EP1296336A1 - Varnish-coated wire - Google Patents
Varnish-coated wire Download PDFInfo
- Publication number
- EP1296336A1 EP1296336A1 EP02450180A EP02450180A EP1296336A1 EP 1296336 A1 EP1296336 A1 EP 1296336A1 EP 02450180 A EP02450180 A EP 02450180A EP 02450180 A EP02450180 A EP 02450180A EP 1296336 A1 EP1296336 A1 EP 1296336A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- wire
- cross
- section
- round
- lacquer
- 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.)
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Classifications
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- 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
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
- H01F27/323—Insulation between winding turns, between winding layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/06—Coil winding
- H01F41/077—Deforming the cross section or shape of the winding material while winding
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/2823—Wires
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/32—Insulating of coils, windings, or parts thereof
- H01F27/327—Encapsulating or impregnating
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F41/00—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties
- H01F41/02—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets
- H01F41/04—Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils, or magnets for manufacturing coils
- H01F41/12—Insulating of windings
- H01F41/127—Encapsulating or impregnating
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/4902—Electromagnet, transformer or inductor
- Y10T29/49071—Electromagnet, transformer or inductor by winding or coiling
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49123—Co-axial cable
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49194—Assembling elongated conductors, e.g., splicing, etc.
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
- Y10T29/49194—Assembling elongated conductors, e.g., splicing, etc.
- Y10T29/49195—Assembling elongated conductors, e.g., splicing, etc. with end-to-end orienting
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
- Y10T428/12556—Organic component
Definitions
- the invention relates to a paint-coated wire with a non-circular cross-section, the two Axes of different lengths, normal to each other and made of a metal wire and a surrounding coating, the insulation and baking properties has, in particular for generating electrical coils, and a method to make the wire.
- Lacquer-coated wires of round cross-section for the production of electrical coils are known. These wires are made of copper, aluminum or another metal or a metal alloy, and have an inner electrically insulating coating and arranged on this, an outer layer of baking varnish.
- the first, inner, paint coating which consists of polyurethane or polyester amide serves for electrical insulation of the wire.
- the second, outer, layer of varnish called wire varnish by wire manufacturers is used to provide a mechanical connection between the windings and the winding layers. It is made from lacquers that subsequently soften the lacquer layer enable. The softening of the lacquer layer can be caused either by the action by heat or by the action of a chemical solvent. Lacquers based on polyvinyl butyral or polyamide are usually used.
- Such wires are used for the production of electrical, self-supporting coils.
- these coils with a wire of round cross-section have the disadvantage that free spaces remain between the adjoining wires. These spaces require a reduced packing density, which affects the efficiency of the Reduce the device in which the coil is used.
- the individual lie Wires of such coils only at narrow contact lines, which also means that since such coils are exposed to electromechanical forces, the durability of such Coils is affected.
- the coils are made of paint-coated To produce wires of rectangular cross section. Such wires are obtained by deforming the metallic core accordingly and then using the insulation layers is provided.
- the object of the invention is now to create a non-circular paint-coated wire, which does not have the mentioned disadvantages of these wires.
- the wire is a lacquer coating has, which in a known manner from an inner electrically insulating lacquer layer and an outer layer of baking varnish, and that the varnish coating on the longer Cross-sectional axis assigned sides has a lower strength than on the the sides to be assigned to the shorter cross-sectional axis.
- the metal wire is surrounded by a single layer of lacquer that covers both the Has insulation properties as well as the baking varnish properties as a cross-sectional axis the side to be assigned are the areas of the surface that are designated on can be viewed as running parallel to a cross-sectional axis.
- the wire has a cross section with an axis ratio of at most 3: 1, being rectangular or advantageously oval cross section.
- the advantage of such a wire according to the invention is that its training enables the manufacture of an electrical coil in which the contiguous Lay the wires close together and bake them together over a large area.
- the layer thickness of the lacquer coating on the wire matches that of the shorter ones Pages to be assigned to the cross-sectional axis are stronger, preferably much stronger, than on the sides to be assigned to the longer cross-sectional axis is in the production of Coils made of lacquer-coated wires, in particular oval cross-section, are possible the arrangement of the wires next to each other resulting gusset rooms with lacquer coating material to be filled in largely.
- the coil production takes place under Heating, so that paint coating material becomes plastic and so in particular in the area of the sides to be assigned to the shorter cross-sectional axes of the wire gusset spaces that form due to the increased amount of lacquer coating here can fill out. Due to the essentially uniform layer thickness is the lacquer coating on all sides or surfaces of the wire according to the invention a tight arrangement and caking of the varnished rectangular wires Cross-section guaranteed in the manufacture of coils in any case.
- the invention also relates to a method for producing a wire with a non-circular shape Cross-section that has two axes of different lengths that are normal to each other and from a metal wire and a lacquer coating surrounding it, the insulation and has baking varnish properties.
- this method is characterized in that that the paint-coated wire of round cross-section by means of rolling is pressed on a cross section with an axis ratio of maximum 3: 1.
- the wire is pressed onto an oval cross section.
