EP0545370A1 - Fil magnétique isolé, son procédé de formation, et isolation correspondant - Google Patents

Fil magnétique isolé, son procédé de formation, et isolation correspondant Download PDF

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Publication number
EP0545370A1
EP0545370A1 EP92120504A EP92120504A EP0545370A1 EP 0545370 A1 EP0545370 A1 EP 0545370A1 EP 92120504 A EP92120504 A EP 92120504A EP 92120504 A EP92120504 A EP 92120504A EP 0545370 A1 EP0545370 A1 EP 0545370A1
Authority
EP
European Patent Office
Prior art keywords
wire
insulation
tape
magnet wire
adhesive
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP92120504A
Other languages
German (de)
English (en)
Inventor
Steven Gross
John D. Hessler
Martin Weinberg
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
STERLING PAPER Corp
Original Assignee
STERLING PAPER Corp
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US07/801,003 external-priority patent/US5254806A/en
Application filed by STERLING PAPER Corp filed Critical STERLING PAPER Corp
Publication of EP0545370A1 publication Critical patent/EP0545370A1/fr
Withdrawn legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H01B13/06—Insulating conductors or cables
    • H01B13/10—Insulating conductors or cables by longitudinal lapping
    • H01B13/106—Insulating conductors or cables by longitudinal lapping the conductor having a rectangular cross-section
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
    • H01B7/29—Protection against damage caused by extremes of temperature or by flame
    • H01B7/292—Protection against damage caused by extremes of temperature or by flame using material resistant to heat

