as shown in Fig. 2, has a first end opening 91a into which the flow control valve main body 10 can be fitted and a second end opening 91b sealed by a lid 99, with the inner diameter increasing along the axis L from the first end opening 91a to the second end opening 91b. A seal member accommodating groove 91c for accommodating a case body seal member Oc is provided in the inner circumferential surface of the first end opening 91a. A notch 91e extending along the axis L is provided in the inner circumferential surface of the second end opening 91a.

[0044] The control board connector 92 is used as a power supply terminal for the control board 98, and is integrally molded by insert molding on the other end side of the case main body 91.

[0045] 2, the coil device 93 includes a bobbin assembly 94Assy (see FIG. 6) that includes a stator 95 having an annular shape, a bobbin 94 incorporated into the stator 95, a coil 93a wound around the outer periphery of the bobbin 94, and a power supply terminal 96a that is attached to the bobbin 94 and connected to the coil 93a. The coil device 93 also includes a grommet 96b attached to protect the terminal 96a, a sealing resin part 97 that seals the outer periphery of the grommet 96b and the bobbin assembly 94Assy, a connector 96c and lead wires 96d attached to the terminal 96a, a connector resin part 96e that seals the connector 96c, and a bracket 96h that protrudes from one end. As will be described in detail later, the stator 95 is made of a metal material such as SEC (electrogalvanized steel sheet) and has a first stator pole tooth portion 95a, a second stator pole tooth portion 95b, a first stator outer casing 95c, and a second stator outer casing 95d. 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 be polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT) containing glass fiber as a reinforcing agent or glass fiber with an inorganic filler added. As will be described in detail later, this reduces the linear expansion coefficient of the bobbin 94 and reliably suppresses expansion and contraction of the sealing resin portion 97 due to temperature changes. Furthermore, the coil 93a is made of a metal material such as copper, and has a first coil 93a1 and a second coil 93a2. When a pulse signal is given from the outside, the coil device 93 rotates the magnet rotor 82 according to the number of pulses.

[0046] In addition, as shown in Figure 2, a convex portion 96h1 that protrudes in the inner diameter direction is formed on the bracket 96h of the coil device 93, and this bracket 96h engages with the cutout portion 91e of the case main body 91, thereby positioning the coil device 93 in the circumferential direction relative to the case main body 91.

[0047] The control board 98 has electronic components such as semiconductor elements and IC chips mounted thereon, and is fixed to the case body 91 as shown in Fig. 2. The control board 98 is electrically connected to the coil 93a via a connector 96c and a lead wire 96d, and controls the drive signal.

[0048] 2, the lid 99 is fitted and fixed to the other end opening 91b of the case body 91. This defines an accommodation space 91f between the lid 99 and the coil device 93 within the case body 91.

[0049] <Assembly process of the stator coil unit and the flow control valve body> The process of assembling the stator coil unit 90 and the flow rate adjustment valve main body 10 will be described with reference to Fig. 2. By carrying out the following assembling process, the flow rate adjustment valve 100a shown in Fig. 1 is provided.

[0050] In order to assemble the stator coil unit 90 to the flow rate adjustment valve main body 10, the stator coil unit 90 is moved toward the flow rate adjustment valve main body 10 in the direction of the axis L, and the convex portion 96h1 of the bracket 96h of the coil device 93 is engaged with one of the plurality of concave portions 81a provided on the same circumference on the outer circumferential surface of the can 81. At the same time, the case main body seal member Oc is sandwiched between the seal member accommodating groove 91c of the one-end opening 91a and the outer circumferential surface of the connecting member 30, thereby creating a sealed state in which the accommodation space 91f is isolated from the external environment.

[0051] <Installing the flow control valve to the housing> The process of attaching the flow rate adjustment valve 100a to the housing H will be described with reference to FIG.

[0052] <About housing> The housing H is made of a metal material such as aluminum and has an insertion hole formed therein with multiple annular steps that gradually decrease in diameter from the other end to the one end along the axis L. A first housing groove G1, a second housing groove G2, and a third housing groove G3 are formed in these multiple annular steps, in that order. A first flow path Fp1 that communicates with the third housing groove G3 is formed in the third housing groove G3 and communicates with the left side (the left side in FIG. 3), and a second flow path Fp2 that communicates with the second housing groove G2 and communicates with the right side (the right side in FIG. 3). A threaded hole Sh is formed in the side wall (the left wall in FIG. 3) of the housing H, adjacent to the first flow path Fp1. A first pipe (not shown) is attached to this threaded hole Sh via a seal joint (not shown) and a fastening bolt (not shown), thereby fluidly connecting the first pipe to the first flow path Fp1. Similarly, a threaded hole Sh is formed in the side wall of the housing H (the right wall in Figure 3) close to the second flow path Fp2, and a second pipe (not shown) is attached to this threaded hole Sh via a seal joint (not shown) and a fastening bolt (not shown), thereby fluidly connecting the second pipe to the second flow path Fp2.

[0053] In the first embodiment, the shape of the housing H as shown in Figure 3 was described, but this is only one 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 control valve 100a to be inserted into this insertion hole.

[0054] <About the installation process> The process of attaching the flow rate adjustment valve 100a to the housing H will be described. The valve body 40 of the flow rate adjustment valve 100a is inserted into the first housing groove G1 along the axial line L direction of the housing H. Then, using a jig such as a wrench (not shown), the valve body 40 is engaged with the outer peripheral surface of the jig engagement portion 45, which has a shape with two parallel surfaces or a hexagonal shape, and rotated to thread the male threaded portion 40scm of the valve body 40 into the female threaded portion Hscf of the housing H, while moving the valve body 40 toward one end in the axial line L direction until the stepped portion 48 of the valve body 40 abuts against a step provided between the first housing groove G1 and the second housing groove G2 in the housing H. In the installed state of this flow rate adjustment valve 100a, the valve port 1a defined by the valve body 40 communicates with the first flow path Fp1 to which primary pressure is introduced, and the side port 1b defined by the valve body 40 communicates with the second flow path Fp2 to which secondary pressure is introduced. At this time, the second shaft seal member O2 is sandwiched between the third accommodating groove G3 and the second annular groove 47 of the valve body 40, sealing the gap between the second accommodating groove G2 and the third accommodating groove G3, and the first shaft seal member O1 is sandwiched between the first accommodating groove G1 and the first annular groove 46, sealing the gap between the first accommodating groove G1 and the external environment.

[0055] <Regarding the previous problem (breakage of crossover wires due to temperature changes)> As described above, when conventional coil device 1600 shown in FIG. 16 is used in an environment with extremely large temperature changes, sealing resin portion 1697 repeatedly expands and contracts. Furthermore, because the periphery of the crossover portion of coil 1693a is tightly fixed to sealing resin portion 1697, tensile and compressive forces are also repeatedly applied to the crossover portion. The wire diameter of coil 1693a is generally small. Therefore, the strength of the crossover portion of coil 1693a is also low. Therefore, the crossover portion cannot withstand the external, forced deformation caused by the expansion and contraction of sealing resin portion 1697, and this leads to the conventional problem (breakage of the crossover portion due to temperature changes), which may result in reduced reliability.

[0056] In contrast, in the first embodiment, the conventional problem (breakage of the crossover wire due to temperature changes) is resolved by simultaneously adopting a crossover wire breakage prevention means (1) (an adhesion strengthening means provided in the axially opposing region of the flange portion), a crossover wire breakage prevention means (2) (the crossover wire is positioned close to or abutting the axially opposing region of the flange portion), and a crossover wire breakage prevention means (3) (the bobbin has a smaller linear expansion coefficient than the sealing resin portion).