- the inventive method is preferably carried out such that the paint-coated Wire of round cross-section between two appropriately spaced rollers is carried out. It is essential that the nip is set in such a way that the ratio of the two differently long, perpendicular to each other cross-sectional axes 3: 1 of the deformed wire is not exceeded.
- lacquer coating each of an inner electrically insulating insulation layer and an outer layer of baked varnish is built up.
- Lacquer coating on the metal wire can also be a single-layer lacquer coating are used, which have insulation and baking varnish properties at the same time.
- Fig. 1 shows a conventional paint-coated wire of round cross-section, the Metal wire 1 'is coated with an inner electrically insulating lacquer layer 2'. about This lacquer layer 2 'is an outer, second baking lacquer layer 3' arranged that a connection between the wires of electrical coils made from them. A such a coil 4 'is shown in Fig. 2.
- the touching coated wires 1 ' are along relatively narrow lines of contact with one another, each via the baking lacquer layer connected. However, there are free spaces between the wires 1 ' 6 ', which entail a reduced packing density.
- Fig. 3 shows a paint-coated wire 1 "rectangular cross-section corresponding to date known prior art.
- Such coated wires are becoming more conventional Made in such a way that a metal wire of round cross-section pressed or pressed and is deformed into a wire 2 "rectangular cross-section.
- On the deformed metal wire 2 " will then be an electrically insulating coating 3" and then a baked varnish layer 4 "applied.
- FIG. 5 shows a wire 1 of oval cross section produced according to the invention a metal wire 2, an electrically insulating coating 3 enveloping it and an outer baking lacquer layer 4 applied thereon.
- coated wires 1 From such coated wires 1 according to the invention rectangular or oval cross-section constructed electrical coils 5, as e.g. are shown in Fig. 6, have an extremely high packing density, since the coated wires 1 with their outer Baking layers 4 without or at least to a large extent without the formation of free spaces Bake on all sides and are connected to each other. This results in there is also a very high level of stability and thus the service life of this self-supporting Coils 5.
- the invention makes it possible to have a disadvantage of non-circular cross-section wires Eradicate use of electrical coils. Such wires tend to stick to the Break places where they leave the coil assembly. You are in this much more fragile than round wires. The reason for this vulnerability is probably in the increased selective dynamic stresses in this area, the non-circular Oppose wires with less resistance than round ones, but the causes are not researched in the final analysis.
- the To produce coils from a wire 1 'in the area in which it is from the (not shown) Connection point is freely led to the coil (section X-X, Fig. 10), the loop 7, and in an initial area 8 on the coil 9, which does not exceed one turn and preferably less than half a turn, to leave it round and only the actual one To produce bobbins from the wire 1 designed according to the invention.
- the transition from the round wire 1 'to the non-circular takes place Wire 1 in the area between the cutting planes VIII-VIII and IX-IX, as in FIG. 8 and 9 can be seen.
- the invention thus relates both to a coil made from a wire according to the invention, the is characterized in that the coil body essentially out of wire Cross-section exists and that at least one of the feed wires (loop) round to the coil Cross-section and over a maximum of one turn, preferably a maximum of half Winding with a round cross section is part of the coil body; as well as a process for Production of such a coil, which is characterized in that between the supply reel for the round wire and the guide device for feeding the wire form rollers for deformation of the wire are arranged at the run-up point on the coil, between an active position in which they push the wire through and an inactive position, in which the wire runs through and remains round, is adjustable, and that the form rollers are in the active position when sections of the wire pass through from which the coil body is formed and that they are brought into the inactive position, when passing through wire sections from which a loop or the transition from the coil is formed into a loop.
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- Engineering & Computer Science (AREA)
- Power Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Coils Of Transformers For General Uses (AREA)
- Insulated Conductors (AREA)
- Manufacture Of Motors, Generators (AREA)
- Coils Or Transformers For Communication (AREA)
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
Lackbeschichteter Draht mit zwei unterschiedlich lange, senkrecht aufeinanderstehende Achsen aufweisendem Querschnitt bestehend aus einem Metalldraht und einer diesen umgebenden Isolations- und Backlackeigenschaften umfassenden Lackbeschichtung, insbesondere zur Erzeugung elektrischer Spulen, wobei die Lackbeschichtung auf den der längeren Querschnittsachse zuzuordnenden Seiten eine geringere Stärke aufweist als auf den der kürzeren Querschnittsachse zuzuordnenden Seiten. Der Draht weist einen Querschnitt mit einem Achsenverhältnis von maximal 3:1 auf.Lacquer-coated wire with two different lengths, perpendicular to each other Cross-section with axes consisting of a metal wire and a surrounding wire Lacquer coating comprising insulation and baking lacquer properties, in particular to produce electrical coils, the paint coating on the longer Cross-sectional axis assigned sides has a lower thickness than on the sides to be assigned to the shorter cross-sectional axis. The wire has a cross section an axis ratio of maximum 3: 1.
