CN212750402U - Wire for magnetic element and inductor and transformer using the same - Google Patents

Abstract

The utility model provides an inductance and transformer that is used for magnetic element's wire rod and adopts this wire rod, wherein, a wire rod for magnetic element includes wire rod body and cladding material, cladding material has first face, second face and first side, second side, first face has viscidity, cladding material is with a winding angle winding on the surface of wire rod body, and first face is kept away from the surface of wire rod body, wherein, winding angle does first side or the second side with contained angle between the extending direction of wire rod body.

Description

Wire for magnetic element and inductor and transformer using the same

Technical Field

The utility model relates to a wire rod and adopt inductance and transformer of this wire rod for magnetic element.

Background

Power electronic products are always developed towards high power density, and more products can be applied to self-adhesive wires. The traditional operation mode is to coat quick-drying glue on the surface of the wire rod, and the surface of the wire rod is enabled to have viscosity through hot air or a solvent, so that the wire rod is not scattered after winding. However, the method is not convenient for small-quantity and various processing of wires, the glue does not meet the requirement of insulation grade, and the method is not suitable for power electronic products with high insulation requirements.

For example, when coils are wound in the industry at present, the coils are usually wound by self-adhesive wires and a heating system, and the price of the wires is far higher than that of normal wires. Or after the common wire is used for winding, the shape of the coil is maintained in a mode of fixing by using adhesive tapes, and the defects that the manual operation is complicated and the coil is easy to deform are overcome.

In order to overcome the above problems, it is urgently needed to find a wire product which can replace the traditional self-adhesive wire, is convenient for subsequent winding and processing molding, can form an independent coil, saves the traditional winding framework, reduces the cost and has stable quality.

SUMMERY OF THE UTILITY MODEL

The utility model provides a pair of wire rod for magnetic element, including wire rod body and cladding material, wherein, cladding material includes first face, second face and first side, second side, first face has viscidity, cladding material is with a winding angle winding on the surface of wire rod body, and first face is kept away from the surface of wire rod body, wherein, winding angle does first side or the second side with contained angle between the extending direction of wire rod body.

In one embodiment, the winding angle is 0-90 degrees.

In one embodiment, the winding angle is 65 degrees.

In one embodiment, the number of layers of the cladding material is at least one, the number of layers of the cladding material depends on an overlap ratio α, the overlap ratio α satisfies 0 ≦ α < 100%, and when the overlap ratio α is 0< α < 100%, the following formula is satisfied:

α＝(A-π*D*cosC)/A，

wherein D represents a diameter of the wire body, and C represents the winding angle.

In one embodiment, the overlapping ratio is 50% to 75%.

In one embodiment, the wire body is a single-stranded wire or a multi-stranded wire.

In one embodiment, the second side of the covering material has a tackiness.

In one embodiment, the coating material is an insulating tape.

In one embodiment, the cladding material is continuously wound around the outer surface of the wire body.

In one embodiment, the cladding material is wound on the outer surface of the wire body in sections.

The utility model also provides an inductance, including iron core and coil, its characterized in that, the coil by the wire rod processing form.

The utility model also provides a transformer, including the winding, the winding by the wire rod processing form.

The utility model discloses a wire rod for magnetic element has following advantage:

1. automatic processing can be realized;

2. the wire has a smooth and soft surface;

3. the wire arrangement is tighter, the position is more accurate, and the heat dissipation is better;

4. the wound hollow coil can not deform, has smaller volume, does not need small adhesive tape or glue for fixation, and has more cost advantage compared with the practice in the industry.

Drawings

FIG. 1 is a schematic view of a wire covered with a layer of cladding material;

FIG. 2 is a schematic view of a wire rod coated with two layers of coating materials

FIG. 3 is a cross-sectional view of the clad material;

FIG. 4 is a schematic representation of a spiral wound wrapping material;

FIG. 5 is a schematic cross-sectional view of a multi-strand wound multi-layer cladding material;

fig. 6 is a schematic view of a wire structure in which a covering material is wound in sections.

Fig. 7 is a schematic view of a wire cake made of the wire rod of the present invention;

fig. 8 is a schematic view of an air-core coil manufactured by using the wire rod of the present invention.