[0057] <About the coil device assembly process> 4 to 8, the assembly process (bobbin molding process, bobbin assembly process, injection molding process, connector sealing process, and stator assembly process) of the coil device 93 will be described. Details will be described later, but the assembly process will be described while showing the crossover wire breakage suppression means (1) (adhesion strengthening means provided in the axially opposing region of the flange portion), the crossover wire breakage suppression means (2) (arranging the crossover wire close to or in contact with the axially opposing region of the flange portion), and the crossover wire breakage suppression means (3) (the bobbin has a smaller linear expansion coefficient than the sealing resin portion).

[0058] <About the bobbin forming process (measures for preventing breakage of the crossover wire (1))> The bobbin molding process will be described with reference to Fig. 4. The bobbin 94 has 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.

[0059] 4(a) and 4(b), the first bobbin 94a has a substantially cylindrical shape and includes a first bobbin body 94ab having a pair of ring-shaped protruding edges at both ends in the direction of the axis L, and a first flange 94af extending radially from the protruding edge at one end of the first bobbin body 94ab. The first flange 94af is provided with a first insertion hole 94af1 into which the terminal 96a (see FIG. 5) is inserted, and has a flange thickness T.

[0060] 4(b) and 4(c), the second bobbin 94b has a generally cylindrical shape and includes a second bobbin body 94bb having a pair of ring-shaped protruding edges at both ends in the direction of the axis L, and a second flange 94bf extending radially from the protruding edge at the other end of the second bobbin body 94bb. The second flange 94bf is provided with a second insertion hole 94bf1 into which the terminal 96a (see FIG. 5) is inserted, and has a flange thickness T.

[0061] Here, as a means for preventing breakage of the crossover line portion (1), details will be described later, the other side of the first flange portion 94af and one side of the second flange portion 94bf are provided with adhesion strengthening means Ar (see the dot pattern in Figures 4(a) and (c)) (for example, an uneven portion (see Figures 9(b) and (c)) or a surface modified portion, etc.).

[0062] This adhesion strengthening means Ar significantly improves the anchor effect between the sealing resin portion 97 and the first flange portion 94af and the second flange portion 94bf during the injection molding process described below (see Figure 9(a)), thereby strengthening the adhesion and thereby suppressing breakage of the first crossover wire portion 93a1c and the second crossover wire portion 93a2c.

[0063] <About the bobbin assembly process (measures to prevent breakage of the crossover wire (2))> The bobbin assembly process will be described with reference to Figure 5. First, an L-shaped terminal 96a is inserted into the first insertion hole 94af1 of the first flange portion 94af and the second insertion hole 94bf1 of the second flange portion 94bf (see arrow A1 in Figure 5). Next, the first coil 93a1 and the second coil 93a2 are wound around the outer periphery of the first bobbin body 94ab and the second bobbin body 94bb, respectively (see A2 in Figure 5). Then, the first crossover portion 93a1c and the second crossover portion 93a2c at both ends of the first coil 93a1 and the second coil 93a2 are connected (for example, soldered) to the terminal 96a via the first winding portion 93a1f and the second winding portion 93a2f, respectively. In addition, the bending of the terminal 96a into an L-shape may be performed after inserting the terminal 96a having a flat shape into the first insertion hole 94af1 and the second insertion hole 94bf1 and connecting the first crossover wire portion 93a1c and the second crossover wire portion 93a2c to the terminal 96a.

[0064] As will be described in detail later, the crossover wire breakage suppression means (2) is configured by arranging the first crossover wire 93a1c and the second crossover wire 93a2c adjacent to or in contact with the other side surface of the first flange 94af and one side surface of the second flange 94bf, respectively. The positions where the first crossover wire 93a1c and the second crossover wire 93a2c are arranged are areas where the anchor effect of the sealing resin portion 97 is significantly improved by the crossover wire breakage suppression means (1) in the injection molding process (see FIG. 9(a)) described below, and therefore breakage of the first crossover wire 93a1c and the second crossover wire 93a2c can be suppressed.

[0065] 5, the first stator pole tooth portion 95a and the second stator pole tooth portion 95b are assembled into 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 arrow A3 in FIG. 5). At this time, the first stator pole tooth portion 95a and the second stator pole tooth portion 95b are partially covered by the first bobbin body 94ab and the second bobbin body 94bb.

[0066] This results in a bobbin assembly 94Assy, as shown in Fig. 6. In this bobbin assembly 94Assy, as crossover wire breakage suppression means (1), the other side of the first flange portion 94af and one side of the second flange portion 94bf are provided with adhesion reinforcement means Ar (see the dot patterns in Figs. 6(a) and 6(b)). Furthermore, as crossover wire breakage suppression means (2), the first crossover wire portion 93a1c and the second crossover wire portion 93a2c are disposed adjacent to or in contact with the other side of the first flange portion 94af and one side of the second flange portion 94bf. In the first embodiment, the first crossover wire portions 93a1c and the second crossover wire portions 93a2c total eight, and the terminals 96a have two common terminals in the center, resulting in six, but the number of crossover wires and terminals is not limited to this.

[0067] <Injection molding process (measures for preventing breakage of crossover wires (3))> The injection molding process will be described with reference to FIG. 7. First, to protect the terminals 96a of the bobbin assembly 94Assy, grommets 96b are attached to the terminals 96a (see arrow A4 in FIG. 7). Then, the bobbin assembly 94Assy with the grommets 96b attached is injection molded in a molding die, and the outer peripheries of the grommet 96b and the bobbin assembly 94Assy are sealed with a sealing resin portion 97 (see A5 in FIG. 7). This 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 crossover wire portion 93a1c and the second crossover wire portion 93a2c are also tightly fixed to the sealing resin portion 97 at the same time.

[0068] Here, as a means (3) for preventing the crossover wire from breaking, the linear expansion coefficients of the first bobbin 94a and the second bobbin 94b are set to be smaller than the linear expansion coefficient of the sealing resin portion 97, thereby preventing the first crossover wire 93a1c and the second crossover wire 93a2c from breaking.

[0069] <Regarding the Connector Sealing Process and the Stator Assembly Process> Referring to FIG. 8, the connector sealing process and the stator assembly process will be described. First, the connector 96c and the lead wire 96d are attached to the terminal 96a (see arrow A6 in FIG. 8). Next, a casting resin (for example, a thermosetting resin material such as an epoxy resin or a polyurethane resin) is poured around the connector 96c and heated and cured to provide a connector resin portion 96e (see A7 in FIG. 8). Then, the first stator outer case 95c and the second stator outer case 95d are incorporated into the bobbin assembly 94Assy, and the mating portions of the first stator outer case 95c and the second stator outer case 95d are spot welded at a plurality of locations (see arrow A8 in FIG. 8).

[0070] <Regarding the bridging wire breakage prevention means (1) to (3)> Referring to FIG. 9(a), the bridging wire breakage prevention means (1) to (3) will be described in detail. First, the bridging wire breakage prevention means (1) is to provide an adhesion strengthening means Ar (see the dot pattern in FIG. 9(a)) for strengthening the adhesion between the sealing resin portion 97 and the first flange portion 94af and the second flange portion 94bf in the axial direction facing regions AF that face the first bridging wire portion 93a1c and the second bridging wire portion 93a2c in the first flange portion 94af and the second flange portion 94bf, respectively, in the axial direction of the axis L. Further, the bridging wire breakage prevention means (2) is to arrange the first bridging wire portion 93a1c and the second bridging wire portion 93a2c in the axial direction facing regions AF of the first flange portion 94af and the second flange portion 94bf, respectively, in a close or contacting manner. Furthermore, the bridging wire breakage prevention means (3) is to make 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.