Verfahren zur Herstellung eines Drahtes mit zwei unterschiedlich lange, senkrecht aufeinanderstehende Achsen aufweisendem Querschnitt bestehend aus einem Metalldraht und einer diesen umgebenden Isolations- und Backlackeigenschaften umfassenden Lackbeschichtung, wobei der lackbeschichtete Draht runden Querschnitts mittels Walzverfahrens auf einen Querschnitt mit einem Achsenverhältnis von maximal 3 : 1 gedrückt wird, wobei der Draht einen ovalen Querschnitt haben kann. Process for the production of a wire with two cross sections of different lengths, perpendicular to each other, consisting of a metal wire and a varnish coating comprising the insulation and baking varnish properties surrounding it, the varnished coated wire having a round cross section being pressed onto a cross section with an axial ratio of maximum 3: 1 by means of a rolling process the wire can have an oval cross-section.
Description
Die Erfindung betrifft einen lackbeschichteten Draht mit unrundem Querschnitt, der zwei unterschiedlich lange, normal zueinander stehende Achsen aufweist und aus einem Metalldraht und einer diesen umgebenden Lackbeschichtung, die Isolations- und Backlackeigenschaften aufweist, insbesondere zur Erzeugung elektrischer Spulen, sowie ein Verfahren zur Herstellung des Drahtes.The invention relates to a paint-coated wire with a non-circular cross-section, the two Axes of different lengths, normal to each other and made of a metal wire and a surrounding coating, the insulation and baking properties has, in particular for generating electrical coils, and a method to make the wire.
Lackbeschichtete Drähte runden Querschnittes für die Herstellung von elektrischen Spulen sind bekannt. Diese Drähte bestehen aus Kupfer, Aluminium oder einem anderen Metall oder einer Metallegierung, und weisen eine innere elektrisch isolierende Beschichtung und auf dieser angeordnet, eine äußere Backlackschicht auf. Die erste, innere, Lackbeschichtung, welche aus Polyurethan oder Polyesteramid besteht, dient der elektrischen Isolierung des Drahtes. Die zweite, äußere, Lackschicht, die von den Drahtherstellern Backlack genannt wird, dient einer mechanischen Verbindung zwischen den Windungen und den Windungslagen. Sie wird aus Lacken hergestellt, die eine nachträgliche Erweichung der Lackschicht ermöglichen. Die Erweichung der Lackschicht kann entweder durch die Einwirkung von Wärme oder durch die Einwirkung eines chemischen Lösungsmittels erfolgen. Üblicherweise werden Lacke auf Basis von Polyvinylbutyral oder Polyamid verwendet.Lacquer-coated wires of round cross-section for the production of electrical coils are known. These wires are made of copper, aluminum or another metal or a metal alloy, and have an inner electrically insulating coating and arranged on this, an outer layer of baking varnish. The first, inner, paint coating, which consists of polyurethane or polyester amide serves for electrical insulation of the wire. The second, outer, layer of varnish called wire varnish by wire manufacturers is used to provide a mechanical connection between the windings and the winding layers. It is made from lacquers that subsequently soften the lacquer layer enable. The softening of the lacquer layer can be caused either by the action by heat or by the action of a chemical solvent. Lacquers based on polyvinyl butyral or polyamide are usually used.
Als "rund" wird in der Beschreibung und den Ansprüchen immer "kreisrund" verstanden, als "unrund" somit als "vom kreisrunden Querschnitt abweichend". Im wesentlichen betreffen die unrunden Querschnitte ovale und rechteckige Querschnitte, wobei letztere abgerundete Kanten aufweisen, somit die eingangs definierten Querschnitte, die zwei unterschiedlich lange, normal zueinander stehende Achsen aufweisen.In the description and claims, "circular" is always understood to be "circular", as "out of round" thus as "deviating from the circular cross-section". Essentially concern the non-circular cross-sections oval and rectangular cross-sections, the latter being rounded Have edges, thus the cross sections defined at the outset, the two different have long, normal axes.
Solche Drähte werden für die Herstellung von elektrischen, selbsttragenden Spulen verwendet. Diese Spulen mit einem Draht runden Querschnittes haben aber den Nachteil, daß zwischen den aneinandergrenzenden Drähten freie Zwischenräume verbleiben. Diese Zwischenräume bedingen eine verminderte Packungsdichte, welche den Wirkungsgrad des Gerätes, in dem die Spule zur Anwendung kommt, mindern. Außerdem liegen die einzelnen Drähte solcher Spulen nur an schmalen Berührungslinien zusammen, wodurch auch, da solche Spulen den elektromechanischen Kräften ausgesetzt sind, die Haltbarkeit solcher Spulen beeinträchtigt wird. Such wires are used for the production of electrical, self-supporting coils. However, these coils with a wire of round cross-section have the disadvantage that free spaces remain between the adjoining wires. These spaces require a reduced packing density, which affects the efficiency of the Reduce the device in which the coil is used. In addition, the individual lie Wires of such coils only at narrow contact lines, which also means that since such coils are exposed to electromechanical forces, the durability of such Coils is affected.
Im Bestreben, dichter gepackte Spulen herzustellen, ist auch bekannt, die Spulen aus lackbeschichteten Drähten rechteckigen Querschnittes herzustellen. Derartige Drähte werden dadurch erhalten, dass der metallische Kern entsprechend verformt und anschließend mit den Isolierschichten versehen wird.In an effort to produce more tightly packed coils, it is also known that the coils are made of paint-coated To produce wires of rectangular cross section. Such wires are obtained by deforming the metallic core accordingly and then using the insulation layers is provided.