Wherein the reference numerals are:

wire body 10

Cladding material 20

Overlapping portion 30

First side 201

Second side 202

First side 203

Second side 204

Width A of the clad material

Width B of the overlapping part

Winding angle C

Diameter D of wire body

Wire cake 40

Air core coil 50

Detailed Description

The detailed description and technical contents related to the present invention are described below with reference to the accompanying drawings:

referring to fig. 1-6, fig. 1 is a schematic structural view of a wire covered with a layer of cladding material; FIG. 2 is a schematic view of a wire structure coated with two layers of coating materials, and FIG. 3 is a cross-sectional view of the coating materials; FIG. 4 is a schematic representation of a spiral wound wrapping material; FIG. 5 is a schematic cross-sectional view of a multi-strand wound multi-layer cladding material; fig. 6 is a schematic view of a wire structure in which a covering material is wound in sections. The utility model provides a wire rod 100 for magnetic element, including wire rod body 10 and cladding material 20, wherein, this cladding material 20 includes first face 201 and second face 202, this first face 201 of this cladding material 20 has viscidity, this cladding material 20 winding is on the surface of this wire rod body 10 to the surface of this wire rod body 10 is kept away from to this first face 201, and this first face 201 is located the outside of cladding material 20 promptly, and is corresponding, and this second face 202 is located the inboard of cladding material 20 and presses close to the surface of this wire rod body 10. In another embodiment, the first side 201 and the second side 202 are both adhesive, for example, the covering material 20 may be a tape, and specifically may be a tape with one-sided adhesive or a tape with both sides adhesive. In some embodiments, the covering material 20 may also be made of materials having different insulation grades, so that the wire 100 has different insulation capabilities.

The cladding material 20 is wound on the outer surface of the wire body 10 at a winding angle C, the cladding material 20 has a first side 203 and a second side 204, and the winding angle C is an included angle between the first side 203 or the second side 204 and the extending direction of the wire body 10, as shown in fig. 4.

The manufacturing method of the wire 100 of the present invention includes the following steps:

step S1, providing the wire body 10;

step S2, providing a coating material 20, wherein the coating material 20 comprises a first side 201 and a second side 202, and the first side 201 of the coating material 20 has viscosity;

step S3, the cladding material 20 is wound around the outer surface of the wire body 10, and the first surface 201 of the cladding material 20 is away from the outer surface of the wire body 10.

Wherein the step S3 may include the steps of:

step S31, winding the cladding material 20 around the outer surface of the wire body 10 at a winding angle C, where the cladding material 20 has a first side 203 and a second side 204, and the winding angle C is an included angle between the first side 203 or the second side 204 of the cladding material 20 and the extending direction of the wire body 10;

step S32, adjusting the winding angle C to wind the covering material 20 around the wire body 10 by a predetermined number of layers.

In one embodiment, in the step S32, the preset number of layers depends on an overlapping rate α, which is a ratio of the width B of the overlapping portion of two adjacent layers of the covering material 20 to the width a of the covering material 20, and satisfies 0 ≦ α ≦ 100%.

The above-mentioned manufacturing method can be realized by using an automatic winding device, and the cladding material is wound on the wire body by using the device.

Referring to fig. 4, when the cladding material 20 is wound on the outer surface of the wire body 10 by a predetermined number of layers, the predetermined number of layers depends on an overlap ratio α, which is a ratio of the width B of the overlapping portion of two adjacent layers of the cladding material 20 to the width a of the cladding material 20, and when the overlap ratio α satisfies 0< α < 100%, the calculation formula of the overlap ratio α is:

α＝B/A＝((A-π*D*cosC))/A，

where D denotes the diameter of the wire body 10, C denotes the winding angle, a denotes the width of the covering material, and the winding angle C may range from 0 to 90 degrees.

In other embodiments, the wire body 10 is a single-stranded wire or a multi-stranded wire, and is classified according to the material, the wire body 10 may also be a copper wire, an aluminum wire or a wire made of other materials, and in other embodiments, the wire body 10 may also be a three-layer insulated wire, a litz wire, or the like, in the present invention, the type of the wire body is not limited.

In other embodiments, the number of the preset layers is at least one, and when the number of the preset layers is 1, the corresponding overlap ratio α is 0; when the predetermined number of layers is greater than 1, the overlapping rate α is greater than 0 and equal to or less than 100%, and particularly, when the overlapping rate α is equal to 100%, that means the winding angle C is 90 degrees, the number of layers of the covering material 20 may be any number of layers. In the present invention, the number of layers of the coating material 20 is determined by the safety requirements in the specific application.

Referring again to fig. 1 and 2, the dashed line indicates that the cladding material is spiraled to the other side of the wire body, wherein the black area in fig. 2 is the overlapping portion of the first layer of cladding material and the second layer of cladding material.

Referring to fig. 4, taking the wire body 10 as a multi-strand wire, the overlapping width B being 8.64mm, the width a of the cladding material 20 being 12mm, the wire diameter D being 2.5mm, and the cladding material 20 being wound around the outer surface of the multi-strand wire at a winding angle of 65 degrees, the actual overlapping ratio is 72%, the wire manufactured according to the above parameters basically has the same insulating ability as a triple insulated wire, and can meet the requirements of most products.