[0071] 9(a), in the first embodiment, the crossover wire breakage suppression means (1) and (2) significantly improve the anchoring effect of the sealing resin portion 97 to the axially opposing region AF of the first flange portion 94af and the second flange portion 94bf, and the first crossover wire portion 93a1c and the second crossover wire portion 93a2c are arranged in the region where the anchoring effect of the sealing resin portion 97 is significantly improved. At the same time, the crossover wire breakage suppression means (3) reduces the expansion and contraction of the first flange portion 94af and the second flange portion 94bf due to temperature changes compared to the sealing resin portion 97. As a result, even when the coil device 93 is used in an environment with extremely large changes in ambient temperature, the sealing resin portion 97, which is tightly fixed around the first crossover portion 93a1c and the second crossover portion 93a2c, is prevented from expanding or contracting due to temperature changes due to the anchor effect on the first flange portion 94af and the second flange portion 94bf. As a result, the first crossover portion 93a1c and the second crossover portion 93a2c, which are tightly fixed to the sealing resin portion 97, are prevented from breaking, thereby improving reliability.

[0072] As described above, in the first embodiment, by simultaneously adopting a crossover wire breakage prevention means (1) (an adhesion strengthening means provided in the axially opposing region of the flange portion), a crossover wire breakage prevention means (2) (the crossover wire is positioned close to or abutting the axially opposing region of the flange portion), and a crossover wire breakage prevention means (3) (the bobbin has a smaller linear expansion coefficient than the sealing resin portion), it is possible to solve the conventional problem (breakage of the crossover wire due to temperature changes) and improve reliability.

[0073] Furthermore, through extensive research, the inventors have further examined the configuration of each of the crossover wire breakage prevention means (1) to (3) in an attempt to further prevent breakage of the first crossover wire portion 93a1c and the second crossover wire portion 93a2c.

[0074] <Considerations on measures to prevent crossover wire breakage (1)> Here, the crossover line breakage suppression means (1-1) (uneven portion, surface modified portion) is shown as a concrete embodiment of the adhesion strengthening means Ar in the crossover line breakage suppression means (1), and the crossover line breakage suppression means (1-2) (uneven portion intersecting with the crossover line) is shown as a means for further improving the anchor effect of this uneven portion.

[0075] <About the means for preventing crossover wire breakage (1-1)> The crossover wire breakage prevention means (1-1) is a concrete embodiment of the adhesion strengthening means Ar in the crossover wire breakage prevention means (1), and provides uneven portions and surface modified portions as adhesion strengthening means Ar in the axially opposing region AF of the first flange portion 94af and the second flange portion 94bf.

[0076] <Transverse wire breakage prevention means (1-1) (uneven portion)> 9(b) and 9(c), the crossover wire breakage suppression means (1-1) (uneven portion) is an uneven portion Ar1 having a V-shaped cross-sectional groove or an uneven portion Ar2 having a U-shaped cross-sectional groove, which are formed by mechanical uneven processing on the other side of the first flange portion 94af and one side of the second flange portion 94bf in the resin-molded bobbin 94 (see FIG. 2). Also, as another example, although not shown, the crossover wire breakage suppression means (1-1) (uneven portion) is an uneven portion formed in the resin-molded product by applying embossing to portions of the mold for the resin-molded bobbin 94 that correspond to the other side of the first flange portion 94af and one side of the second flange portion 94bf. In this way, by adopting the crossover wire breakage prevention means (1-1) (uneven portion) as the adhesion strengthening means Ar in the crossover wire breakage prevention means (1), there is no need to make major changes to the assembly process of the coil device 93, and it can be achieved by simply incorporating an additional process to form the uneven portion, thereby reducing manufacturing costs.

[0077] Here, the uneven portion Ar1 having V-shaped cross-sectional grooves, the uneven portion Ar2 having U-shaped cross-sectional grooves, and the uneven portion formed by texturing the molding die, which are the cross-wire breakage suppression means (1-1) (uneven portion), 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. This prevents excessive stress concentration and cracking in the first flange portion 94af and the second flange portion 94bf, which are caused by the uneven portion, even when the coil device 93 is used in an environment with extremely large ambient temperature changes. Furthermore, the anchor effect created by the uneven portion reliably prevents expansion and contraction due to temperature changes in the sealing resin portion 97, which is tightly fixed around the first cross-wire portion 93a1c and the second cross-wire portion 93a2c.

[0078] In the first embodiment, the crossover line breakage prevention means (1-1) (uneven portion) uses, as the adhesion strengthening means Ar, an uneven portion Ar1 having a groove with a V-shaped cross section, an uneven portion Ar2 having a groove with a U-shaped cross section, or an uneven portion formed on a resin molded product by embossing on a molding die, but is not limited to these, and may also use, for example, an uneven portion having a groove with a different cross section shape, or an uneven portion formed by embossing on a resin molded bobbin 94.

[0079] <Crossover wire breakage prevention means (1-1) (surface modification part)> Furthermore, although not shown, the crossover wire breakage suppression means (1-1) (surface modified portion) is a surface modified portion formed by ultraviolet irradiation or primer application on the other side of the first flange portion 94af and one side of the second flange portion 94bf in the resin-molded bobbin 94. In this way, by employing the crossover wire breakage suppression means (1-1) (surface modified portion) as the adhesion strengthening means Ar in the crossover wire breakage suppression means (1), there is no need to make major process changes in the assembly process of the coil device 93, and this can be achieved by simply incorporating an additional process for forming the surface modified portion, thereby reducing manufacturing costs.

[0080] <Means for preventing crossover line breakage (1-2) (concave and convex portions intersect with crossover lines)> The crossover wire breakage suppression means (1-2) (uneven portion intersects with the crossover wire) causes the uneven portions Ar1 and Ar2 in the crossover wire breakage suppression means (1-1) (uneven portion) to extend in a direction that intersects with each of the first crossover wire 93a1c and the second crossover wire 93a2c when viewed from the direction of the axis L. This further improves the anchor effect of the uneven portions Ar1 and Ar2 in the direction in which the first crossover wire 93a1c and the second crossover wire 93a2c extend, and more reliably suppresses expansion and contraction due to temperature changes in the sealing resin portion 97 that is tightly fixed around the first crossover wire 93a1c and the second crossover wire 93a2c.

[0081] <Considerations on measures to prevent crossover wire breakage (2)> Here, in the crossover wire breakage prevention means (2), the routing and connection configuration of the first crossover wire portion 93a1c and the second crossover wire portion 93a2c are devised so that when connecting the first crossover wire portion 93a1c and the second crossover wire portion 93a2c to the terminal 96a, pre-tensioning force is minimized to be applied to the first crossover wire portion 93a1c and the second crossover wire portion 93a2c.The crossover wire breakage prevention means (2-1) (the crossover wire is arranged out of contact with the area opposing the axis perpendicularly) and the crossover wire breakage prevention means (2-2) (only the tip of the winding portion of the crossover wire is fixed) are shown.

[0082] <About the means for preventing crossover wire breakage (2-1) (arranging the crossover wire in a non-contact manner with the opposing area in the direction perpendicular to the axis)> 9(a), the crossover wire breakage suppression means (2-1) (disposing the crossover wires out of contact with the axis-orthogonal facing area) disposes the first crossover wire 93a1c and the second crossover wire 93a2c in a non-contact state in the axis-orthogonal facing area AOF of the first flange 94af and the second flange 94bf. This allows the first crossover wire 93a1c and the second crossover wire 93a2c to be connected to the terminal 96a in a bent state in a direction orthogonal to the axis L. This makes it possible to suppress pre-tension force from being applied to the first crossover wire 93a1c and the second crossover wire 93a2c when connecting the first crossover wire 93a1c and the second crossover wire 93a2c to the terminal 96a and when the sealing resin portion 97 shrinks during molding in the injection molding process (see FIG. 7).