Der Nachteil dieser beschichteten Drähte mit einem metallischen Kern rechteckigen Querschnittes besteht allerdings darin, daß, bedingt durch das Herstellungsverfahren, die Beschichtungen nicht in gleichmäßiger Stärke (Dicke) auf dem Metallkern aufgebracht sind. Grund dafür ist die fehlende Symmetrie des eckigen Metalldrahtes in Verbindung mit der Oberflächenspannung des Materials der Beschichtungen. Aus diesem Grund weisen solche Drähte Beschichtungen mit konvexen Außenflächen auf. Wenn nun solche Drähte zu Spulen verarbeitet werden, so berühren aneinandergrenzende Drähte auch nur entlang relativ schmaler Berührungslinien, wobei wie bei den Spulen, die aus Drähten runden Querschnittes hergestellt werden, Zwischenräume zwischen den einzelnen Drähten verbleiben. Da die Lackbeschichtung und damit auch die äußere Backlackschicht auf dem Draht in unterschiedlichen Stärken über die Rechteckflächen verteilt aufgebracht sind, und die Drähte einander nur in relativ eng begrenzten Berührungsbereichen zusammenbacken, ist auch der Packungszusammenhalt der einzelnen Drähte in der Spule nicht optimal. Dadurch wird wiederum die Lebensdauer und die mechanische Selbsttragfähigkeit der Spule stark beeinträchtigt.The disadvantage of these coated wires with a metallic core of rectangular cross section is, however, that, due to the manufacturing process, the coatings are not applied to the metal core in a uniform thickness. The reason for this is the lack of symmetry of the square metal wire in connection with the Surface tension of the material of the coatings. For this reason, such Wire coatings with convex outer surfaces. If now such wires to coils are processed, adjacent wires touch only along relative Narrow lines of contact, whereby as with the coils, which consist of wires of round cross-section are produced, spaces remain between the individual wires. Since the lacquer coating and thus also the outer layer of baking lacquer on the wire in different thicknesses are distributed over the rectangular areas, and the Bake wires together in relatively narrow contact areas only the package cohesion of the individual wires in the coil is also not optimal. Thereby the service life and the mechanical self-bearing capacity of the coil become strong impaired.
Aufgabe der Erfindung ist nun die Schaffung eines unrunden lackbeschichteten Drahtes, der die genannten Nachteile dieser Drähte nicht aufweist.The object of the invention is now to create a non-circular paint-coated wire, which does not have the mentioned disadvantages of these wires.
Diese Aufgabe wird erfindungsgemäß dadurch gelöst, daß der Draht eine Lackbeschichtung aufweist, die in bekannter Weise aus einer inneren elektrisch isolierenden Lackschicht und einer äußeren Backlackschicht besteht, und daß die Lackbeschichtung auf den der längeren Querschnittsachse zuzuordnenden Seiten eine geringere Stärke aufweist als auf den der kürzeren Querschnittsachse zuzuordnenden Seiten. Nach einer erfindungsgemäßen Alternative ist der Metalldraht mit einer einzigen Lackschicht umgeben, die sowohl die Isolationseigenschaften als auch die Backlackeigenschaften aufweist Als einer Querschnittsachse zuzuordnende Seite werden die Bereiche der Oberfläche bezeichnet, die am ehesten parallel zu einer Querschnittsachse verlaufend angesehen werden können. This object is achieved in that the wire is a lacquer coating has, which in a known manner from an inner electrically insulating lacquer layer and an outer layer of baking varnish, and that the varnish coating on the longer Cross-sectional axis assigned sides has a lower strength than on the the sides to be assigned to the shorter cross-sectional axis. According to an inventive Alternatively, the metal wire is surrounded by a single layer of lacquer that covers both the Has insulation properties as well as the baking varnish properties as a cross-sectional axis the side to be assigned are the areas of the surface that are designated on can be viewed as running parallel to a cross-sectional axis.
In einer vorteilhaften erfindungsgemäßen Ausgestaltung weist der Draht einen Querschnitt mit einem Achsenverhältnis von maximal 3:1 auf, wobei er rechteckigen oder vorteilhafterweise ovalen Querschnitts ist.In an advantageous embodiment according to the invention, the wire has a cross section with an axis ratio of at most 3: 1, being rectangular or advantageously oval cross section.