Definitions

  • This invention relates to an improved insulated magnet wire, to a method of forming the same, and also to a coil formed therefrom.
  • an electrical insulation material, in tape form is commonly employed as electrical insulation for the magnet wire.
  • the insulating tape is coated with a heat-cured adhesive substance which substance is cured by heating after application of the tape to a wire, which wire is essentially square or rectangular in cross section.
  • U. S. Patent No. 4,159,920 to G. Andersson et al, granted July 3, 1979 describes a typical prior art method for insulating a magnet wire with a wrapped insulation tape which is precoated with an epoxy adhesive resin. The epoxy must be thermally cured after application thereof to the magnet wire to insure adhesion between the tape and the wire.
  • British Patent Specification 1,233,862 published June 3, 1971 discloses a similar procedure for coating and forming magnet wire.
  • An additional contributor to rupture of insulation on a coiled magnet wire is the cross-sectional shape of the wire after it has been formed into a coil.
  • an insulated magnet wire of essentially square or rectangular shape as described in the prior art, is wound around a mandrel to form a coil winding, plastic deformation of the wire results as the wire is taken through the ninety degree bends of the coil.
  • the tensile forces on the side of the wire opposite the mandrel cause the width of that side of the wire to contract, while the compressive forces on the side of the wire facing the mandrel cause the width of that side of the wire to expand whereupon the resulting magnet wire cross section assumes a trapezoidal configuration.
  • the resultant trapezoidal configuration of the wire increases the overall width of the magnet wire, so as to significantly increase the amount of space taken up by the wire in each adjacent turn in the coil.
  • the trapezoidal cross-section of the wound magnet wire also creates sharp edges on the wire at the corners of the windings which can result in rupture of the insulation tape thereby causing electrical arcing between adjacent winding turns.
  • current prior art processes for applying the insulation tape are relatively slow and must be accomplished as separate, off-line operations since process speed is dependent on the time required to heat and reheat the wire.
  • This invention relates in its first aspect to a magnet wire which has a cross-sectional configuration that reduces abrasion of the insulation tape, and also occupies minimal space during the electrical magnet wire winding operation in that the cross sectional configuration of the wire of this invention produces a dimensionally stable wire that will not substantially deform when wound into a coil.
  • Other aspects of the invention are defined in claims 5, 8 and 12.
  • the insulation tape is a fibrous sort, flexible material which has one side thereof coated with a pressure-sensitive adhesive to provide pressure sensitive bonding properties to the insulation tape without the need to heat-cure the wrapped wire.
  • the adhesive is covered with a coated release strip that is stiffer or more rigid than the insulation tape to prevent stretching of the insulation tape prior to application thereof to the wire.
  • the release strip also prevents the adhesive from being exposed to contaminants prior to application thereof to the wire.
  • the coated release strip is removed from the insulation tape to uncover the adhesive immediately prior to application of the insulation tape to the magnet wire surface.
  • It is a further object of the invention is to provide a new conductor wire shape having a modified rectangular cross-section that minimizes the space required for each turn when the insulated magnet wire is formed, while decreasing damage to the insulation tape.
  • FIG 1 depicts the modified retangular cross-sectional shape of a magnet wire conductor 10 prior to application of a layer of insulation tape where the radius of curvature R of the opposing ends 10C and 10D of the conductor 10 equals, or is greater than the wire thickness T defined between the opposing sides 10A and 10B of the conductor 10. It has been determined that this optimum side geometry, which is proportional to the thickness of the wire, beneficially reduces abrasion to the insulation tape when the latter is applied to the magnet wire and subjected to subsequent coil winding operations, as will be described in greater detail hereinafter. The optimum geometry also reduces the space that each turn of the magnetic wire requires within an electrical magnet wire winding.
  • the magnet wire geometry depicted in FIG 1 does not cause expansion of the width of the magnet wire during the winding operation because when the side radius R is equal to or larger than the wire thickness T, the conductor wire 10 cannot be deformed to the trapezoidal configuration during the coil winding process. The formation of sharp edges on the covered wire is thus prevented. Since the conductor wire 10 will not physically deform during the coil winding operation, it will not, when wound, laterally expand at the corners of the winding. This allows the use of thicker insulation tapes. For example, a rectangular wire having a width dimension of .300 inch which is used to form a coil that can expand to a dimension of .312 inch wide when bent 90 degrees around a winding mandrel.
  • the width dimension of the wire will not expand when the insulated wire is wound into a coil, thus allowing the use of bulkier insulation in the same coil space. If the side radius of the wire is substantially less than the thickness of the wire, then the mass of the coil will be insufficient for optimum coil performance.
  • the improved abrasion resistance imparted to the magnet wire having the cross-section depicted in FIG 1 allows the use of softer, more flexible insulation tapes that stretch in all directions to allow the insulation tape to elongate and conform to any changes in the magnet wire configuration that occur during the magnet wire winding operation.
  • the fibrous highly stretchable insulation tape allows greater flexibility to the wrapped wire.
  • the insulated magnet wire of the prior art must pass a flexibility qualification standard which requires that the wrapped wire must be wrappable on an arbor with a 4:1 diameter proportion relative to the major cross-sectional dimension of the wrapped wire, without exhibiting any insulation cracking or splitting.
  • the insulated magnet wire of this invention can be wrapped on an arbor with a 1:1 arbor/wire diameter ratio without cracking or splitting the insulation tape. This quality is a highly desirable result of the invention, which cannot be met by the prior art heat-cured insulated magnet wire. Since the insulation tape of this invention does not require heat to bond it to the wire, it will retain its initial soft and flexible properties.
  • the magnet wire conductor 10 (hereafter "conductor") is formed into an insulated covered magnet wire 11 by the application of a continuous web of electrical insulating material 12 which includes a coating of pressure-sensitive adhesive 13 as illustrated in FIG 2. In some applications, the insulation covering may be omitted across the top and one end of the conductor, in order to conserve insulation.
  • the electrical insulating material is a soft, flexible fibrous material, and can be formed, for example, of glass fibers, aramid fibers, polymer fibers, and combinations thereof. Fibrous aramid materials that are manufactured utilizing spunlacing or hydraulic fiber entaglement techniques are especially beneficial since they normally possess multi-directional elongation properties.
  • An insulating tape composite 15 consisting of an insulation tape component 14 and release strip component 16 can best be seen by referring now to FIG 3C.
  • the insulation tape component 14 is prepared by coating the insulation material 12 with the pressure sensitive adhesive 13, as depicted in Figure 3A.
  • the release strip component 16 is prepared by coating a release paper material 17 with a release agent 18.
  • the release strip component 16 is affixed to the insulation tape component 14 by covering the adhesive 16 with the release agent 18.
  • the resulting insulating tape composite 15 can be rolled into a continuous reel for easy shipment and handling and can be later applied to the wire conductor 10 as best seen by referring to FIG 4.
  • the wire coating assembly 19 is arranged next to a continous source of the conductor 10 as it is being formed or extruded, or can be arranged independently as an off-line operation, if desired.
  • the insulating tape composite 15 described earlier is drawn from a supply reel 20 by a pair of driven rollers 21.
  • the driven rollers are synchronized with the speed of the continuous source of the conductor 10 as it is drawn through the wire covering assembly so that slack as indicated at 15' is created thereby eliminating any tension on the insulating tape composite 15 between the drive rollers 2 and the point of application to the conductor, so as to prevent any premature stretching of the insulating tape composite 15.
  • the insulating tab composite 15 is guided to the conductor 10 by passing through the guide block 22.
  • the release strip component 16 is separated from the insulating tape component by means of a stripper block 24 and taken up by reel 29.
  • the adhesive 13 is thus exposed so that pressure sensitive bonding of the insulation tape component 14 to wire side 10A is accomplished, while folding the remaining unbonded portions of the insulation tape component 14 to facilitate bonding thereof to the ends 10C and 10D of the conductor 10.
  • a set of opposing elastomeric rollers indicated generally by the numeral 25 apply pressure to the ends 10C, 10D and deform to press and bond the insulation tape component 14 to the conductor ends 10C and 10D, while folding the remainder of the insulation tape component 14 around each conductor end 10C and 10D in position to facilitate bonding to conductor side 10A or 10B.
  • the final bonding step is completed as roller 27 applies pressure to side 10A or 10B to complete the insulation covered magnet wire 11 as illustrated in Figure 2.
  • the completed insulated magnet wire is then collected on a reel 28 as shown for later use, or as mentioned previously can be fed directly into a coil winding station.
  • the release strip component 16 when the insulating tape composite 14 is drawn from the supply reel 20 by the driven rollers 21, the release strip component 16, due to the stiffness properties of the paper material, functions to prevent any premature stretching of the insulation tape component 15, thus preserving the elongation properties of the insulation tape 15.
  • the release strip component 16 functions to also protect the adhesive from contaminants until the moment that the adhesive-coated insulation tape 15 is applied to the conductor.
  • the release strip component 16 is collected on a reel 29.
  • An insulated covered magnet wire is produced for use in transformers, motors, and the like according to this invention by using a stretchable insulation covering, which is applied to a magnet wire of modified rectangular cross-section.
  • a pressure-sensitive adhesive without the use of supplemental solvents or the application of heat, the invention results in a cost-effective environmentally favorable magnet wire-forming process.
  • the pressure sensitive adhesive which is preferred for use with the spunlaced aramid insulation is a thermosetting polymethymethacrylate crosslinkable pressure sensitive adhesive of high molecular weight which is saturated and resistant to oxidation.
  • the preferred release agent coated onto the paper release strip is polydimethylsiloxane which is thermoset with a crosslinker and catalyst, and which forms a surface on the paper release strip which resists penetration by the acrylic adhesive which it covers. The release strip thus peels readily away of the adhesive coated surface of the insulation when the insulation is laid onto the conductor wire.
  • this invention involves the use of a wire with a modified cross section, which allows the application of a sort, flexible insulation tape to the wire. No lateral expansion of the wire will occur when the covered wire is formed into a coil. The result is a faster insulating process and a more flexible insulated wire.