[0083] <About the means for preventing breakage of the crossover wire (2-2) (fixing only the tip of the winding part of the crossover wire)> The crossover wire breakage prevention means (2-2) (fixing only the tip of the winding portion of the crossover wire portion) fixes only the tip (only the right side of 93a1f, 93a2f in Figure 9(a)) of the first winding portion 93a1f and the second winding portion 93a2f, respectively, when connecting the first crossover wire portion 93a1c and the second crossover wire portion 93a2c to the terminal 96a, as shown in Figure 9(a), and leaves the remaining winding portions free to deform in a direction perpendicular to the axis L. This allows the first crossover wire portion 93a1c and the second crossover wire portion 93a2c to be connected to the terminal 96a in a bent state in a direction perpendicular to the axis L, thereby preventing pre-tensile force from being applied to the first crossover wire portion 93a1c and the second crossover wire portion 93a2c when connecting the first crossover wire portion 93a1c and the second crossover wire portion 93a2c to the terminal 96a and when the sealing resin portion 97 shrinks during molding in the injection molding process (see Figure 7).

[0084] <Considerations on measures to prevent crossover wire breakage (3)> Here, the following three specific examples of the crossover wire breakage prevention means (3) are shown: crossover wire breakage prevention means (3-1) (adding a reinforcing agent to the bobbin), crossover wire breakage prevention means (3-2) (the bobbin and the sealing resin part are made of the same material, and more reinforcing agent is added to the bobbin than to the sealing resin part), and crossover wire breakage prevention means (3-3) (the linear expansion coefficient of the bobbin is 40% or less of the breaking tension of the coil).

[0085] <Comparative evaluation of crossover wire breakage prevention measures (3-1) and (3-2)> Here, in order to determine the relative merits of the crossover wire breakage suppression means (3-1) and (3-2) in preventing breakage of the crossover wires 93a1c, 93a2c, a comparative evaluation was carried out on the bobbin 94 and the sealing resin portion 97 in the coil device 93 shown in Table 1, depending on the type of resin material, the presence or absence of a reinforcing agent (linear expansion coefficient), and the presence or absence of an adhesion strengthening means. Note that under all of the conditions in Table 1, the crossover wire breakage suppression means (2) (the crossover wire is disposed close to or in contact with the axially opposing region of the flange portion) and the crossover wire breakage suppression means (3) (the bobbin has a smaller linear expansion coefficient than the sealing resin portion) are provided.

[0086] The notation in Table 1 will be explained below. In Table 1, "Cu" and "α" represent "annealed copper" and "linear expansion coefficient (×10 -5 / °C)" and "PPS" and "PBT" respectively represent thermoplastic resin materials, "polyphenylene sulfide" and "polybutylene terephthalate." In addition, "◎" in the "Rupture occurrence evaluation" column in Table 1 indicates that "there is no change in wire diameter and no breakage occurs" for crossover wire portions 93a1c, 93a2c when a temperature change of 160°C (from -40°C to 120°C) is applied to coil device 93 for 1,000 cycles (2 hours). Similarly, the "Good," "Bad," and "Bad" symbols in the "Fracture Occurrence Assessment" column in Table 1 indicate whether the crossover wires 93a1c and 93a2c are broken or broken without a change in wire diameter, whether the crossover wires 93a1c and 93a2c are broken or broken after 500 cycles of a 160°C temperature change (from -40°C to 120°C) for two hours. Because direct measurement of the crossover wire diameter is difficult, the crossover wire diameter is measured based on changes in the coil resistance (increasing resistance corresponds to decreasing wire diameter). Furthermore, for reference, the fifth and sixth rows of Table 1 (enclosed in black frames) indicate that the crossover wires 93a1c and 93a2c break when the crossover wire breakage prevention means (1) (the adhesion strengthening means provided in the axially opposing regions of the flanges) is not provided. However, further explanation is omitted here.

[0087] [Table 1]

[0088] First, in the third and fourth rows of Table 1, all of the crossover wire breakage suppression measures (1) to (3) are simultaneously provided, and a crossover wire breakage suppression measure (3-1) is provided by adding a reinforcing agent to the resin material forming the bobbin 94. As a result, the linear expansion coefficient of the bobbin 94 becomes smaller than that of the sealing resin portion 97, and the breakage occurrence superiority / inferiority evaluation can be evaluated as "Good." Furthermore, in the first and second rows of Table 1, a crossover wire breakage suppression measure (3-2) is provided by making the bobbin 94 and the sealing resin portion 97 out of the same material, and adding a larger amount of reinforcing agent to the resin material forming the bobbin 94 than to the resin material forming the sealing resin portion 97. As a result, the linear expansion coefficient of the bobbin 94 becomes smaller than that of the sealing resin portion 97 and approaches that of the coil 93a, and the breakage occurrence superiority / inferiority evaluation can be evaluated as "Good." In this way, by employing the crossover wire breakage suppression means (3-1) and the crossover wire breakage suppression means (3-2), breakage of the crossover wires 93a1c and 93a2c can be further suppressed.

[0089] In the first embodiment, the bobbin 94 and the sealing resin portion 97 are made of the same material, and the difference in linear expansion coefficient is set depending on the presence or absence of a reinforcing agent and the amount of the reinforcing agent, but this is not limited to this. Here, since cross-linked polyphenylene sulfide has a smaller linear expansion coefficient than linear polyphenylene sulfide, for example, the bobbin 94 and the sealing resin portion 97 may be made of the same material (polyphenylene sulfide (PPS)), and cross-linked polyphenylene sulfide may be used for the bobbin 94 while linear polyphenylene sulfide may be used for the sealing resin portion 97.

[0090] <Measures to prevent crossover wire breakage (3-3) (Coefficient of linear expansion of bobbin that is 40% or less of the coil breakage tension)> The inventors set the linear expansion coefficient of the bobbin 94 so that 40% of the breaking tension of the coil 93a is the allowable tension (safety factor 2.5) that is safe for use, as a condition for ensuring that the crossover portions 93a1c, 93a2c will not break even when the coil device 93 is used under extremely large temperature changes (160°C from -40°C to 120°C). The reason for this is that the sealing resin portion 97, which is tightly fixed around the periphery of the crossover portions 93a1c, 93a2c, has an anchor effect on the bobbin 94, which suppresses expansion and contraction due to temperature changes. Therefore, for example, when the temperature rises, it is not the sealing resin portion 97 that applies tensile force to the coil 93a, but rather the elongation of the bobbin 94 that has a relatively large effect. Therefore, the crossover wire breakage prevention means (3-3) sets the linear expansion coefficient of the bobbin 94 so that the tensile force acting on the crossover wires 93a1c, 93a2c due to temperature changes is 40% or less of the breaking tension of the coil 93a. Below, an example process for calculating the linear expansion coefficient of the bobbin 94 will be described.

[0091] For example, if the wire diameter of the coil 93a is 0.2 (mm) and the breaking tension is 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 ) where the length Ly of the crossover wire portions 93a1c and 93a2c is 5 (mm). The longitudinal elastic modulus E of the coil 93a made of a general annealed copper wire is 118×10 3 (N / mm 2 )

[0092] Here, the equation that expresses the relationship between stress σ and strain ε is the following (Equation 1), the stress σ at the time of allowable tension is the following (Equation 2), and the strain ε, which is the displacement per unit length, is the following (Equation 3). σ=εE (Equation 1) σ=Ty / A (Equation 2) ε=ΔLy / Ly (Equation 3)

[0093] Therefore, by introducing (Equation 2) and (Equation 3) into (Equation 1), the following (Equation 4) can be calculated, which can then be transformed into the following (Equation 5). Ty / A=E×ΔLy / Ly (Equation 4) ΔLy=Ty×Ly / (A×E) (Formula 5)

[0094] Here, when the values ​​of the allowable tension Ty, the length Ly of the crossover wire portions 93a1c and 93a2c, the cross-sectional area A of the coil 93a, and the modulus of longitudinal elasticity E of the coil 93a, which are known as described above, are introduced into (Equation 5), the displacement of the crossover wire portion when the allowable tension is applied is given by ΔLy = 3.0 (N) × 5 (mm) / (0.0314 (mm 2 )×118×10 3 (N / mm 2 )) = 0.004 (mm).