Der Vorteil eines solchen erfindungsgemäßen Drahtes besteht darin, daß seine Ausbildung die Herstellung einer elektrischen Spule ermöglicht, bei der die aneinandergrenzenden Drähte eng aneinander liegen und über eine große Fläche zusammenbacken. Durch die Tatsache, daß die Schichtstärke der Lackbeschichtung des Drahtes an den der kürzeren Querschnittsachse zuzuordnenden Seiten stärker, bevorzugt wesentlich stärker, ist als an den der längeren Querschnittsachse zuzuordnenden Seiten ist es bei der Herstellung von Spulen aus lackbeschichteten Drähten insbesondere ovalen Querschnittes möglich, die bei der Anordnung der Drähte nebeneinander sich ergebenden Zwickelräume mit Lackbeschichtungsmaterial weitgehend auszufüllen. Die Spulenherstellung erfolgt nämlich unter Erwärmung, so daß dabei Lackbeschichtungsmaterial plastisch wird und so die insbesondere im Bereich der den kürzeren Querschnittsachsen des Drahtes zuzuordnenden Seiten sich bildenden Zwickelräume durch die hier in vermehrten Maße vorhandene Lackbeschichtungsmasse ausfüllen kann. Durch die im wesentlichen gleichmäßige Schichtstärke der Lackbeschichtung auf allen Seiten bzw. Flächen des erfindungsgemäßen Drahtes ist eine enge Anordnung und ein Zusammenbacken der lackbeschichteten Drähte rechteckigen Querschnitts bei der Herstellung von Spulen jedenfalls gewährleistet.The advantage of such a wire according to the invention is that its training enables the manufacture of an electrical coil in which the contiguous Lay the wires close together and bake them together over a large area. Through the The fact that the layer thickness of the lacquer coating on the wire matches that of the shorter ones Pages to be assigned to the cross-sectional axis are stronger, preferably much stronger, than on the sides to be assigned to the longer cross-sectional axis is in the production of Coils made of lacquer-coated wires, in particular oval cross-section, are possible the arrangement of the wires next to each other resulting gusset rooms with lacquer coating material to be filled in largely. The coil production takes place under Heating, so that paint coating material becomes plastic and so in particular in the area of the sides to be assigned to the shorter cross-sectional axes of the wire gusset spaces that form due to the increased amount of lacquer coating here can fill out. Due to the essentially uniform layer thickness is the lacquer coating on all sides or surfaces of the wire according to the invention a tight arrangement and caking of the varnished rectangular wires Cross-section guaranteed in the manufacture of coils in any case.
Durch den Wegfall von Zwischenräumen zwischen aneinandergrenzenden Drähten und das allseitige feste Zusammenbacken der Drähte wird die Standfestigkeit der elektrischen Spule und damit deren Lebensdauer gegenüber den bisher hergestellten bekannten Spulen mit einem Draht eckigen Querschnittes um bis zu 50 %, somit ganz erheblich, erhöht.By eliminating gaps between adjacent wires and that All-round solid caking of the wires will increase the stability of the electrical Coil and thus their lifespan compared to the previously known coils with a square cross-section wire increased by up to 50%, thus quite considerably.
Die Erfindung betrifft auch ein Verfahren zur Herstellung eines Drahtes mit unrundem Querschnitt, der zwei unterschiedlich lange, normal zueinander stehende Achsen aufweist und aus einem Metalldraht und einer diesen umgebenden Lackbeschichtung, die Isolations - und Backlackeigenschaften aufweist. Dieses Verfahren ist erfindungsgemäß dadurch gekennzeichnet, daß der lackbeschichtete Draht runden Querschnitts mittels Walzverfahrens auf einen Querschnitt mit einem Achsenverhältnis von maximal 3 : 1 gedrückt wird.. Gemäß einer bevorzugten Ausführungsform wird der Draht auf einen ovalen Querschnitt gedrückt. The invention also relates to a method for producing a wire with a non-circular shape Cross-section that has two axes of different lengths that are normal to each other and from a metal wire and a lacquer coating surrounding it, the insulation and has baking varnish properties. According to the invention, this method is characterized in that that the paint-coated wire of round cross-section by means of rolling is pressed on a cross section with an axis ratio of maximum 3: 1. According to In a preferred embodiment, the wire is pressed onto an oval cross section.
In überraschender Weise wurde gefunden, daß ein Drücken des beschichteten Drahtes bis zu diesem maximalen Ausmaß möglich ist, ohne Beeinträchtigung der Lackbeschichtung und unter Erzielung einer im wesentlichen gleichmäßigen Beschichtungsstärke an den einzelnen Flächen des Drahtes.Surprisingly, it was found that pressing the coated wire up to to this maximum extent is possible without affecting the paint coating and to achieve a substantially uniform coating thickness on the individual Surfaces of the wire.
Das erfindungsgemäße Verfahren wird vorzugsweise derart durchgeführt, daß der lackbeschichtete Draht runden Querschnittes zwischen zwei entsprechend beabstandeten Walzen durchgeführt wird. Dabei ist es eben wesentlich, daß der Walzenspalt derart eingestellt ist, daß das Verhältnis der zwei unterschiedlich langen, senkrecht aufeinanderstehenden Querschnittsachsen 3:1 des verformten Drahtes nicht überschritten wird.The inventive method is preferably carried out such that the paint-coated Wire of round cross-section between two appropriately spaced rollers is carried out. It is essential that the nip is set in such a way that the ratio of the two differently long, perpendicular to each other cross-sectional axes 3: 1 of the deformed wire is not exceeded.
