Method for manufacturing superconducting coils, superconducting coils, and superconducting magnet products

Abstract

To reduce the manufacturing costs (labor and expenses) of superconducting coils. [Solution] The method for manufacturing a superconducting coil involves placing the coil windings in an easily removable mold made of elastic resin, which is created using a master piece that simulates the shape of the coil windings that constitute a conductive coil (steps S105 to S115), injecting resin into the mold and hardening it to fix the shape of the coil windings (step S120), and then removing it from the mold to form a superconducting coil (step S125).

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a superconducting coil, a superconducting coil, and a superconducting magnet product.

Background Art

[0002] When using a superconductor with zero electric resistance in direct current, a coil (electromagnet) with a high current density can be realized. As this type of coil (electromagnet), it is used for applications that generate a strong magnetic field in a large space, such as superconducting magnets for accelerators for high-energy physics and magnets for MRI (Magnetic Resonance Imaging) devices. In recent years, the temperature range of superconducting applications has been expanding by using high-temperature superconductors that do not require cooling with liquid helium. Note that a "high-temperature superconductor" is a superconductor with a critical temperature of 25 K or higher. Also, not only applications that require a large magnetic field space but also uses in which a magnetic field is applied to a relatively small space, such as field magnets for rotating machines and coils for magnetic refrigeration, are increasing. These coils utilize the magnetic field leaking outside a flat coil with a relatively low winding height like a pancake winding rather than using the magnetic field space inside a wound coil like a solenoid coil. Also, these coils are used by arranging a large number of small coils. Patent Document 1 discloses a magnet device for a magnetic refrigeration device configured with a gap in a flat coil. Non-Patent Document 1 discloses a rotor of a superconducting motor for a ship propulsion machine configured by arranging racetrack-shaped coil packs.

[0003] Conventional methods for manufacturing superconducting coils involve impregnating the superconducting wire with resin after it has been wound (i.e., impregnating the gaps in the solid with another substance) to integrate the windings. In particular, coils using metallic superconducting materials such as NbTi (niobium titanium) and Nb3Sn (niobium tin) are operated near the temperature of liquid helium (4K), which has an extremely low specific heat, and are easily quenched by even slight heat generated by the slippage (wire motion) of the coil windings. To prevent this, the coil windings in these superconducting magnets are firmly impregnated with resin, and the resin is impregnated under vacuum pressure to prevent quenching due to heat released by cracking of the resin, ensuring that no bubbles or defects remain inside the resin that could cause cracks. Quenching is a phenomenon in which a normal conducting region (resistive region) is generated in a minute area of ​​the superconducting coil due to some disturbance, and the normal conducting region rapidly expands due to the heat generated in that area, causing the entire superconducting coil to transition to a normal conducting state. Furthermore, even if resin cracking occurs, the amount of resin used is minimized to reduce the energy released, and any excess resin is removed.

[0004] To facilitate the removal of excess resin after disassembly following the resin impregnation process, a release agent is applied to the coil, and clay or similar material is filled into recesses where resin accumulates and at the coil winding exit points to prevent excess resin from adhering. Resin impregnation is extremely important for low-temperature superconducting coils, and processes such as pressurized vacuum impregnation and resin disassembly increase manufacturing costs (labor and expenses). [Prior art documents] [Patent Documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2022-136671 [Non-patent literature]

[0006] [Non-Patent Document 1] Toshiyuki Yanagimoto, Doctoral Dissertation: "Research on the Practical Application of High-Temperature Superconducting Motors for Marine Propulsion Systems," Tokyo University of Marine Science and Technology Graduate School, Degree Awarded: 2017, Degree Number: 12614, Doctoral Dissertation No. 476, Internet<URL: / http: / / id.nii.ac.jp / 1342 / 00001549 / > [Overview of the Initiative] [Problems that the invention aims to solve]

[0007] The prior art disclosed in Patent Document 1 and the prior art disclosed in Non-Patent Document 1 are prone to unstable coil windings during manufacturing. In such prior art, it is desirable to securely fix the coil windings in order to improve electrical characteristics. However, to date, no technology has been established to securely fix coil windings inexpensively, which increases the manufacturing cost (man-hours and expenses) of superconducting coils.

[0008] The present invention was made to solve the aforementioned problems, and its main objective is to provide a method for manufacturing superconducting coils, a superconducting coil, and a superconducting magnet product that reduces the manufacturing cost (man-hours and expenses) of superconducting coils. [Means for solving the problem]

[0009] To achieve the above objective, the present invention provides a method for manufacturing a superconducting coil, comprising: placing the superconducting coil winding in an easily removable mold made of elastic resin using a master piece that simulates the shape of the superconducting coil winding; injecting resin into the mold and hardening it to fix the shape of the superconducting coil winding; and removing it from the mold to form a superconducting coil. Other methods will be described later. [Effects of the Invention]

[0010] According to the present invention, the manufacturing cost (man-hours and expenses) of superconducting coils can be reduced. [Brief explanation of the drawing]