[0095] The calculation results show that when the crossover wire portions 93a1c, 93a2c have a wire diameter of 0.2 (mm) and a length of 5 (mm), if a tensile force is forcibly applied from the outside and they are stretched beyond 0.004 (mm), the allowable tension Ty will be exceeded, increasing the risk of breakage of the crossover wire portions 93a1c, 93a2c.

[0096] The calculations up to this point have not taken into account the expansion of the crossover wire portions 93a1c and 93a2c due to temperature changes. Therefore, from here on, we will consider the displacement ΔLty of the crossover wire portions 93a1c and 93a2c due to temperature changes. The linear expansion coefficient αy of a coil made of general annealed copper wire is 1.7×10 -5 ( / °C), and the temperature difference Δt is set to 160°C, assuming a temperature range of -40°C to 120°C. Therefore, when the length Ly of the crossover wires 93a1c, 93a2c is 5 mm, the displacement ΔLty at a temperature change of 160°C is ΔLty = αy × Ly × Δt = 0.0136 mm. However, because the displacement ΔLty due to temperature change is due to the temperature change of the crossover wires 93a1c, 93a2c themselves, no tensile force is generated.

[0097] Therefore, the displacement of the crossover wire portions 93a1c, 93a2c at the time of the allowable tension and the temperature change of 160°C is 0.0176 (mm), which is the sum of the displacement ΔLy (0.004 (mm)) at the time of the allowable tension and the displacement ΔLty (0.0136 (mm)) due to the temperature change.

[0098] From here on, it is assumed that the displacement ΔLy+ΔLty of the crossover wire portions 93a1c, 93a2c at this allowable tension and a temperature change of 160°C is caused by the displacement ΔLp of the bobbin 94 at a temperature change of 160°C through the anchor effect of the sealing resin portion 97 and the adhesion strengthening means Ar.

[0099] The displacement ΔLp of the bobbin 94 at this temperature change of 160°C is given by the following (Equation 6) when the linear expansion coefficient of the bobbin 94 is αp, the length of the bobbin 94 is Lp, and the temperature difference is Δt. Rearranging the linear expansion coefficient αp of the bobbin 94 gives the following (Equation 7). ΔLp=αp×Lp×Δt (Equation 6) αp=ΔLp / (Lp×Δt) (Equation 7)

[0100] Here, when the previously known values ​​of the displacement ΔLp (=ΔLy+ΔLty) of the bobbin 94 due to temperature change, the length Lp (=Ly) of the bobbin 94, and the temperature difference Δt are substituted into (Equation 7), the following is obtained: αp=0.0176(mm) / (5(mm)×160(℃))=2.2×10 -5 ( / ℃).

[0101] Therefore, in this example, the linear expansion coefficient of the resin material of the bobbin 94 is 2.2×10 -5If a bobbin 94 having a linear expansion coefficient smaller than 1.0, even if the coil 93a elongates due to temperature changes, the linear expansion coefficient of the bobbin 94 can be kept below the safe allowable tension (safety factor 2.5) for use of the coil 93a. As can be seen from Table 1, this brings the linear expansion coefficient of the bobbin 94 closer to the linear expansion coefficient of the coil 93a. In this way, by employing the crossover wire breakage prevention means (3-3), the crossover wires 93a1c, 93a2c will not break even when used under extremely large temperature changes, and the safety of use of the coil device 93 can be greatly improved.

[0102] As described above, in the first embodiment, by simultaneously adopting a crossover wire breakage prevention means (1) (an adhesion strengthening means provided in the axially opposing region of the flange portion), a crossover wire breakage prevention means (2) (the crossover wire is positioned close to or abutting the axially opposing region of the flange portion), and a crossover wire breakage prevention means (3) (the bobbin has a smaller linear expansion coefficient than the sealing resin portion), it is possible to solve the conventional problem (breakage of the crossover wire due to temperature changes) and improve reliability.

[0103] In the first embodiment, the crossover wire breakage suppression means (1) is improved by employing the crossover wire breakage suppression means (1-1) (uneven portion, surface modified portion), which can reduce manufacturing costs. Furthermore, by employing the crossover wire breakage suppression means (1-2) (uneven portion intersecting the crossover wire), the anchor effect in the extension direction of the crossover wires 93a1c, 93a2c is further improved, and expansion and contraction of the sealing resin portion 97 due to temperature changes can be more reliably suppressed.

[0104] In addition, in the first embodiment, the crossover wire breakage prevention means (2) is improved by adopting a crossover wire breakage prevention means (2-1) (the crossover wire is arranged out of contact with the area facing the axis perpendicularly) and / or a crossover wire breakage prevention means (2-2) (only the tip of the winding part of the crossover wire is fixed), thereby making it possible to prevent pre-tension force from being applied to the crossover wire parts 93a1c, 93a2c when the crossover wire parts 93a1c, 93a2c are connected to the terminal 96a and when the sealing resin part 97 is molded and shrinks.

[0105] In the first embodiment, the crossover wire breakage suppression means (3) is improved by adopting a crossover wire breakage suppression means (3-1) (adding a reinforcing agent to the bobbin) and a crossover wire breakage suppression means (3-2) (the bobbin and the sealing resin part are made of the same material, and a larger amount of reinforcing agent is added to the bobbin than to the sealing resin part), thereby further suppressing breakage of the crossover wires 93a1c, 93a2c. Also, by adopting a crossover wire breakage suppression means (3-3) (a bobbin linear expansion coefficient that is 40% or less of the coil breaking tension), the safety of the coil device 93 during use can be significantly improved.

[0106] In the first embodiment, in addition to the crossover wire breakage suppression means (1) to (3), all of the crossover wire breakage suppression means (1-1), (1-2), (2-1), (2-2), (3-1), (3-2), and (3-3) are employed, but this is not limited to this. For example, as long as at least the crossover wire breakage suppression means (1) to (3) are employed simultaneously, it is also possible to employ none of the crossover wire breakage suppression means (1-1), (1-2), (2-1), (2-2), (3-1), (3-2), and (3-3), or to employ a combination including at least one of them.

[0107] (Second embodiment) A flow control valve 100b according to a second embodiment will be described using Figures 10 and 15. In the second embodiment, the main differences from the first embodiment are the configuration of the coil device 93' and the crossover wire breakage suppression means (3-2') (a reinforcing agent is added to the bobbin and the sealing resin portion) and the configuration of the coil device 93 and the crossover wire breakage suppression means (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), but the other basic configurations are substantially the same as those of the first embodiment. Here, the same components are denoted by the same reference numerals, and duplicated explanations will be omitted.

[0108] As will be described in more detail later, in the second embodiment, similar to the first embodiment, by simultaneously adopting means (1) to (3) for preventing crossover wire breakage, it is possible to eliminate the conventional problem (crossover wire breakage due to temperature changes) and improve reliability.