In der Zeichnung ist der Gegenstand der Erfindung näher erläutert, wobei in einem der
Deutlichkeit halber ganz wesentlich überhöhtem Maßstab die
Die Erfindung wird beispielsweise an Hand von lackbeschichteten Drähten näher erläutert, deren Lackbeschichtung jeweils aus einer inneren elektrisch isolierenden Isolationsschicht und einer äußeren Backlackschicht aufgebaut ist. An Stelle der zweischichtig aufgebauten Lackbeschichtung auf dem Metalldraht kann auch eine einschichtige Lackbeschichtung zum Einsatz kommen, die gleichzeitig Isolations- und Backlackeigenschaften aufweist.The invention is explained in more detail, for example, on the basis of coated wires, the lacquer coating each of an inner electrically insulating insulation layer and an outer layer of baked varnish is built up. Instead of the two-layer structure Lacquer coating on the metal wire can also be a single-layer lacquer coating are used, which have insulation and baking varnish properties at the same time.
Fig. 1 zeigt einen herkömmlichen lackbeschichteten Draht runden Querschnitts, wobei der
Metalldraht 1' mit einer inneren elektrisch isolierenden Lackschicht 2' ummantelt ist. Über
dieser Lackschicht 2' ist eine äußere, zweite Backlackschicht 3' angeordnet, die einer Verbindung
zwischen den Drähten von aus diesen hergestellten elektrische Spulen dient. Eine
solche Spule 4' ist in Fig. 2 dargestellt. Die einander berührenden lackbeschichteten Drähte
1' sind an entlang relativ schmaler Berührungslinien miteinander jeweils über die Backlackschicht
verbunden. Zwischen den Drähten 1' verbleiben jedoch freie Zwischenräume
6', die eine verminderte Packungsdichte mit sich bringen.Fig. 1 shows a conventional paint-coated wire of round cross-section, the
Metal wire 1 'is coated with an inner electrically insulating
Fig. 3 zeigt einen lackbeschichteten Draht 1" rechteckigen Querschnitts entsprechend bisher
bekannten Standes der Technik. Solche beschichtete Drähte werden herkömmlicher
Weise so hergestellt, daß ein Metalldraht runden Querschnitts gedrückt oder verpreßt und
zu einem Draht 2" rechteckigen Querschnitts verformt wird. Auf den verformten Metalldraht
2" werden dann zuerst eine elektrisch isolierende Lackbeschichtung 3" und darauf
eine Backlackschicht 4" aufgebracht. Zufolge der fehlenden Symmetrie des im Querschnitt
im wesentlichen rechteckigen Drahtes 2" weisen diese Drähte herstellungsbedingt Beschichtungen
in nicht gleichmäßiger Stärke auf, wobei die Drähte insbesondere an ihren
Breitseiten, Beschichtungen 3", 4" mitunter unregelmäßig nach außen bombierte Außenflächen
aufweisen.Fig. 3 shows a paint-coated
Dadurch entstehen bei der Verarbeitung auch von solcher Art herkömmlich hergestellten
Drähten zu elektrischen Spulen 5" zwischen den Windungen bzw. Lagen von Windungen
wiederum freie Zwischenräume 6", die eine verminderte Packungsdichte und Standfestigkeit
der elektrischen Spule bedingen.This creates conventionally manufactured products of this type
Wires to 5 "electrical coils between the turns or layers of turns
again
In Fig. 5 ist ein erfindungsgemäß hergestellter Draht 1 ovalen Querschnitts dargestellt, der
aus einem Metalldraht 2, einer diesen umhüllenden elektrisch isolierenden Beschichtung 3
und einer darauf aufgebrachten äußeren Backlackschicht 4 besteht. Durch ein kontinuierliches
schonendes Drücken eines lackbeschichteten Drahtes runden Querschnitts, der zufolge
der gegebenen Symmetrie mit Lackbeschichtungen in gleichmäßiger Stärke herstellbar
ist, auf einen ovalen Querschnitt mit einem Verhältnis der zwei unterschiedlich langen,
senkrecht aufeinanderstehenden Querschnittsachscn von maximal 3 : 1 weist schließlich
der so gedrückte beschichtete Draht 1 an allen Seiten jeweils Beschichtungen in stufenlos
gleichmäßig verlaufender Stärke auf. Dabei ist die Oberfläche der Beschichtung im wesentlichen
glatt. Die elektrisch isolierende Beschichtung 3 und die äußere Backlackschicht
4 weisen durchschnittlich jeweils Stärken zwischen 5 und 10 µm auf.5 shows a
Aus solchen beschichteten erfindungsgemäß hergestellten Drähten 1 rechteckigen oder
ovalen Querschnitts aufgebaute elektrische Spulen 5, wie sie z.B. in Fig. 6 gezeigt sind,
haben eine äußerst hohe Packungsdichte, da die beschichteten Drähte 1 mit ihren äußeren
Backschichten 4 ohne bzw. wenigstens in hohem Maße ohne Ausbildung von freien Zwischenräumen
allseitig zusammenbacken und miteinander verbunden sind. Dadurch ergibt
sich auch eine sehr hohe Standfestigkeit und damit Lebensdauer dieser selbsttragenden
Spulen 5.From such
Die Erfindung ermöglicht es, einen Nachteil der Drähte unrunden Querschnittes bei der Verwendung von elektrischen Spulen auszumerzen. Solche Drähte neigen dazu, an den Stellen, an denen sie aus dem Spulenverband austreten, zu brechen. Sie sind diesbezüglich wesentlich anfälliger als runde Drähte. Der Grund für diese Anfälligkeit liegt vermutlich in den erhöhten punktuellen dynamischen Beanspruchungen in diesem Bereich, denen unrunde Drähte geringeren Widerstand entgegensetzen als runde, doch sind die Ursachen nicht in letzter Konsequenz erforscht.The invention makes it possible to have a disadvantage of non-circular cross-section wires Eradicate use of electrical coils. Such wires tend to stick to the Break places where they leave the coil assembly. You are in this much more fragile than round wires. The reason for this vulnerability is probably in the increased selective dynamic stresses in this area, the non-circular Oppose wires with less resistance than round ones, but the causes are not researched in the final analysis.