[0011] [Figure 1A] This is a flowchart showing the overall operation of the method for manufacturing a superconducting coil according to the embodiment. [Figure 1B] This is a flowchart showing the overall operation in a modified example of the method for manufacturing a superconducting coil according to the embodiment. [Figure 2] This is an explanatory diagram of a coil bobbin used in the manufacture of superconducting coils. [Figure 3] This is an explanatory diagram of a formed product (coil pack) as an example of a superconducting coil. [Figure 4] This is an explanatory diagram for the Masterpiece. [Figure 5] This is an explanatory diagram of the formwork. [Figure 6] This is an explanatory diagram of the coil windings, current connection points, and lead wires installed on the formwork. [Figure 7] This is an explanatory diagram of the cooling copper plate placed on the formwork. [Figure 8] This is an explanatory diagram of the resin injection process. [Figure 9] This is an explanatory diagram of the vacuum degassing process during resin injection. [Figure 10] This is an explanatory diagram of a rotor body, an example of a superconducting magnet product. [Figure 11] This is an explanatory diagram of the superconducting coil used in the rotor body. [Modes for carrying out the invention]

[0012] Hereinafter, embodiments of the present invention (hereinafter referred to as "these embodiments") will be described in detail with reference to the drawings. Note that each figure is merely a schematic representation to the extent necessary for a thorough understanding of the present invention. Therefore, the present invention is not limited to the illustrated examples. Furthermore, in each figure, common or similar components are denoted by the same reference numerals, and their redundant descriptions are omitted.

[0013] Furthermore, this embodiment also aims to provide a method for manufacturing superconducting coils that takes into account the following issues, as the prior art has the following problems. (1) When manufacturing a large number of small coils, it is wasteful to perform resin impregnation using the same method and equipment as conventional relatively large coil windings, and the resin disassembly work becomes difficult. In high-temperature superconducting magnets operating in a temperature range of 10 K or more compared to low-temperature metal-based superconducting materials, the specific heat becomes significantly larger. Therefore, in the manufacture of high-temperature superconducting magnets, quenching due to resin cracking can be hardly considered. Also, operations such as vacuum pressure impregnation work and resin disassembly work are costly. Therefore, when manufacturing a plurality of small coil packs and combining them to form a magnet device, it is preferable that the resin impregnation work and disassembly work can be performed more simply and easily. Also, in order to realize reduction of man-hours (costs) associated with resin impregnation work and to realize resin impregnation only for the winding, it is also desired to provide a packaged superconducting coil. (2) Further, conventional superconducting coils are integrated by impregnating resin with superconducting wire wound tightly around a coil bobbin having a flange and a winding core. However, in coils with relatively small electromagnetic force, flanges and winding cores are not always necessary, and in many cases, only a pack of coil windings with a minimum number of attachments (for example, electrode parts, heat conduction plates, etc.) attached is sufficient. Therefore, it is also desired to provide a superconducting coil with the flange and winding core removed.

[0014] <Manufacturing method of superconducting coil> Hereinafter, referring to FIGS. 1A and 1B, the manufacturing method of the superconducting coil 101 (FIG. 3) according to the present embodiment will be described. FIG. 1A is a flowchart showing the overall operation of the manufacturing method of the superconducting coil 101 according to the present embodiment. FIG. 1B is a flowchart showing the overall operation in a modification of the manufacturing method of the superconducting coil 101 according to the present embodiment.

[0015] As shown in FIG. 1A, the manufacturing method of the superconducting coil 101 according to the present embodiment has steps S105 to S125.

[0016] Step S105 is a process of constructing (creating) a mold 50 (Figure 5) made of elastic resin that is easy to release, using a masterpiece 30 (Figure 4) that simulates the shape of the coil winding 10 (Figure 3) that constitutes the superconducting coil 101 (Figure 3). Step S110 is the process of manufacturing the coil winding 10 (Figure 2) using the wind-and-react method or the react-and-wind method described later. Step S115 is the process of installing the coil winding 10 on the formwork 50 (Figure 6). Step S120 is the process of injecting the resin 60 into the mold 50 and curing the resin 60 (Figure 8). This process hardens the shape of the coil winding 10. Step S125 is the process of removing the molded product (coil pack 70 (Figure 3)) from the mold 50. This process forms the superconducting coil 101 (Figure 3).

[0017] The manufacturing method for the superconducting coil according to this embodiment may be changed from the manufacturing method shown in Figure 1A to the manufacturing method shown in Figure 1B. The manufacturing method shown in Figure 1A involves hardening the shape of the coil winding 10 alone. In contrast, the manufacturing method shown in Figure 1B involves hardening the shape of the coil winding 10 and the attached parts 20.

[0018] The manufacturing method shown in Figure 1B includes steps S105a, S115a, and S120a instead of steps S105, S115, and S120 shown in Figure 1A.

[0019] Step S105a is a process of constructing (creating) a mold 50 (Figure 5) made of elastic resin that is easy to release, using a masterpiece 30 (Figure 4) that simulates the shape of the coil windings 10 (Figure 3) and accessories 20 (Figure 3) that make up the superconducting coil 101 (Figure 3). Step S115a is the process of installing the coil winding 10 and attachments 20 on the formwork 50 (Figure 6). Step S120a is the process of injecting the resin 60 into the mold 50 and curing the resin 60 (Figure 8). This process integrates the coil winding 10 and the attachment 20 and hardens their shapes. Details of each process will be described later, referring to Figures 2 to 9.

[0020] The details of each step in the manufacturing method shown in Figure 1B will be explained below with reference to Figures 2 to 9. Note that the manufacturing method shown in Figure 1A is the same as the manufacturing method shown in Figure 1B, but with the accessory 20 removed.

[0021] (Overview of coil bobbins) Figure 2 is an explanatory diagram of a coil bobbin 21 used in the manufacture of a superconducting coil 101. Figure 2 shows an example of a coil bobbin 21 used in the manufacture of a superconducting coil 101. In Figure 2, the first figure from the top shows the state in which the coil winding 10 is wound around the winding core 22 of the coil bobbin 21. The second figure from the top shows the state in which the coil bobbin 21 is separated into the winding core 22 and the two flanges 23. The third figure from the top (i.e., the first figure from the bottom) shows the shape of the coil winding 10 taken out of the coil bobbin 21.

