JP2000113730A - Compound lightweight ribbon wire, insulated compound lightweight ribbon wire, and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a compound lightweight ribbon wire capable of soldering, weight saving, and capable of making light and compact electronic devices etc., and having good heat releasing performance, and to provide an insulated compound lightweight ribbon wire obtained by providing the ribbon wire with insulating coating, also to provide a manufacturing method thereof. SOLUTION: A zinc thin film 2 is formed on the surface of a stretching pure aluminum conductor 1 having an outside diameter of less 1.0 mm and an aluminum purity of more 90%, by a zincate conversion process. A copper coating 3 is formed on the outer surface of the zinc thin film 2 by electroplating with copper, to form a copper coating aluminum conductor 4a. Then, the copper coating aluminum conductor 4a is made into a copper coating aluminum wire 4b of the desired size by cold plastic forming, thereafter it is further formed into the compound lightweight ribbon wire 4 of the desired size by cold rolling work.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wire rod such as a coil used in various electronic devices, and more particularly, to a composite lightweight ribbon wire formed by rolling a copper-coated aluminum wire into a ribbon wire, an insulated composite lightweight wire. The present invention relates to a ribbon wire and a manufacturing method thereof.

[0002]

2. Description of the Related Art In recent years, as electronic devices and electronic components have become lighter, thinner and smaller, the diameter of conductors such as coils used in these devices has also been reduced. Aluminum conductors or aluminum alloy conductors (hereinafter abbreviated as aluminum conductors) that are 1/3 or less of copper have been adopted. However, aluminum conductors have an electrochemically low potential. For example, when a new metal surface formed by wire drawing or the like comes into contact with air, an oxide film is instantaneously formed on the surface. Is a very difficult metal material. In addition, due to the lack of mechanical strength of the aluminum conductor itself, a special connection technique was required to maintain sufficient reliability at the connection location.

As described above, since the aluminum conductor has a problem in connection by soldering, the specific gravity is slightly larger than that of the aluminum conductor. Method) or a method of forming a copper pipe coating layer on the outer periphery of an aluminum conductor by welding a copper tape into a pipe (tape welding method). It is marketed as an electric cable.

Further, the copper clad aluminum wire is cold-rolled to form a ribbon wire, so that the area occupancy ratio of the round wire and the ribbon wire is reduced as shown in FIG. It becomes possible to reduce the size by 20 to 30% as compared with the line, which greatly contributes to the reduction in size and weight. In addition, by increasing the ratio of the thickness to the width, the heat radiation property is improved.

[0005]

However, in order to manufacture the above-mentioned copper-clad aluminum wire by the roll pressure welding method or the tape welding method, the processing method is limited to a large diameter size (for example, a conductor diameter of 7 mm). The diameter of the large diameter product is reduced by wire drawing (for example, φ0.10 m
m), excessive work hardening was caused by the processing history, resulting in brittleness. Therefore, when cold rolling is further performed, there is a problem that the base aluminum is exposed and causes poor appearance. In addition, when the ratio of the thickness to the width of the conductor (hereinafter, abbreviated as a rolling ratio) is 1: 4 or more, the appearance defect becomes remarkably remarkable. In the above-mentioned problem, although the work hardening is alleviated by performing the heat treatment in the intermediate step, a brittle intermetallic compound layer is formed at the interface due to the thermal diffusion reaction between the aluminum layer and the copper coating layer.

Furthermore, in the roll pressure welding method or the tape welding method, since the joining of the boundary surface between the aluminum conductor and the copper coating layer is a physical / mechanical joining such as pressure bonding, the lack of the joining causes the base aluminum to be unrolled during rolling. There was a problem that was exposed.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned various problems of the prior art, and can be soldered and reduced in weight. It is an object of the present invention to provide a composite lightweight ribbon wire having good properties, an insulated composite lightweight ribbon wire provided with an insulating coating on the ribbon wire, and a method for producing the same.

[0008]

In order to achieve the above object, as a first aspect, the present invention relates to an aluminum conductor or an aluminum alloy conductor having an outer diameter of 1.0 mm or less (hereinafter abbreviated as aluminum conductor) (1) A zinc thin film (2) is formed by zinc substitution on the surface of the aluminum foil, and a copper-coated aluminum conductor (4a) with a copper coating (3) formed by electrolytic copper plating on the outer periphery of the zinc thin film (2) is cold-worked. After being adjusted to a copper-coated aluminum wire (4b) of a desired size by cold rolling, the composite lightweight ribbon wire (4) of a desired size is further adjusted by cold rolling.