In some embodiments, when the overlapping rate a is more than or equal to 50% and less than or equal to 67%, 2-3 insulating layers are arranged on the surface of the coated wire rod under the condition that the overlapping distance meets the safety distance and the requirement of an insulation and voltage resistance test, so that the coated wire rod can be used for reinforcing insulation in products such as information communication products and the like; when the overlapping rate is 67% < a ≦ 75%, the surface of the coated wire has 3-4 insulating layers under the condition that the overlapping distance meets the safety distance and the requirement of the insulation withstand voltage test, and the coated wire can replace a common three-layer insulated wire to be used for strengthening insulation. Referring again to fig. 6, the different overlapping ratios result in different numbers of layers of cladding material 20 in the cross-sectional view.

In some embodiments, the covering material 20 may be continuously wound around the outer surface of the wire body 10.

In other embodiments, the covering material 20 may be wound on the outer surface of the wire body 10 in sections, as shown in fig. 6, that is, the position where the covering material 20 needs to be wound may be calculated in an early stage, in the wire manufacturing process, the covering material 20 is selectively wound at a suitable position of the wire body 10, and the covering material 20 does not need to be wound at other positions, so long as it is ensured that the finally processed and formed coils can be effectively bonded and meet the safety requirements, so that the cost can be further reduced.

The utility model discloses a viscidity covers the wire rod outward and can use in inductance and transformer, and the coil in the inductance can adopt the wire rod processing of this application to form, and the winding in the transformer can adopt the wire rod processing of this application to form. Fig. 7 is a schematic view of a wire cake made of the wire rod of the present invention; fig. 8 is a schematic view of an air-core coil manufactured by using the wire rod of the present invention. Wire cake 40, hollow coil 50 all adopt the utility model discloses a wire rod coiling forms, the utility model discloses a wire rod's outside viscidity face can guarantee to overlap between the insulating layer and can not misplace, and the coiling hollow coil can not warp, need not little adhesive tape or glue fixed.

The utility model discloses a wire rod for magnetic component, through the overlap ratio of control viscidity insulating layer (being cladding material), make the cross-section of wire rod have the insulating layer of different numbers of piles to realize different insulating ability, can select for use according to the product insulation demand is nimble; the outer side adhesive surface of the wire can ensure that the insulation layers are overlapped without dislocation, and the insulation safety distance is ensured; the coating material 20 can be continuously wound on the outer surface of the wire body 10 or wound on the outer surface of the wire body 10 in sections, and the operation method can be operated continuously or in sections; the wire is convenient for subsequent winding processing and forming to form an independent coil, and a traditional winding framework is omitted;

the wire for magnetic elements of the present invention has the following advantages,

1. automatic processing can be realized;

2. the surface of the wire rod is smooth and soft;

3. the wire arrangement is tighter, the position is more accurate, and the heat dissipation is better;

4. the hollow coil wound by the wire rod has the advantages of no deformation, smaller volume, no need of small adhesive tape or glue for fixation, and higher cost advantage compared with the industry practice.

Claims (12)

1. The utility model provides a wire rod for magnetic element, its characterized in that includes wire rod body and cladding material, the cladding material has first face, second face and first side, second side, first face has viscidity, the cladding material is with a winding angle winding on the surface of wire rod body, and first face is kept away from the surface of wire rod body, wherein, the winding angle does first side or the second side with the contained angle between the extending direction of wire rod body.

2. The wire of claim 1, wherein the winding angle is 0-90 degrees.

3. The wire of claim 1, wherein the winding angle is 65 degrees.

4. The wire rod according to claim 1, wherein the number of layers of the covering material is at least one, the number of layers of the covering material depends on an overlap ratio α, the overlap ratio α satisfies 0 ≦ α < 100%, and when the overlap ratio α is 0< α < 100%, the following formula is satisfied:

α＝(A-π*D*cosC)/A，

wherein D represents a diameter of the wire body, C represents the winding angle, and a represents a width of the clad material.

5. The wire according to claim 4, wherein the overlapping ratio is 50% to 75%.

6. The wire of claim 1, wherein the wire body is a single wire or a multi-wire.

7. The wire of claim 1, wherein the second face of the cladding material is tacky.

8. The wire of claim 1, wherein the cladding material is a tape.

9. The wire of claim 1, wherein the cladding material is continuously wound around the outer surface of the wire body.

10. The wire of claim 1, wherein the cladding material is wrapped in sections around an outer surface of the wire body.

11. An inductor comprising a coil, wherein the coil is formed from the wire of any one of claims 1 to 10.

12. A transformer comprising a winding, wherein the winding is formed from a wire as claimed in any one of claims 1 to 10.

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