[0022] As shown in the first figure from the top in Figure 2, the coil bobbin 21 has a winding core 22 and a flange 23. The winding core 22 is a component around which a metal coil is wound. The coil is wound spirally multiple times around the winding core 22 to form the coil winding 10. The winding core 22 has a cylindrical shape. The flange 23 is a flat plate-shaped component positioned above and below the winding core 22. The flange 23 defines the upper and lower positions of the coil (coil winding 10) wound around the winding core 22.

[0023] As shown in the second figure from the top in Figure 2, the coil bobbin 21 can be separated into the winding core 22 and the two flanges 23. By separating the coil bobbin 21 into the winding core 22 and the two flanges 23, the coil winding 10 can be removed from the coil bobbin 21, as shown in the third figure from the top in Figure 2.

[0024] In this explanation, the coil winding 10 is taken out of the coil bobbin 21. However, it is also possible to use the coil bobbin 21 as an accessory 20 to the coil winding 10 without taking out the coil winding 10 from the coil bobbin 21. That is, in the method for manufacturing a superconducting coil, the accessory 20 may be a coil bobbin 21 equipped with a winding core 22 and a flange 23.

[0025] Furthermore, the accessory 20 is detachable from the coil winding 10 and can be individually placed on the formwork 50 (Figure 5).

[0026] (Overview of the coil pack) Figure 3 is an explanatory diagram of a coil pack 70 (formed product) formed as an example of a superconducting coil 101. Figure 3 shows an example of a coil pack 70. The coil pack 70 is a formed product formed as an example of a superconducting coil 101. As shown in Figure 3, the coil pack 70 has a configuration comprising a coil winding 10, a cooling copper plate 103, and a current connection section 104. In the example shown in Figure 3, the coil winding 10 has an elongated cylindrical shape. The coil winding 10 is hardened with resin 60 so that its shape is fixed. Two current connection sections 104 are arranged on one end of the coil winding 10 in the longitudinal direction (upper left side in Figure 3). The current connection section 104 is a metal member for conducting current to the coil winding 10. The coil winding 10 is electrically connected to the two current connection sections 104 via two metal lead wires 107 (Figure 6). A cooling copper plate 103 is positioned above the coil winding 10. The cooling copper plate 103, along with the lead wires 107 (Figure 6), seals the top of the coil winding 10. Here, the cooling copper plate 103 and the current connection part 104 are described as accessories 20 of the coil winding 10.

[0027] The coil pack 70 consists of a coil winding 10 from which the core 22 has been removed, with a cooling copper plate 103 and a current connection section 104 integrated into it. The cooling copper plate 103 and the current connection section 104 are fastened together by bolts (not shown) with copper flexible conductors (not shown) for heat transfer and current conduction, respectively.

[0028] The coil winding 10 of the superconducting coil 101 is wound around a coil bobbin 21 equipped with a flange 23 and a winding core 22. Depending on the application, the coil winding 10 may have a configuration in which the flange 23 and winding core 22 are removed after the coil winding. In the case of pancake coils made by winding tape wire, the coil winding 10 may not have a flange 23 from the beginning and may be coiled by housing it in a coil case. Here, we will consider a magnet device that combines multiple coils of almost the same type, and the coil winding 10 of the modularized superconducting coil 101 that constitutes this magnet device will be called a coil pack 70. Here, we assume that the coil pack 70 is one in which the superconducting coil winding 10 and the electrode part are integrated by resin impregnation. However, the coil winding 10 may also have a configuration in which accessories 20 such as the flange 23, winding core 22, and cooling copper plate 103 for cooling are integrated with resin 60. The designation "Coil Pack 70" does not limit the composition or structure, but rather signifies the concept of a coil module integrated with the necessary component resins.

[0029] (Manufacturing procedure for coil packs (W&R coils)) The coil windings 10 used in the coil pack 70 are manufactured by the wind-and-react method or the react-and-wind method. The wind-and-react method is a method in which a coil is formed by winding a precursor wire and then heat-treating the winding. On the other hand, the react-and-wind method is a method in which a coil is formed by heat-treating a precursor wire and then winding it. Below, as an example, the manufacturing procedure for a coil pack 70 wound with MgB2 (magnesium diboride) superconducting wire will be described.

[0030] MgB2 wire can be used to manufacture coils using either the wind-and-react method (where the precursor wire is wound and then the winding is heat-treated to form the coil) or the react-and-wind method (where the precursor wire is heat-treated and then wound to form the coil). However, this explanation will focus on coils manufactured using the wind-and-react method, which allows for winding with a smaller radius of curvature.

[0031] MgB2 wire is generally manufactured by filling a metal tube with Mg (magnesium) and B (boron) powder, which are the raw materials for MgB2, and then drawing (wire drawing) the metal tube filled with the powder. Alternatively, MgB2 wire can be manufactured by filling a metal tube with MgB2 powder that has been preheated, and then drawing (wire drawing) the metal tube filled with the powder. When manufacturing a coil winding 10 using MgB2 wire, electrical insulation is formed around the wire. In this case, in the wind and react method, heat treatment exceeding 600°C in an inert gas is performed to braid heat-resistant filaments such as glass fibers around the wire, thereby forming insulation around the wire.