[0109] <About the coil device> 15, the coil device 93' includes a bobbin assembly 94' (see FIG. 13) that includes a stator 95' having an annular shape, a bobbin 94' that is integral with the stator 95', a coil 93a' that is wound around the outer periphery of the bobbin 94', and a power supply terminal 96a' that is attached to the bobbin 94' and connected to the coil 93a'. The coil device 93' also includes a substrate 96f' and lead wires 96d that are connected to the terminal 96a', a cover 96g' that houses the bobbin assembly 94' with the substrate 96f' attached, and a sealing resin part 97' that seals the gap between the cover 96g' and the outer periphery of the bobbin assembly 94'. As will be described in detail later, the stator 95' is made of a metal material such as SEC (electrogalvanized steel sheet) and has a first stator pole tooth portion 95a', a second stator pole tooth portion 95b', a first stator outer casing 95c', a second stator outer casing 95d', and a third stator outer casing 95e'. The bobbin 94' is made of a resin material such as polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT). The resin material forming the bobbin 94' may be polyphenylene sulfide (PPS) or polybutylene terephthalate (PBT) containing glass fiber or glass fiber with an inorganic filler added as a reinforcing agent. As will be described in detail later, this reduces the linear expansion coefficient of the bobbin 94' and reliably suppresses expansion and contraction of the sealing resin portion 97' due to temperature changes. Furthermore, the coil 93a' is made of a metal material such as copper, similar to the coil 93a of the first embodiment, and has a first coil 93a1' and a second coil 93a2'.

[0110] <About the coil device assembly process> 11 to 15, the assembly process of the coil device 93' (stator assembling process, injection molding process, bobbin assembling process, cover mounting process, and electrical component sealing process) will be described. Details will be described later, but the assembly process will be described while showing the crossover wire breakage suppression means (1) (adhesion strengthening means provided in the axially opposing region of the flange portion), the crossover wire breakage suppression means (2) (arranging the crossover wire close to or abutting the axially opposing region of the flange portion), and the crossover wire breakage suppression means (3) (the bobbin has a smaller linear expansion coefficient than the sealing resin portion).

[0111] <About the stator assembly process> The stator assembly process will be described with reference to Figure 11(a). First, the first stator outer casing 95c' is assembled into the first stator pole tooth portion 95a', and the second stator outer casing 95d' is assembled into the second stator pole tooth portion 95b' (see arrow A1' in Figure 11(a)).

[0112] <Injection molding process (cross wire breakage prevention means (1))> The injection molding process will be described with reference to FIG. 11(b). The first stator pole tooth portion 95a', the second stator pole tooth portion 95b', the first stator outer casing 95c', and the second stator outer casing 95d' are assembled together and then insert-molded to form a bobbin 94' (see A2' in FIG. 11). As shown in FIG. 11(b), the bobbin 94' has a substantially cylindrical shape and includes a bobbin body 94a' having ring-shaped protruding edges at both ends in the axial direction L and at the center, and a flange portion 94f' extending radially from the ring-shaped protruding edges at the center of the bobbin body 94a'. At this time, a portion of the stator 95' (see FIG. 15(a)) is covered by the bobbin body 94a'. The flange portion 94f' is provided with a first insertion hole 94f1' and a second insertion hole 94f2' into which a first terminal 96a1' and a second terminal 96a2' (see FIG. 12) are inserted, and has a flange portion thickness T'.

[0113] Here, as will be described in detail later, as a means for preventing breakage of the crossover line portion (1), one side and the other side of the flange portion 94f' are provided with an adhesion strengthening means Ar (see the dot pattern in Figure 11(b)) (for example, an uneven portion (see Figures 9(b) and (c)) or a surface modified portion, etc.), as in the first embodiment.

[0114] This adhesion strengthening means Ar significantly improves the anchor effect between the sealing resin portion 97' and the flange portion 94f' and strengthens the adhesion during the electrical equipment sealing process described below (see Figures 15(a) and (b)), thereby suppressing breakage of the first crossover wire portion 93a1c' and the second crossover wire portion 93a2c'.

[0115] <About the bobbin assembly process (measures to prevent breakage of the crossover wire (2))> The bobbin assembly process will be described with reference to Figures 12 and 13. First, the first terminal 96a1' and the second terminal 96a2' are inserted into the first insertion hole 94f1' and the second insertion hole 94f2' of the flange portion 94f', respectively (see arrow A3' in Figure 12). Next, 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', respectively (see A4' in Figure 12). Then, the first crossover portion 93a1c' and the second crossover portion 93a2c' at both ends of the first coil 93a1' and the second coil 93a2' are connected (for example, soldered) to the first terminal 96a1' and the second terminal 96a2' via the first winding portion 93a1f' and the second winding portion 93a2f', respectively.

[0116] As will be described in detail later, the crossover wire breakage suppression means (2) is configured by arranging the first crossover wire 93a1c' and the second crossover wire 93a2c' adjacent to or in contact with one side surface and the other side surface of the flange portion 94f'. The positions at which the first crossover wire 93a1c' and the second crossover wire 93a2c' are arranged are areas where the anchor effect of the sealing resin portion 97' is significantly improved by the crossover wire breakage suppression means (1) in the electrical component sealing process (see FIG. 15(b)) described below, and therefore breakage of the first crossover wire 93a1c' and the second crossover wire 93a2c' can be suppressed.

[0117] This results in the formation of a bobbin assembly 94' as shown in Figure 13. In this bobbin assembly 94', adhesion reinforcing means Ar (see the dot patterns in Figures 13(a) and 13(b)) is provided on one side and the other side of the flange portion 94f' as crossover wire breakage suppression means (1). Furthermore, as crossover wire breakage suppression means (2), the first crossover wire 93a1c' and the second crossover wire 93a2c' are disposed adjacent to or abutting one side and the other side of the flange portion 94f'. In the second embodiment, there are a total of eight first crossover wires 93a1c' and second crossover wires 93a2c', and six first terminals 96a1' and second terminals 96a2' because each terminal has a common terminal in the center, but the numbers of crossover wires and terminals are not limited to these.

[0118] <About the cover installation process> The cover attachment process will be described with reference to FIG. 14. First, lead wires 96d are connected (for example, soldered) to terminals 96a' of the bobbin assembly 94' assembly via a substrate 96f' (see arrow A5' in FIG. 14). Then, a third stator outer casing 95e' having a C-shape when viewed from the direction of axis L is fitted onto the outer periphery of the bobbin assembly 94' assembly (see arrow A6' in FIG. 14). Then, a cover 96g' made of a resin material is fitted onto the bobbin assembly 94' assembly from the direction of axis L (see arrow A7' in FIG. 14). Then, the bobbin assembly 94' assembly with the cover 96g' attached is turned upside down (see arrow A8' in FIG. 14).

[0119] <About the electrical component sealing process (crossover wire breakage prevention measures (3))> The electrical component sealing process (crossover wire breakage suppression means (3)) will be described using Figure 15. Note that the explanatory diagrams of Figures 11 to 14 are upside down compared to the explanatory diagram of Figure 15. A casting resin (e.g., a thermosetting resin material such as epoxy resin or polyurethane resin) is poured into the space formed inside the cover 96g' and outside the bobbin assembly 94' Assy, and is heated and hardened to form a sealing resin portion 97' (see A9' in Figure 15(a)). At this time, the peripheries of the first crossover wire portion 93a1c' and the second crossover wire portion 93a2c' are tightly adhered and fixed to the sealing resin portion 97'.

[0120] Here, as a means (3) for preventing the crossover wire from breaking, the linear expansion coefficient of the bobbin 94' is set to be smaller than the linear expansion coefficient of the sealing resin part 97', thereby preventing the first crossover wire part 93a1c' and the second crossover wire part 93a2c' from breaking.