[0009] The composite lightweight ribbon wire of the first aspect is:
It can be soldered, is lightweight, and has good heat dissipation. In addition, the copper-coated aluminum conductor (4a) is subjected to cold plastic working to form a copper-coated aluminum wire of a desired size.
When the adjustment is made to (4b), the work hardening due to the working history is unlikely to occur and the material is hardly fragile, so that rolling can be easily performed. Note that a copper-coated aluminum conductor in which a copper coating is continuously coated on the surface of an aluminum conductor having an outer diameter exceeding 1.0 mm by electrolytic copper plating on the outer periphery of a zinc thin film formed by zinc substitution is preferably subjected to cold rolling. When the size is adjusted to an excessively large value, excessive work hardening due to the processing history is liable to occur, and the material becomes brittle, and the aluminum is exposed during the rolling process, resulting in poor appearance.

According to a second aspect of the present invention, the aluminum conductor (1) is made of a pure aluminum for spreading having an aluminum purity of 90% or more or an aluminum-magnesium (Al-Mg) alloy for spreading having an aluminum purity of 90% or more. , Aluminum-magnesium-silicon (Al-Mg-Si)
In composite lightweight ribbon wire made of alloy.

In the composite lightweight ribbon wire according to the second aspect, the aluminum conductor (1) has an aluminum purity of 90%.
% Or more pure aluminum for stretching or Al-Mg alloy for stretching with aluminum purity of 90% or more, Al-Mg-Si
Alloys are preferably used.

As a third aspect, the present invention relates to a composite lightweight ribbon wire in which the ratio of the thickness and the width of the conductor of the composite lightweight ribbon wire (4) is 1: 3 or more.

In the composite lightweight ribbon wire of the third aspect, as described above, when the copper-coated aluminum conductor (4a) is adjusted to a copper-coated aluminum wire (4b) of a desired size by cold plastic working, Since it is difficult to cause work hardening due to the processing history and is not easily brittle, not only rolling work is easily possible, but also copper coating by electrolytic copper plating (3)
Is formed, the adhesion at the interface between the aluminum conductor and the copper coating layer is good. Therefore, by the above-mentioned mutual effect,
In the rolling process, a composite lightweight ribbon wire having a rolling ratio of 1: 3 or more can be easily manufactured.

As a fourth aspect, the present invention resides in a composite lightweight ribbon wire in which the copper coverage of the copper-coated aluminum conductor (4a) is 20% or less.

In the composite lightweight ribbon wire according to the fourth aspect, the copper-clad aluminum conductor (4a) has a copper coverage of 20%.
% Or less, the specific gravity is as close as possible to the aluminum conductor, so that the weight can be further reduced.

According to a fifth aspect of the present invention, there is provided an insulated composite lightweight ribbon wire in which an insulating coating and / or a fusion coating is further formed on the outer periphery of the composite lightweight ribbon wire.

In the above-described fifth aspect of the present invention, since the insulating and / or fusion coating is further formed on the outer periphery of the composite and lightweight ribbon wire, it can be applied to a coil winding of an electronic device. It can be preferably used.

According to a sixth aspect of the present invention, an outer diameter of 1.0 m
m, a zinc substitution step of forming a zinc thin film (2) on the outer periphery of an aluminum conductor (1) having a thickness of not more than m,
An electroplating step of forming a copper coating (3) having a copper coating rate of 20% or less on the outer periphery of the copper-coated aluminum conductor (4a) to form a copper-coated aluminum conductor (4a), and subjecting the copper-coated aluminum conductor (4a) to cold plastic working Copper-coated aluminum wire of desired size
(4b) a cold plastic working step, and the copper-coated aluminum wire (4b) is subjected to cold rolling to form a composite lightweight ribbon wire (4) having a conductor thickness to width ratio of 1: 3 or more. And a cold rolling process step of adjusting.

In the method for manufacturing a composite lightweight ribbon wire according to the sixth aspect, the first to fourth steps are performed by a zinc substitution step, an electroplating step, a cold plastic working step, and a cold rolling step.
Thus, the composite lightweight ribbon wire of the aspect (1) can be efficiently manufactured.

According to a seventh aspect, the present invention provides a method of manufacturing a composite lightweight ribbon wire according to the sixth aspect, further comprising the steps of: The present invention relates to a method of manufacturing an insulated composite lightweight ribbon wire provided with a paint application and baking step of applying and baking a paint to form an insulating film and / or a fusion film.