Wie in den Fig. 7 bis 10 gezeigt, ist es durch das erfindungsgemäße Verfahren möglich, die
Spulen aus einem Draht 1' herzustellen, der in dem Bereich, in dem er von der (nicht dargestellten)
Anschlußstelle frei zur Spule geführt wird (Schnitt X-X, Fig. 10), der Schlaufe
7, und in einem Anfangsbereich 8 auf der Spule 9, der eine Windung nicht übersteigt und
vorzugsweise unter einer halben Windung liegt, rund zu belassen und nur den eigentlichen
Spulenkörper aus dem erfindungsgemäß ausgebildeten Draht 1 herzustellen. Beim dargestellten
Ausführungsbeispiel erfolgt der Übergang vom runden Draht 1' zum unrunden
Draht 1 im Bereich zwischen den Schnittebenen VIII-VIII und IX-IX, wie aus den Fig. 8
und 9 ersichtlich ist.As shown in FIGS. 7 to 10, it is possible through the inventive method, the
To produce coils from a wire 1 'in the area in which it is from the (not shown)
Connection point is freely led to the coil (section X-X, Fig. 10), the
Dies ist deshalb möglich, weil der Draht bis zum Wickeln der Spule rund ist und erst während der Zufuhr zum Wickeln verformt wird. Bei den unrunden Drähten gemäß dem Stand der Technik wäre es völlig aussichtslos, den Kern über die Drahtlänge entsprechend ungleichmäßig auszubilden und dann die jeweils passenden Stellen zu suchen und zu verwenden. Erst durch diese Ausgestaltung der Erfindung ist es möglich, Spulen samt ihren elektrischen Zuleitungen einstückig, aber mit über die Länge des Drahtes unterschiedlichem Querschnitt herzustellen und so die für die jeweilige Stelle bestgeeignete Querschnittsform zur Verfügung zu stellen.This is possible because the wire is round until the coil is wound and only during the feed is deformed for winding. For the non-round wires according to the status In terms of technology, it would be completely hopeless to make the core uneven over the wire length train and then look for and use the appropriate positions. It is only through this embodiment of the invention that it is possible to coil them together electrical leads in one piece, but with different over the length of the wire To produce a cross-section and thus the most suitable cross-sectional shape for the respective position to provide.
In der Praxis erfolgt das so, dass bei der automatischen Spulenherstellung das runde Drahtende
vom Manipulator ergriffen wird, mit der vorgesehenen Überlänge zum Wickelpunkt
geführt wird, und dass während dieser Zufuhrbewegung die Formrollen so zugestellt werden,
dass ein Teil der ersten Windung der Spule 9 aus rundem Draht 1' besteht, während
die restliche und die weiteren Windungen aus unrundem Draht 1 bestehen. Auf analoge
Weise werden die Formrollen auseinandergeführt, wenn die Stelle des Drahtes zu Ihnen
gelangt, ab der auf der fertigen Spule wieder runder Draht vorliegen soll.In practice, this is done in such a way that the round wire end is used in automatic coil production
is gripped by the manipulator with the intended excess length to the winding point
is guided, and that during this feed movement the form rollers are delivered in such a way
that part of the first turn of the coil 9 consists of round wire 1 ', while
the remaining and the further turns consist of
Es betrifft somit die Erfindung sowohl eine Spule aus einem erfindungsgemäßen Draht, die dadurch gekennzeichnet ist, dass der Spulenkörper im wesentlichen aus Draht unrunden Querschnitts besteht und dass zumindest einer der Zufuhrdrähte (Schlaufe) zur Spule runden Querschnitt aufweist und über maximal eine Windung, bevorzugt maximal eine halbe Windung, mit rundem Querschnitt Teil des Spulenkörpers ist; als auch ein Verfahren zur Herstellung einer solchen Spule, das dadurch gekennzeichnet ist, dass zwischen der Vorratshaspel für den runden Draht und der Führungsvorrichtung für die Zufuhr des Drahtes zum Auflaufpunkt auf der Spule Formrollen zur Deformation des Drahtes angeordnet sind, die zwischen einer aktiven Position, in der sie den durchlaufenden Draht verdrücken und einer inaktiven Position, in der der Draht durchläuft und rund bleibt, verstellbar sind, und dass die Formrollen in der aktiven Position sind, wenn Abschnitte des Drahtes durchlaufen, aus denen der Spulenkörper gebildet wird und dass sie in die inaktive Lage gebracht werden, wenn Drahtabschnitte durchlaufen, aus denen eine Schlaufe bzw. der Übergang von der Spule zur Schlaufe gebildet wird.The invention thus relates both to a coil made from a wire according to the invention, the is characterized in that the coil body essentially out of wire Cross-section exists and that at least one of the feed wires (loop) round to the coil Cross-section and over a maximum of one turn, preferably a maximum of half Winding with a round cross section is part of the coil body; as well as a process for Production of such a coil, which is characterized in that between the supply reel for the round wire and the guide device for feeding the wire form rollers for deformation of the wire are arranged at the run-up point on the coil, between an active position in which they push the wire through and an inactive position, in which the wire runs through and remains round, is adjustable, and that the form rollers are in the active position when sections of the wire pass through from which the coil body is formed and that they are brought into the inactive position, when passing through wire sections from which a loop or the transition from the coil is formed into a loop.