[0032] A fiberglass-coated wire is wound onto a coil bobbin 21 with a metal core 22 and flange 23. This coil bobbin 21 is constructed from integrated parts that are separated to facilitate removal after heat treatment. After heat treatment of the wound coil in an appropriate atmosphere and temperature, the coil bobbin 21 is disassembled to remove only the coil winding 10.

[0033] The removed coil winding 10 is placed in a resin impregnation mold 50 (Figure 5) made of an elastic resin such as silicone resin, and after soldering the electrodes to the protrusions, a cooling copper plate 103 (Figure 7) is placed inside the mold 50. After pouring the thermosetting resin, which has been degassed in advance, into the mold 50, the mold 50 is moved to a vacuum container 110 and the pressure is reduced to allow the resin 60 to thoroughly penetrate into the inside of the coil winding 10.

[0034] The mold 50 into which the resin 60 has been poured is moved into a constant temperature bath, and the resin 60 is cured at a predetermined temperature. After that, the mold 50 is removed from the constant temperature bath, and the coil pack 70 is removed from the mold 50.

[0035] (Creation of formwork) Figure 4 is an explanatory diagram of the masterpiece 30. The masterpiece 30 is a component used when constructing (creating) the formwork 50 (Figure 5). Here, the masterpiece 30 is described as having a configuration that simulates the shape of a coil pack 70, including the coil windings 10.

[0036] The masterpiece 30 does not necessarily have to be the same shape as the coil pack 70, and may have screw holes or fine notches. There are no restrictions on the method of manufacturing the masterpiece 30. In this embodiment, the masterpiece 30 is described as being created by cutting out a block formed by laminating thick sheets of polyvinyl chloride. In this embodiment, the masterpiece 30 is described as having a shape that includes a cooling copper plate 103 (Figure 3) placed on the coil winding 10 and a current connection part 104 (Figure 3) placed at the end of the coil winding 10. The fine shape of the masterpiece 30 may be formed using a 3D printer. The masterpiece 30 may also be formed by integrating the cut-out parts with adhesive. A release agent may be applied to the surface of the masterpiece 30. The masterpiece 30 is then placed in a case (not shown), and molding silicone resin 40 is poured into the case and allowed to harden. After the resin hardens, the masterpiece 30 is removed from the case to form the mold 50. Because the silicone resin 40 is elastic, the masterpiece 30 can be easily removed from the case to create the mold 50.

[0037] Figure 5 is an explanatory diagram of the mold 50. The mold 50 is constructed to simulate the shape of the coil pack 70. The mold 50 is made of an elastic material, silicone resin 40, which makes it easy to release the formed coil pack 70 (superconducting coil 101) from the mold.

[0038] The mold 50 has a shape that accommodates the coil pack 70 (Figure 3) inside. The mold 50 is also formed with dimensions that allow for minimal play to be installed (inserted) the heat-treated coil windings 10 (Figure 6), the current connection section 104 (Figure 6), the lead wires 107 (Figure 6), and the cooling copper plate 103 (Figure 7). Note that Figure 5 does not show introduction channels, air vents, or recesses for storing the resin 60 to improve the flow of the resin 60. These components should be installed appropriately as needed.

[0039] (Differences in effects due to differences in coil manufacturing methods) Although we have described the wind-and-react method for coils using MgB2, the coil winding 10 can take any form. The same procedure can be used to form a coil pack 70 even for a pancake coil made by winding REBCO conductor, a type of tape-shaped copper oxide superconductor.

[0040] There are slight differences in the effects of the present invention between coils made by the react-and-wind method and coils made by the wind-and-react method. Since the react-and-wind coil is made by winding a wire that already has a superconductor formed on it, high-temperature heat treatment to generate the superconductor is unnecessary. Therefore, since elastic strain remains in the wound superconducting coil, the winding core 22 and flange 23 of the coil bobbin 21 cannot be removed before resin impregnation. Consequently, when performing resin impregnation using this method, the coil bobbin 21 is always necessary to maintain the shape of the coil winding 10, and limitations arise when rationalizing this (for example, by removing one side of the flange 23 to expand the usable magnetic field space).

[0041] On the other hand, in coils produced by the wind-and-react method, the heat treatment used to generate the superconductor anneals the metal in the matrix portion that makes up the wire, releasing its strain. As a result, the winding after heat treatment does not unwind (springback) even without the coil bobbin 21. Therefore, the winding core 22 and flange 23 can be removed, and a compact coil pack can be formed by installing a minimal heat conductive plate (for example, high-purity aluminum tape).

[0042] Furthermore, the wire insulation (glass-coated insulation) used in the wind-and-react method becomes brittle after heat treatment, and the coil winding 10 becomes soft and easily loses its shape. The present invention has the advantage of being able to impregnate the winding with resin while maintaining its external shape by inserting it into the mold 50, making it ideal for forming compact coil packs of wind-and-react method coils.

[0043] (Other effects when making coil packs) To explain the other effects of coil manufacturing according to this embodiment, the coil manufacturing procedure will be described in more detail. Figure 6 shows the intermediate state of the coil pack 70 during assembly. Figure 6 is an explanatory diagram of the coil winding 10, current connection section 104, and lead wires 107 installed in the mold 50. In the example shown in Figure 6, the coil winding 10 and two current connection sections 104 are arranged inside the mold 50. Two lead wires 107 are also arranged on the coil winding 10 and each current connection section 104. Of the two lead wires 107, one lead wire 107 (the lead wire 107 on the left in Figure 6) is positioned on the inner circumference side of the coil winding 10. The other lead wire 107 (the lead wire 107 on the right in Figure 6) is positioned on the outer circumference side of the coil winding 10. The two lead wires 107 are positioned on the inner and outer circumferences of the coil winding 10, respectively, allowing current to flow through the spirally wound coil winding 10.