[0121] <Measures (1) to (3) for preventing crossover wire breakage> The crossover wire breakage prevention measures (1) to (3) will be described in detail with reference to FIG. 15(b). First, the crossover wire breakage prevention measure (1) is to provide adhesion strengthening means Ar (see the dot pattern in FIG. 15(b)) that strengthens the adhesion between the sealing resin portion 97' and the flange portion 94f' in the axially facing region AF of the flange portion 94f', which faces the first crossover wire 93a1c' and the second crossover wire 93a2c' in the axially facing region AF of the flange portion 94f'. Furthermore, the crossover wire breakage prevention measure (2) is to position the first crossover wire 93a1c' and the second crossover wire 93a2c' adjacent to or in contact with the axially facing region AF of the flange portion 94f'. Furthermore, the crossover wire breakage prevention measure (3) is to make the linear expansion coefficient of the bobbin 94' smaller than the linear expansion coefficient of the sealing resin portion 97'.

[0122] 15(b), in the second embodiment, the crossover wire breakage suppression means (1) and (2) significantly improve the anchoring effect of the sealing resin portion 97' to the axially opposing region AF of the flange portion 94f', and the first crossover wire 93a1c' and the second crossover wire 93a2c' are arranged in the region where the anchoring effect of the sealing resin portion 97' is significantly improved. At the same time, the crossover wire breakage suppression means (3) reduces the expansion and contraction of the flange portion 94f' due to temperature changes compared to the sealing resin portion 97'. As a result, even if the coil device 93' is used in an environment where the ambient temperature changes significantly, the sealing resin portion 97', which is tightly fixed around the first crossover wire portion 93a1c' and the second crossover wire portion 93a2c', has an anchor effect on the flange portion 94f', which suppresses expansion and contraction due to temperature changes, thereby suppressing breakage of the first crossover wire portion 93a1c' and the second crossover wire portion 93a2c' and improving reliability.

[0123] As described above, in the second embodiment, similar to the first embodiment, by simultaneously adopting a crossover wire breakage prevention means (1) (an adhesion strengthening means provided in the axially opposing region of the flange portion), a crossover wire breakage prevention means (2) (the crossover wire is positioned close to or abutting the axially opposing region of the flange portion), and a crossover wire breakage prevention means (3) (the bobbin has a smaller linear expansion coefficient than the sealing resin portion), it is possible to solve the conventional problem (breakage of the crossover wire due to temperature changes) and improve reliability.

[0124] <Consideration of measures (1) to (3) to prevent crossover wire breakage> The examination of the crossover wire breakage suppression means (1) to (3) in the second embodiment is similar to that in the first embodiment, and will be briefly explained below with reference to FIG. 15(b).

[0125] In the second embodiment, the crossover wire breakage suppression means (1) is improved by employing a crossover wire breakage suppression means (1-1) (uneven portion, surface modified portion), which can reduce manufacturing costs. Also, by employing a crossover wire breakage suppression means (1-2) (uneven portion intersecting the crossover wire), the anchor effect in the direction in which the crossover wires 93a1c', 93a2c' extend is further improved, and expansion and contraction of the sealing resin portion 97' due to temperature changes can be more reliably suppressed.

[0126] Furthermore, in the second embodiment, the crossover wire breakage prevention means (2) is improved by adopting a crossover wire breakage prevention means (2-1) (the crossover wire is arranged out of contact with the area facing in the direction perpendicular to the axis) and / or a crossover wire breakage prevention means (2-2) (only the tip of the winding part of the crossover wire is fixed), thereby making it possible to prevent pre-tension force from being applied to the crossover wire parts 93a1c', 93a2c' when the crossover wire parts 93a1c', 93a2c' are connected to the terminal 96a' and when the sealing resin part 97' is molded and shrunk.

[0127] In addition, in the second embodiment, the crossover wire breakage suppression means (3) is improved by adopting a crossover wire breakage suppression means (3-1) (adding a reinforcing agent to the bobbin) and a crossover wire breakage suppression means (3-2') (adding a reinforcing agent to the bobbin and the sealing resin portion), and by further reducing the linear expansion coefficients of the bobbin 94' and the sealing resin portion 97', it is possible to further suppress breakage of the crossover wires 93a1c', 93a2c'.Furthermore, by adopting a crossover wire breakage suppression means (3-3) (a bobbin linear expansion coefficient that is 40% or less of the coil's breaking tension), it is possible to extremely increase the safety of use of the coil device 93'.

[0128] <Comparative evaluation of crossover wire breakage prevention measures (3-1) and (3-2')> Here, in order to determine the relative merits of the breakage occurrence of the crossover wires 93a1c', 93a2c' in the crossover wire breakage suppression means (3-1) and (3-2'), a comparative evaluation was carried out as in the first embodiment, as shown in Table 2. Note that under all of the conditions in Table 2, as in Table 1, the crossover wire breakage suppression means (2) (the crossover wire is disposed close to or in contact with the axially opposing region of the flange portion) and the crossover wire breakage suppression means (3) (the bobbin has a smaller linear expansion coefficient than the sealing resin portion) are provided.

[0129] Below, only the differences between the notation in Table 2 and Table 1 will be explained. In Table 2, "EP" indicates "epoxy resin," a thermosetting resin material. For reference, the fifth and sixth lines (areas surrounded by black frames) in Table 2 indicate that breakage of the crossover wires 93a1c', 93a2c' occurs when there is no crossover wire breakage suppression means (1) (adhesion strengthening means provided in the axially opposing regions of the flange portions), but a description of this will be omitted here.

[0130] Here, polyurethane resin generally has a larger coefficient of linear expansion than epoxy resin, so by adding a reinforcing agent to polyurethane resin, the coefficient of linear expansion can be made closer to that of epoxy resin without the addition of a reinforcing agent. Therefore, although not shown in Table 2, when polyurethane resin is used as the sealing resin part 97', adding a reinforcing agent will result in a "fracture occurrence superiority evaluation" equivalent to that of epoxy resin without the addition of a reinforcing agent.

[0131] [Table 2]

[0132] First, in the third and fourth rows of Table 2, all of the crossover wire breakage suppression measures (1) to (3) are simultaneously provided, and a reinforcing agent is added to the resin material forming the bobbin 94' as a crossover wire breakage suppression measure (3-1). This makes the linear expansion coefficient of the bobbin 94' smaller than that of the sealing resin portion 97', so the breakage occurrence superiority / inferiority evaluation can be evaluated as "Good." Furthermore, in the first and second rows of Table 2, a crossover wire breakage suppression measure (3-2') is provided by adding (even more) a reinforcing agent to the bobbin 94' and the sealing resin portion 97'. This makes the linear expansion coefficients of the bobbin 94' and the sealing resin portion 97' even smaller, approaching that of the coil 93a', so the breakage occurrence superiority / inferiority evaluation can be evaluated as "Excellent." In this way, by employing the crossover wire breakage suppression means (3-1) and the crossover wire breakage suppression means (3-2'), breakage of the crossover wires 93a1c' and 93a2c' can be further suppressed.

[0133] <Measures to prevent crossover wire breakage (3-3) (Coefficient of linear expansion of bobbin that is 40% or less of the coil breakage tension)> In the second embodiment, as in the first embodiment, by adopting a crossover wire breakage prevention means (3-3), the crossover wire portions 93a1c', 93a2c' are reliably prevented from breaking even when used under extremely large temperature changes, thereby extremely increasing the safety of use of the coil device 93'.

[0134] As described above, in the second embodiment, similar to the first embodiment, by simultaneously adopting a crossover wire breakage prevention means (1) (an adhesion strengthening means provided in the axially opposing region of the flange portion), a crossover wire breakage prevention means (2) (the crossover wire is positioned close to or abutting the axially opposing region of the flange portion), and a crossover wire breakage prevention means (3) (the bobbin has a smaller linear expansion coefficient than the sealing resin portion), it is possible to solve the conventional problem (breakage of the crossover wire due to temperature changes) and improve reliability.