In the method for manufacturing an insulated composite lightweight ribbon wire according to the seventh aspect, a paint application and baking step is provided following each step of the method for manufacturing a composite lightweight ribbon wire according to the sixth aspect. The insulated composite lightweight ribbon wire of the fifth aspect can be efficiently manufactured.

[0022]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The contents of the present invention will be described below in more detail with reference to an embodiment shown in the drawings. Note that the present invention is not limited by this. FIG. 1 is a schematic diagram for explaining a copper-coated aluminum conductor, a copper-coated aluminum wire, and a composite lightweight ribbon wire of the present invention, and FIG. 1A is a cross-sectional view showing the copper-coated aluminum conductor and the copper-coated aluminum wire. FIG. 2B is a cross-sectional view showing a composite lightweight ribbon wire. FIG. 2 is a flow chart showing a manufacturing process of the composite lightweight ribbon wire and the insulating composite lightweight ribbon wire of the present invention. In these figures, 1 is an aluminum conductor or aluminum alloy conductor, 2 is a zinc thin film, 3 is a copper coating, 3a is a strike copper plating film, 3b is a thick copper plating film, 4 is a composite lightweight ribbon wire, and 4a is copper. The coated aluminum conductor, 4b, is a copper-coated aluminum wire.

-First Embodiment- A first embodiment will be described with reference to FIGS. (The same applies to the following embodiments.) First, in the zinc substitution step F1, an aluminum wire having an outer diameter of 0.90 mm and an aluminum purity of 99.0% is used as the aluminum conductor (1), and the surface of the aluminum conductor (1) is After degreasing and etching, a zinc thin film (2) having a thickness of 0.20 μm was formed by zinc substitution.

Subsequently, in the electroplating step F2, first,
The aluminum conductor (1) on which the zinc thin film (2) is formed is heated at a bath temperature of 40 ° C.
Immersed in a strike copper plating solution with a current density of 2 A / d
m^Two1 minute depending on the plating conditions
A strike copper plating film (3a) is formed, and a bath temperature of 40
Immersed in a copper sulfate plating bath at a temperature of 8 A / dm ^Two
25 minutes depending on the plating conditions
A thick copper plating film (3b) is formed, and both copper plating films (3b
a), a copper coating (3) consisting of (3b) is provided.
A copper-coated aluminum conductor (4a) was used. In addition, this copper coating
The copper coverage of the aluminum conductor (4a) is 15%.

Subsequently, in the cold plastic working step F3, the copper-coated aluminum conductor (4a) having an outer diameter of 0.98 mm is used as a base material, the wire is passed through a die using a wire drawing machine, and wire drawing is performed. A copper-coated aluminum wire (4b) having a diameter of 0.172 mm was produced.

Subsequently, in the cold rolling step F4, the copper-coated aluminum wire (4b) having an outer diameter of 0.155 mm is rolled by a cold rolling mill to form a conductor having a conductor thickness of 0.06 mm and a conductor width of 0.40 mm. Composite lightweight ribbon wire with a rolling ratio of 1: 6.7
(4) was manufactured.

Second Embodiment First, in the zinc substitution step F1, the aluminum conductor (1) is used for spreading A having an outer diameter of 0.90 mm and an aluminum purity of 95.0%.
A zinc thin film (2) having a thickness of 0.20 μm was formed in the same manner as in the first embodiment except that an l-Mg alloy wire was used.

Subsequently, the electroplating step F2 is performed in the first
In the same manner as in the first embodiment, a copper-coated aluminum conductor (4a) having a diameter of 0.98 mm was obtained. The copper coverage of the copper-coated aluminum conductor (4a) is 15%.

Subsequently, in the cold plastic working step F3, the copper-coated aluminum conductor (4a) having an outer diameter of 0.98 mm is used as a base material, and wire drawing is performed in the same manner as in the first embodiment. A copper-coated aluminum wire (4b) having a diameter of 0.190 mm was produced.

Subsequently, in the cold rolling step F4, the copper-coated aluminum wire (4b) having an outer diameter of 0.190 mm is rolled in the same manner as in the first embodiment, and the conductor thickness is 0.05 mm.
Conductor width. A composite lightweight ribbon wire (4) having a rolling ratio of 60 mm and 1:12 was produced.

Third Embodiment First, in the zinc substitution step F1, an aluminum conductor (1) for wrought A having an outer diameter of 0.90 mm and an aluminum purity of 97.0% is used.
A zinc thin film (2) having a thickness of 0.20 μm was formed in the same manner as in the first embodiment except for using an l-Mg-Si alloy wire.