[0044] The mold 50 contains the current connection section 104 and the coil winding 10. The coil winding 10 is wound starting from the inside and ending on the outside. The beginning and end of the coil winding, i.e., the lead wires 107, are soldered to the current connection section 104. Since the lead wires 107 are positioned above the current connection section 104, the current connection section 104 is installed in the mold 50 before the coil winding 10. The mold 50 serves as both a container for resin impregnation and a fixing jig for the soldering work. If the mold 50, which also serves as a fixing jig, were not available, some kind of jig would be required.

[0045] Figure 7 is an explanatory diagram of a cooling copper plate 103 placed on a mold 50. In the example shown in Figure 7, the cooling copper plate 103 is positioned on the coil winding 10, two current connection parts 104, and two lead wires 107. The cooling copper plate 103 is positioned so as to fit inside the mold 50. Together with the current connection parts 104 and lead wires 107, the cooling copper plate 103 constitutes an accessory 20 added to the coil winding 10.

[0046] Kapton sheets (not shown) are inserted between the coil winding 10 and the cooling copper plate 103, and between the current connection part 104 and the cooling copper plate 103 to provide electrical insulation. The cooling copper plate 103 and the current connection part 104 are fastened together with screws (not shown). The current connection part 104, which is a heavy object, is soldered to the lead wires 107 of the coil winding 10. When soldering the lead wires 107 to the current connection part 104, the formwork 50 functions as a fixing jig to assist in the installation.

[0047] Thus, the mold 50 functions not only as a container for resin impregnation but also as an auxiliary fixing jig when creating the coil pack 70. The use of the mold 50 allows for obtaining excellent superconducting current transport characteristics in the wind-and-react coil method, where the superconducting current transport characteristics deteriorate due to deformation of the superconducting wire after heat treatment.

[0048] Furthermore, if the coil winding 10 and the cooling copper plate 103 are fixed by some method, and the current connection part 104 is also fixed, the coil pack 70 can be manufactured. However, in this case, it becomes difficult to solder and attach the current connection part 104 and the lead wires 107.

[0049] (resin injection) Next, the resin injection process will be explained. Figure 8 is an explanatory diagram of the resin injection operation. In the example shown in Figure 8, a resin reservoir 108 is installed above the mold 50 during the resin injection operation. The resin reservoir 108 is a container with a funnel-shaped lower section. A resin reservoir 61 is housed inside the resin reservoir 108. The resin reservoir 61 is the section in which the resin 60 is stored. The resin 60 in the resin reservoir 61 has its viscosity reduced or is heated and melted by a heating means (not shown), and is poured into the mold 50 from the bottom of the resin reservoir 108.

[0050] The formwork 50 is equipped with a coil winding 10, a current connection section 104, and a cooling copper plate 103. A certain amount of space is required to insert and position these components into the formwork 50, and resin 60 is injected into this space and the space between the windings of the coil winding 10. Although the injected resin 60 is in a low viscosity state, it is important to reduce the pressure and remove the air in order to inject it into every corner without leaving any air in the gaps. Since it takes a certain amount of time for the resin 60 to penetrate into the interior of the coil winding 10, a resin reservoir 108 is used as a container to store and hold the amount of resin 60 needed for injection.

[0051] A resin reservoir 108 is installed on the upper side of the mold 50 so that the resin 60 is naturally injected into the mold 50 using gravity. The resin reservoir 108 is conceptual and is not limited to the shape of the container shown. The resin reservoir 108 just needs to have a volume to hold the resin 60 and be positioned so that the resin 60 flows naturally into the mold 50 due to gravity. The mold 50 is configured to surround only the part below the cooling copper plate 103. However, the mold 50 may have an upper part that is formed higher than the top surface of the cooling copper plate 103, as in general sand casting, and the upper part may have a volume for accumulating the resin 60. However, considering the ease of creating the coil pack 70, the height of the mold 50 would be increased, so it is not desirable to provide an upper part in the mold 50 and inject the resin 60 into the upper part. Therefore, it is preferable to form a recess on the upper surface of the mold 50, which is formed lower than the upper surface of the cooling copper plate 103, to serve as a volume space for accumulating the resin 60. If the amount of resin to be filled is large, the resin reservoir 108 may be configured to be attached to the mold 50 as a separate, detachable container.

[0052] Resin 60 is poured into the resin reservoir 108. Then, the resin 60 is introduced from the resin reservoir 108 into the inside of the mold 50 via injection grooves (not shown) formed in the mold 50.

[0053] By properly forming air vents and resin injection channels in the mold 50, the resin 60 penetrates into the interior of the mold 50. With such a mold 50, air can be removed using a vacuum pump or the like to prevent residual air from causing poor resin filling, and the resin injection time can be reduced.

[0054] Figure 9 is an explanatory diagram of the vacuum degassing process in resin injection. In the example shown in Figure 9, resin 60 is poured into the mold 50 by the resin injection process. In the example shown in Figure 9, the coil windings 10, accessories 20, resin reservoir 108, etc., are placed inside the vacuum container 110 along with the mold 50. The height of the resin liquid level 60t after resin injection is set to be lower than the highest position 103t of the accessories 20. In this embodiment of the superconducting coil manufacturing method, the resin 60 can be poured into the mold 50 so that the shapes of the coil windings 10 and accessories 20 can be cured with the resin 60. After this, in the superconducting coil manufacturing method according to this embodiment, the resin reservoir 61 is removed and the resin 60 is cured. As a result, the superconducting coil manufacturing method according to this embodiment can manufacture the superconducting coil 101 while reducing manufacturing costs (man-hours and expenses).