Claims (8)
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AT0149201A AT412682B (en) | 2001-09-19 | 2001-09-19 | PAINT-COATED WIRE |
AT20011492 | 2001-09-19 |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1296336A1 true EP1296336A1 (en) | 2003-03-26 |
EP1296336B1 EP1296336B1 (en) | 2013-04-10 |
Family
ID=3688277
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP02450180.1A Expired - Lifetime EP1296336B1 (en) | 2001-09-19 | 2002-08-27 | Varnish-coated wire |
Country Status (6)
Country | Link |
---|---|
US (1) | US6789311B2 (en) |
EP (1) | EP1296336B1 (en) |
JP (1) | JP4271919B2 (en) |
KR (1) | KR100919937B1 (en) |
CN (1) | CN1240080C (en) |
AT (1) | AT412682B (en) |
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GB2419029B (en) * | 2003-06-19 | 2007-09-05 | Belden Cdt Networking Inc | Electrical cable comprising geometrically optimized conductors |
US7358436B2 (en) | 2004-07-27 | 2008-04-15 | Belden Technologies, Inc. | Dual-insulated, fixed together pair of conductors |
US7696437B2 (en) | 2006-09-21 | 2010-04-13 | Belden Technologies, Inc. | Telecommunications cable |
WO2011003642A3 (en) * | 2009-07-06 | 2012-02-23 | Robert Bosch Gmbh | Electric machine and method for producing the electric machine having at least one winding |
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JP4618690B2 (en) * | 2007-06-07 | 2011-01-26 | 立山科学工業株式会社 | Wireless IC tag and method of manufacturing wireless IC tag |
CN102111030A (en) * | 2011-03-22 | 2011-06-29 | 于芳昊 | Generator and motor applying noncircular cross section wires inside |
US9245671B2 (en) * | 2012-03-14 | 2016-01-26 | Ut-Battelle, Llc | Electrically isolated, high melting point, metal wire arrays and method of making same |
JP5814291B2 (en) * | 2013-04-11 | 2015-11-17 | トヨタ自動車株式会社 | Manufacturing method of assembly of strands |
AT516197A1 (en) * | 2014-09-05 | 2016-03-15 | Voestalpine Stahl Gmbh | Coil and method of making a coil-wound electrical steel laminate |
DE102015213616A1 (en) * | 2015-07-20 | 2017-01-26 | Schaeffler Technologies AG & Co. KG | Coil winding of HF stranded wire, electric machine with such a coil winding and method for its production |
TWI618619B (en) * | 2016-12-30 | 2018-03-21 | Wire manufacturing process | |
JP7047649B2 (en) * | 2018-07-30 | 2022-04-05 | 株式会社オートネットワーク技術研究所 | Wire harness |
CN112837849B (en) * | 2020-12-30 | 2022-01-04 | 松田电工(台山)有限公司 | Stretch-proof enameled wire and guide wheel device thereof |
CN112908635B (en) * | 2021-01-15 | 2021-10-08 | 中变集团上海变压器有限公司 | Dry-type transformer with elliptical coil |
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US7462782B2 (en) | 2003-06-19 | 2008-12-09 | Belden Technologies, Inc. | Electrical cable comprising geometrically optimized conductors |
US7358436B2 (en) | 2004-07-27 | 2008-04-15 | Belden Technologies, Inc. | Dual-insulated, fixed together pair of conductors |
US7696437B2 (en) | 2006-09-21 | 2010-04-13 | Belden Technologies, Inc. | Telecommunications cable |
WO2011003642A3 (en) * | 2009-07-06 | 2012-02-23 | Robert Bosch Gmbh | Electric machine and method for producing the electric machine having at least one winding |
Also Published As
Publication number | Publication date |
---|---|
CN1240080C (en) | 2006-02-01 |
CN1417810A (en) | 2003-05-14 |
KR20030025183A (en) | 2003-03-28 |
US20030054192A1 (en) | 2003-03-20 |
AT412682B (en) | 2005-05-25 |
JP2003178629A (en) | 2003-06-27 |
US6789311B2 (en) | 2004-09-14 |
KR100919937B1 (en) | 2009-10-05 |
EP1296336B1 (en) | 2013-04-10 |
JP4271919B2 (en) | 2009-06-03 |
ATA14922001A (en) | 2004-10-15 |
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