[0135] In the second embodiment, similarly to the first embodiment, the crossover wire breakage suppression means (1) is improved by employing a crossover wire breakage suppression means (1-1) (uneven portion, surface modified portion), thereby reducing manufacturing costs. Furthermore, by employing a crossover wire breakage suppression means (1-2) (uneven portion intersecting the crossover wire), the anchor effect in the direction in which the crossover wires 93a1c', 93a2c' extend is further improved, and expansion and contraction of the sealing resin portion 97' due to temperature changes can be more reliably suppressed.

[0136] In addition, in the second embodiment, as in the first embodiment, the crossover wire breakage prevention means (2) is improved by adopting a crossover wire breakage prevention means (2-1) (the crossover wire is arranged out of contact with the area facing in the direction perpendicular to the axis) and / or a crossover wire breakage prevention means (2-2) (only the tip of the winding part of the crossover wire is fixed), thereby making it possible to prevent pre-tension force from being applied to the crossover wire parts 93a1c', 93a2c' when the crossover wire parts 93a1c', 93a2c' are connected to the terminal 96a' and when the sealing resin part 97' is molded and shrunk.

[0137] In the second embodiment, the crossover wire breakage suppression means (3) is improved by adopting a crossover wire breakage suppression means (3-1) (adding a reinforcing agent to the bobbin) and a crossover wire breakage suppression means (3-2') (adding a reinforcing agent to the bobbin and the sealing resin portion), thereby further suppressing breakage of the crossover wires 93a1c', 93a2c'. Also, by adopting a crossover wire breakage suppression means (3-3) (a bobbin linear expansion coefficient that is 40% or less of the coil breakage tension), the safety of use of the coil device 93' can be significantly improved.

[0138] In the second embodiment, in addition to the crossover wire breakage suppression means (1) to (3), all of the crossover wire breakage suppression means (1-1), (1-2), (2-1), (2-2), (3-1), (3-2'), and (3-3) are employed, but this is not limited to this. For example, as long as at least the crossover wire breakage suppression means (1) to (3) are employed simultaneously, it is also possible to employ none of the crossover wire breakage suppression means (1-1), (1-2), (2-1), (2-2), (3-1), (3-2'), and (3-3), or to employ a combination including at least one of them.

[0139] <Other> The flow control valves 100a, 100b equipped with the coil devices 93, 93' of this embodiment are highly reliable even when used in an environment with extremely large changes in ambient temperature, and therefore, needless to say, are applicable to all fluid devices and fluid circuits, including refrigeration cycles. Furthermore, the present invention is not limited to the above-described embodiments, and appropriate changes and modifications can be made without departing from the technical spirit of the present invention. [Explanation of symbols]

[0140] 100a, 100b Flow control valve 1a Valve port 1b Lateral Port 2 Valve chamber 3 Closed space 10 Flow control valve body 20 Support member 21 Fixing bracket 21a Through hole 23 screw hole 23a Female thread 24 bearing hole 25 slide hole 26 Guide rail 27 Cylindrical part 30 Connecting member 30scm male thread engagement 40 Valve body 40scf female thread engagement 40scm male thread engagement 41 Insertion hole 42 Valve seat 43 Opening 44 Outer surface 45 Jig engagement part 46 First annular groove 47 Second annular groove 48 Step 50 drive shaft 51 Threaded part 51a Male thread 52 Guide section 53 Tsuba 60 Valve body 61 Valve holder 61a One end 61b Other end 62 Valve body 63 Washer 64 Spring holder 65 compression coil spring 70 Coil material 71 Coil section 72 Claw 80 rotor unit 81 Can 81a Recess 82 Magnet rotor 84 Magnet part 85 Disc Section 86 Metal fittings 87 protrusion 90,90' stator coil unit 91 Case body 91a One end opening 91b Other end opening 91c Sealing material receiving groove 91e Notch 91st floor storage space 92 Control board connector 93,93' Coil device 93a,93a' coil 93a1, 93a1' First coil (coil) 93a2, 93a2' Second coil (coil) 93a1c, 93a1c' First crossover section 93a1f, 93a1f' First winding portion 93a2c,93a2c' Second crossover section 93a2f, 93a2f' Second winding part 94,94' bobbin 94a First Bobbin (Bobbin) 94ab First bobbin body (bobbin body) 94af First flange part (flange part) 94af1 Insertion hole 94b Second bobbin (bobbin) 94bb Second bobbin body (bobbin body) 94bf Second flange part (flange part) 94bf1 Insertion hole 94f' flange 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 Grommet 96c Connector 96d Lead wire 96e Connector resin part 96f' board 96g cover 96h bracket 96h1 convex part 97,97' Sealing resin part 98 Control Board 99 Lid AF Axial facing area AOF: Area facing perpendicular to the axis Ar Adhesion strengthening means Ar1,Ar2 Uneven part E: Coil modulus of elasticity Fp1 First flow path Fp2 Second flow path G1 First Receiving Groove G2 Second Receiving Groove G3 3rd Receiving Groove H Housing Hscf female thread engagement part L axis Ly Length of the crossover O1 First shaft seal member O2 Second shaft seal member Oc Case body sealing material Sc1 1st threaded part Sc2 2nd threaded part Sh screw hole T, T' flange thickness Ty Allowable coil tension ΔLp Displacement of the bobbin due to temperature change ΔLty: Displacement of the crossover wire due to temperature change ΔLy Displacement of the crossover wire at the time of allowable tension

Claims

1. a stator; a bobbin made of a resin material, the bobbin having a bobbin body having a generally cylindrical shape centered on an axis line, and a flange portion extending radially outward from the bobbin body; a power supply terminal fixed to the flange portion; a coil wound around the bobbin body, the coil having crossover wire portions at both ends thereof connected to the terminals; a sealing resin portion that seals the bobbin including the flange portion, the coil including the crossover portion, and the terminal; a crossover wire breakage prevention means for preventing the crossover wire from breaking; Equipped with The crossover line breakage prevention means is providing an adhesion strengthening means for strengthening adhesion between the sealing resin portion and the flange portion in an axially opposing region of the flange portion that faces the bridge portion in the axial direction; The bridge portion is disposed adjacent to or in contact with the axially opposing region of the flange portion; and A coil device, wherein the bobbin has a linear expansion coefficient smaller than that of the sealing resin portion.

2. 2. The coil device according to claim 1, wherein the adhesion strengthening means is an uneven portion or a surface modified portion provided in the axially opposing region of the flange portion.

3. 3. The coil device according to claim 2, wherein the uneven portion extends in a direction intersecting the crossover portion when viewed from the axial direction.

4. the flange portion has an axis-orthogonal direction opposing region that faces the bridge portion in a direction orthogonal to the axis, 2. The coil device according to claim 1, wherein the crossover wire breakage prevention means arranges the crossover wire in a non-contact state in the region of the flange portion that faces the axis perpendicular direction.

5. the crossover portion has a winding portion wound around the terminal, 5. The coil device according to claim 4, wherein the crossover wire breakage prevention means fixes only the tip of the winding portion to the terminal.

6. The coil device according to claim 1, characterized in that the resin material forming the bobbin is glass fiber as a reinforcing agent, or polyphenylene sulfide (PPS) in which inorganic filler is added to glass fiber, or polybutylene terephthalate (PBT).

7. The coil device described in claim 6, characterized in that the crossover wire breakage prevention means, when the resin material forming the bobbin and the resin material forming the sealing resin portion are the same material, makes the resin material forming the bobbin contain a larger amount of the reinforcing agent than the resin material forming the sealing resin portion.

8. The coil device according to claim 1, characterized in that the crossover wire breakage prevention means sets the linear expansion coefficient of the resin material forming the bobbin so that the tension acting on the crossover wire at the operating temperature is 40% or less of the breaking tension of the coil.

9. A flow rate adjusting valve comprising the coil device according to any one of claims 1 to 8.

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