[0055] To further explain, a resin reservoir 108 is placed above the mold 50 containing the coil windings 10 and the current connection section 104, and resin 60 is poured into the mold 50 to fill the inside of the mold 50 with resin 60. Then, the mold 50 is placed inside a vacuum container 110 and the pressure is reduced using a vacuum pump (not shown). The reduced pressure exhausts the air in the gaps between the coil windings 10 and the mold 50, and the resin 60 quickly fills the gaps.

[0056] (Resin curing, coil pack molding) Once resin injection is complete under reduced pressure, heat treatment is performed to cure the resin. If the resin reservoir 108 is configured to be removable, the resin reservoir 108 is removed and the mold 50 is placed in a constant temperature bath (not shown). The resin 60 is then cured at an appropriate temperature inside the constant temperature bath (not shown). After the resin has cured, the resin-impregnated coil pack 70 is removed from the mold 50. After this, excess resin 60 and burrs formed by the injection path for resin injection are trimmed, and the coil pack 70 is completed by shaping it with a file or similar tool.

[0057] (Use of coil packs) The coil pack 70 (superconducting coil 101) formed in this manner has a configuration that includes current and heat / cold introduction terminals. The coil packs 70 are modularized with the same shape. Therefore, by arranging multiple coil packs 70 symmetrically, a superconducting magnet device can be formed.

[0058] The coil pack 70 (superconducting coil 101) can be used, for example, in the rotor body 111 of the superconducting motor R0 shown in Figure 10. Figure 10 is an explanatory diagram of the rotor body 111 as an example of a superconducting magnet product. The rotor body 111 is a superconducting magnet product incorporated into, for example, a superconducting motor R0 for driving ships. In the example shown in Figure 10, the rotor body 111 comprises a rotor 122, a high-temperature superconducting coil 124, a damper 125, and an output shaft 126. A stator 121 incorporating an armature coil 123 is arranged around the rotor body 111. The stator 121 is the stator of the motor. The rotor 122 is the rotor of the motor. The armature coil 123 is a coil incorporated into the stator 121. The high-temperature superconducting coil 124 is a coil of high-temperature superconductor that operates in a temperature range of 10K or higher. The damper 125 is a component that shields against the fluctuating magnetic field from the armature coil 123. The output shaft 126 is a shaft component that outputs rotational force from the motor.

[0059] Figure 11 is an explanatory diagram of the superconducting coil 101 used in the rotor body 111. As shown in Figure 11, the rotor body 111 is manufactured by arranging multiple coil packs 70 (superconducting coils 101) symmetrically. In the example shown in Figure 11, four modularized coil packs 70 (superconducting coils 101) are attached to an iron rotor body 111. Examples of superconducting magnet products using multiple coil packs 70 (superconducting coils 101) can be applied to magnets for magnetic refrigeration devices, such as those disclosed in Patent Document 1.

[0060] <Main characteristics of the manufacturing method for superconducting coils> The method for manufacturing a superconducting coil according to this embodiment can be configured to have the following characteristics.

[0061] (1) As shown in Figure 1A, the method for manufacturing a superconducting coil according to this embodiment has steps S105 to S125.

[0062] Step S105 is a process of constructing (creating) an easily demoldable mold 50 (Figure 5) using silicone resin 40 (elastic resin) with a masterpiece 30 (Figure 4) that simulates the shape of the coil winding 10 (Figure 3) that constitutes the superconducting coil 101 (Figure 3). Step S110 is the process of manufacturing the coil winding 10 (Figure 2) using the wind-and-react method or the react-and-wind method described later. Step S115 is the process of installing the coil winding 10 on the formwork 50 (Figure 6). Step S120 is the process of injecting the resin 60 into the mold 50 and curing the resin 60 (Figure 8). This process hardens the shape of the coil winding 10. Step S125 is the process of removing the molded product (coil pack 70 (Figure 3)) from the mold 50. This process forms the superconducting coil 101 (Figure 3).

[0063] The method for manufacturing a superconducting coil according to this embodiment involves constructing (creating) an easily removable mold 50 made of silicone resin 40 (elastic resin) using a masterpiece 30 that simulates the shape of the coil winding 10 that constitutes the superconducting coil 101. Then, the method for manufacturing a superconducting coil according to this embodiment involves placing the coil winding 10 in the mold 50. After this, the method for manufacturing a superconducting coil according to this embodiment involves injecting resin 60 into the mold 50 and hardening the resin 60 to fix the shape of the coil winding 10. Then, the method for manufacturing a superconducting coil according to this embodiment involves removing the formed product (coil pack 70) from the mold 50 to form the superconducting coil 101.

[0064] In other words, the method for manufacturing a superconducting coil according to this embodiment involves creating a convex mold (masterpiece 30) that simulates the coil windings 10 that constitute the superconducting coil 101, and then using the convex mold to create a concave mold (mold 50) molded from silicone resin 40 (elastic resin). Then, in the method for manufacturing a superconducting coil according to this embodiment, the coil windings 10 are placed in the mold 50. After this, in the method for manufacturing a superconducting coil according to this embodiment, impregnation resin 60 is injected into the mold 50 and the resin 60 is hardened. Then, after the resin 60 has hardened, the superconducting coil 101 is formed by removing the formed product (coil pack 70) from the mold 50.