Landscapes

  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulating Of Coils (AREA)
  • Insulated Conductors (AREA)
EP92120504A 1991-12-02 1992-12-01 Fil magnétique isolé, son procédé de formation, et isolation correspondant Withdrawn EP0545370A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US07/801,003 US5254806A (en) 1991-12-02 1991-12-02 Insulated magnet wire, method of forming the same, and transformer windings formed therefrom
US80174591A 1991-12-03 1991-12-03
US801745 1991-12-03
US801003 1991-12-03

Publications (1)

Publication Number Publication Date
EP0545370A1 true EP0545370A1 (fr) 1993-06-09

Family

ID=27122279

Family Applications (1)

Application Number Title Priority Date Filing Date
EP92120504A Withdrawn EP0545370A1 (fr) 1991-12-02 1992-12-01 Fil magnétique isolé, son procédé de formation, et isolation correspondant

Country Status (3)

Country Link
EP (1) EP0545370A1 (fr)
JP (1) JPH0644828A (fr)
CA (1) CA2084352A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT406921B (de) * 1998-08-20 2000-10-25 Asta Elektrodraht Gmbh Elektrischer leiter

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR100893981B1 (ko) * 2007-12-27 2009-04-20 엘에스전선 주식회사 사각형 에나멜 전선 및 사각형 에나멜 전선의 도체선
CN104934154A (zh) * 2015-06-24 2015-09-23 无锡锡洲电磁线有限公司 铜扁线的u形衬纸添加装置

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1962932A1 (de) * 1969-02-05 1970-09-03 Ford Werke Ag Anordnung bei einer dynamoelektrischen Maschine zur Halterung einer Feldwicklung
US3558803A (en) * 1969-08-26 1971-01-26 Revere Copper & Brass Inc Magnet strip conductor
EP0150685A2 (fr) * 1984-02-01 1985-08-07 ISOLPIAVE s.r.l. Procédé et machine pour isoler des conducteurs électriques pour transformateurs par encollage d'une feuille de revêtement isolante et conducteurs ainsi isolés

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE1962932A1 (de) * 1969-02-05 1970-09-03 Ford Werke Ag Anordnung bei einer dynamoelektrischen Maschine zur Halterung einer Feldwicklung
US3558803A (en) * 1969-08-26 1971-01-26 Revere Copper & Brass Inc Magnet strip conductor
EP0150685A2 (fr) * 1984-02-01 1985-08-07 ISOLPIAVE s.r.l. Procédé et machine pour isoler des conducteurs électriques pour transformateurs par encollage d'une feuille de revêtement isolante et conducteurs ainsi isolés

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AT406921B (de) * 1998-08-20 2000-10-25 Asta Elektrodraht Gmbh Elektrischer leiter

Also Published As

Publication number Publication date
CA2084352A1 (fr) 1993-06-03
JPH0644828A (ja) 1994-02-18

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