[0065] In this embodiment of the superconducting coil manufacturing method, the coil windings 10, which tend to become unstable during manufacturing, can be fixed in shape by curing them with resin 60 injected into a mold 50. Furthermore, since this embodiment of the superconducting coil manufacturing method uses a mold 50 made of silicone resin 40 (elastic resin), the dismantling of the mold 50 is easy. In addition, the silicone resin 40 (elastic resin) mold 50 functions as a guide when integrating the coil windings 10 and their accessories 20 (Figure 7). Therefore, in this embodiment of the superconducting coil manufacturing method, the manufacturing and assembly of the mold 50 is easy, and the molded product (coil pack 70) can be manufactured with a minimum number of components. Moreover, the mold 50 can be reused multiple times. Therefore, in this embodiment of the superconducting coil manufacturing method, the manufacturing cost (man-hours and expenses) of the superconducting coil 101 can be reduced.

[0066] (2) In the manufacturing method of the superconducting coil according to this embodiment, steps S105a, S115a, and S120a shown in Figure 1B may be performed instead of steps S105, S115, and S120 shown in Figure 1A. The manufacturing method shown in Figure 1B involves hardening the shape of the coil winding 10 and the attachment 20. That is, in this manufacturing method, the masterpiece 30 has a shape that simulates the shape of the coil winding 10 and the attachment 20.

[0067] Step S105a is a process of constructing (creating) a mold 50 (Figure 5) made of elastic resin that is easy to release, using a masterpiece 30 (Figure 4) that simulates the shape of the coil windings 10 (Figure 3) and accessories 20 (Figure 3) that make up the superconducting coil 101 (Figure 3). Step S115a is the process of installing the coil winding 10 and attachments 20 on the formwork 50 (Figure 6). Step S120a is the process of injecting the resin 60 into the mold 50 and curing the resin 60 (Figure 8). This process integrates the coil winding 10 and the attachment 20 and hardens their shapes.

[0068] This method for manufacturing a superconducting coil involves constructing (creating) an easily removable mold 50 made of silicone resin 40 (elastic resin) using a masterpiece 30 that simulates the shapes of the coil windings 10 and attachments 20 that constitute the superconducting coil 101. Then, the coil windings 10 and attachments 20 are placed in the mold 50. After this, the method for manufacturing a superconducting coil involves injecting resin 60 into the mold 50 and hardening the resin 60 and attachments 20 to fix the shapes of the coil windings 10 and attachments 20. Finally, the method for manufacturing a superconducting coil involves removing the formed product (coil pack 70) from the mold 50 to form the superconducting coil 101. This method for manufacturing a superconducting coil fixes the shapes of the coil windings 10 and attachments 20, which tend to be unstable during manufacturing, by hardening them with resin 60 injected into the mold 50.

[0069] This method for manufacturing superconducting coils allows for the integration and fixation of the coil windings 10 and accessories 20, which tend to be unstable during manufacturing, by curing them with resin 60 injected into a mold 50. Furthermore, because this method uses a mold 50 made of silicone resin 40 (elastic resin), the dismantling of the mold 50 is easy. The silicone resin 40 (elastic resin) mold 50 also functions as a guide when integrating the coil windings 10 and their accessories 20. Therefore, this method for manufacturing superconducting coils allows for easy manufacturing and assembly of the mold 50 and enables the production of the formed product (coil pack 70) with a minimum number of components. Moreover, the mold 50 can be reused multiple times. Therefore, this method for manufacturing superconducting coils can reduce the manufacturing cost (man-hours and expenses) of the superconducting coil 101.

[0070] (3) The method for manufacturing a superconducting coil as described in item (2) above, characterized in that the accessory 20 is a coil bobbin 21 (Figure 2) equipped with a winding core 22 and a flange 23.

[0071] The method for manufacturing a superconducting coil according to this embodiment allows for the manufacture of a superconducting coil 101 that incorporates a coil bobbin 21 (Figure 2) as an accessory 20 to the coil winding 10.

[0072] (4) The method for manufacturing a superconducting coil as described in item (2) above, characterized in that the accessory 20 is separable from the coil winding 10 and can be individually arranged in the mold 50.

[0073] The method for manufacturing a superconducting coil according to this embodiment can manufacture a superconducting coil 101 in which the attachments 20 are separable from the coil windings 10 and the attachments 20 are individually arranged in the mold 50.

[0074] (5) As shown in Figure 9, the method for manufacturing a superconducting coil described in item (2) above is characterized in that the height position of the resin liquid level 60t after resin injection is lower than the highest position 103t of the attachment 20.

[0075] In this embodiment, the method for manufacturing a superconducting coil allows the resin 60 to be poured into the mold 50 so that the shape of the coil winding 10 and the attachments 20 can be cured with the resin 60. This method for manufacturing a superconducting coil according to this embodiment can efficiently fix the shape of the coil winding 10 and the attachments 20, which tend to become unstable during manufacturing.

[0076] (6) The method for manufacturing a superconducting coil as described in item (2) above, characterized in that the coil winding 10 is manufactured by the wind and react method.

[0077] The method for manufacturing a superconducting coil according to this embodiment can produce a superconducting coil 101 that incorporates a coil winding 10 manufactured by the wind-and-react method.

[0078] (7) The method for manufacturing a superconducting coil described in item (2) above is characterized in that the coil winding 10 is manufactured by the react and wind method.

[0079] The method for manufacturing a superconducting coil according to this embodiment can manufacture a superconducting coil 101 that incorporates a coil winding 10 manufactured by the react-and-wind method. The coil winding 10 manufactured by the wind-and-react method described in item (6) and the coil winding 10 manufactured by the act-and-wind method described in item (7) have different characteristics. Therefore, depending on the application, a superconducting coil 101 with different characteristics can be manufactured by using either the coil winding 10 manufactured by the wind-and-react method described in item (6) or the coil winding 10 manufactured by the act-and-wind method described in item (7).

[0080] (8) As shown in Figures 8 and 9, in the method for manufacturing a superconducting coil according to item (1) or item (2) above, during the resin injection operation, a resin reservoir 61 containing the resin 60 is placed above the mold 50 and the resin 60 is injected. This method for manufacturing a superconducting coil is characterized in that the resin reservoir 61 is removed and the resin 60 is cured when the resin hardens.

[0081] The method for manufacturing a superconducting coil according to this embodiment allows for the manufacture of a superconducting coil 101 while reducing manufacturing costs (man-hours and expenses).

[0082] (9) In this embodiment, the superconducting coil 101 is formed by the penetration and curing of the resin 60 into a coil pack, or the coil winding 10 and the accessories 20 are integrally formed into a coil pack by the penetration and curing of the resin 60.

[0083] As shown in Figure 1A or Figure 1B, the superconducting coil 101 according to this embodiment is manufactured by the superconducting coil manufacturing method described in item (1) or (2) above. In the superconducting coil 101 according to this embodiment, the coil windings 10, which tend to become unstable during manufacturing, are cured with resin 60 and then packaged into a coil pack. Therefore, the manufacturing cost (man-hours and expenses) of the superconducting coil 101 can be reduced.

[0084] (10) As shown in Figure 11, the superconducting magnet product (rotor body 111) according to this embodiment has a plurality of superconducting coils 101 as described in item (9) above arranged symmetrically.

[0085] In this embodiment, the superconducting magnet product has its coil windings 10, which tend to become unstable during manufacturing, packaged into a coil pack by penetration curing of resin 60. Therefore, the superconducting magnet product according to this embodiment can reduce manufacturing costs (man-hours and expenses).

[0086] As described above, the manufacturing method of the superconducting coil according to this embodiment can reduce the manufacturing cost (man-hours and expenses) of the superconducting coil 101.

[0087] The present invention is not limited to the embodiments described above, and includes various modifications. For example, the embodiments described above are described in detail for the purpose of clearly illustrating the present invention, and are not necessarily limited to those having all the configurations described. Furthermore, it is possible to replace some of the configurations of the embodiments with other configurations, and it is also possible to add other configurations to the configurations of the embodiments. In addition, it is possible to add, delete, or replace some of the configurations of each configuration with other configurations. [Explanation of Symbols]

[0088] 10. Coil winding (superconducting coil winding) 20 Accessories (Coil winding accessories) 21. Coil bobbin (included) 22 cores 23 Flange 30 Masterpieces 40 Silicone resin (elastic resin) 50 formwork 60 resin 60t resin liquid level 61 Resin accumulation 70 Coil Packs (Formed Products) 101 Superconducting Coil 103 Cooling copper plate (accessory) 103t highest position 104 Current connection section 107 Lead line 108 Resin reservoir 110 Vacuum container 111 Rotor Body (Superconducting Magnet Product) 121 stata 122 Rotor 123 Armature coil 124 High-temperature superconducting coil 125 damper 126 Output shaft R0 Superconducting Motor

Claims

1. A superconducting coil winding is formed by placing the superconducting coil winding in an easily removable mold made of elastic resin, which is created using a master piece that simulates the shape of a superconducting coil winding; injecting resin into the mold and hardening it to fix the shape of the superconducting coil winding; and then removing it from the mold. A method for manufacturing a superconducting coil, characterized by the following features.

2. The aforementioned masterpiece has a shape that simulates the shape of the coil windings as well as the coil winding accessories. The superconducting coil winding and coil winding accessories are placed in the mold, resin is injected into the mold and hardened to fix the shape of the superconducting coil winding and coil winding accessories, and the superconducting coil is formed by removing them from the mold. A method for manufacturing a superconducting coil according to feature 1.

3. The coil winding accessory is a coil bobbin equipped with a winding core and a flange. The method for manufacturing a superconducting coil according to feature 2.

4. The coil winding accessories are separable from the superconducting coil winding and can be individually arranged in the mold. The method for manufacturing a superconducting coil according to feature 2.

5. The height of the resin liquid after resin injection is lower than the highest position of the coil winding attachment. The method for manufacturing a superconducting coil according to feature 2.

6. The aforementioned superconducting coil winding was manufactured using the wind-and-react method. The method for manufacturing a superconducting coil according to feature 2.

7. The aforementioned superconducting coil winding was manufactured using the reacted and wound method. The method for manufacturing a superconducting coil according to feature 2.

8. During the resin injection process, a resin reservoir containing the accumulated resin is placed above the mold, and the resin is injected. When the resin hardens, the resin reservoir is removed, and the resin hardens. A method for manufacturing a superconducting coil according to claim 1 or 2.

9. The superconducting coil windings are packaged into a coil pack by resin penetration curing, or the superconducting coil windings and coil winding accessories are integrally packaged into a coil pack by resin penetration curing. A superconducting coil characterized by the following features.

10. Multiple superconducting coils according to claim 9 are arranged symmetrically. A superconducting magnet product characterized by its features.

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