Subsequently, the electroplating step F2 is performed in the first
In the same manner as in the first embodiment, a copper-coated aluminum conductor (4a) having a diameter of 0.98 mm was obtained. The copper coverage of the copper-coated aluminum conductor (4a) is 15%.

Subsequently, in the cold plastic working step F3, the copper-coated aluminum conductor (4a) having an outer diameter of 0.98 mm is used as a base material, and wire drawing is performed in the same manner as in the first embodiment. A copper-coated aluminum wire (4b) having a diameter of 0.142 mm was produced.

Subsequently, in a cold rolling step F4, the copper-coated aluminum wire (4b) having an outer diameter of 0.175 mm is rolled in the same manner as in the first embodiment, and the conductor thickness is 0.03 m.
m, conductor width. A composite lightweight ribbon wire (4) having a 54 mm rolling ratio of 1:18 was produced.

Fourth Embodiment A polyurethane paint is applied to the outer periphery of the composite lightweight ribbon wire (4) having a rolling ratio of 1: 6.7 obtained in the first embodiment as a paint application and baking step. After baking, a 5 µm thick insulation film is provided, and then a nylon-epoxy fusion coating is applied to the outer periphery of the insulation film and baked to form a 5 µm thickness fusion film. (Not shown).

Fifth Embodiment A paint application and baking step is performed on the outer periphery of the composite lightweight ribbon wire (4) having a rolling ratio of 1:12 obtained in the second embodiment, as follows.
After applying and baking a polyurethane paint to form a 5 μm thick insulating film, further applying a nylon-epoxy fusing paint on the outer periphery and baking to form a 5 μm thick fusing film,
An insulated composite lightweight ribbon wire (not shown) was manufactured.

-Sixth Embodiment- As a coating and baking step, the outer periphery of the composite lightening ribbon wire (4) having a rolling ratio of 1:18 obtained in the third embodiment is coated with a paint.
After applying and baking a polyurethane paint to form a 5 μm thick insulating film, further applying a nylon-epoxy fusing paint on the outer periphery and baking to form a 5 μm thick fusing film,
An insulated composite lightweight ribbon wire (not shown) was manufactured.

The composite lightweight ribbon wires obtained in the first to third embodiments had good appearances as shown in the cross-sectional photographs in the photographic diagrams of FIGS. 3 to 5, respectively. FIG. 3 shows the first
The composite lightweight ribbon wire obtained in the embodiment of FIG.
FIG. 5 shows a composite lightweight ribbon wire obtained in the third embodiment, and FIG. 5 shows a composite lightweight ribbon wire obtained in the third embodiment.
Moreover, the composite lightweight ribbon wire of each embodiment did not expose the base aluminum, and also had good solderability.

The insulated composite lightweight ribbon wires obtained in the fourth to sixth embodiments have good appearance, good general properties such as pinholes, dielectric breakdown voltage, and the like, and furthermore have a good fusibility. Was also good.

[0040]

The composite lightweight ribbon wire obtained by the present invention can be soldered, is reduced in weight, and has good heat dissipation. Further, using a copper-coated aluminum conductor obtained by continuously coating a copper coating by electrolytic copper plating on the outer periphery of a zinc thin film formed by zinc substitution on the surface of an aluminum conductor having an outer diameter of 1.0 mm or less as a base material, When adjusting to a copper-coated aluminum wire of a desired size by cold plastic working, work hardening due to the working history is unlikely to occur, and the wire is hardly fragile, so that rolling can be easily performed. Further, the interface between the aluminum conductor and the copper coating layer does not expose the base aluminum due to the interaction with the adhesion obtained by the electroplating, so that a desired ribbon wire rolling ratio can be easily designed.

Further, in the insulated composite lightweight ribbon wire obtained by the present invention, since an insulating coating and / or a fusion coating is further formed on the outer periphery of the composite lightweight ribbon wire, the coil winding of the electronic device is formed. And the like. Therefore, the present invention greatly contributes to the reduction in the size and weight of electronic devices and components, and the present invention has an extremely large effect of contributing to industry.

[Brief description of the drawings]

FIG. 1 is a schematic diagram illustrating a copper-coated aluminum conductor, a copper-coated aluminum wire, and a composite lightweight ribbon wire of the present invention. (A) is sectional drawing which shows a copper-coated aluminum conductor and a copper-coated aluminum wire. (B) is a sectional view showing a composite lightweight ribbon wire.

FIG. 2 is a flowchart showing a manufacturing process of the composite lightweight ribbon wire and the insulating composite lightweight ribbon wire of the present invention.

FIG. 3 is a photographic view showing a cross section of the composite lightweight ribbon wire obtained in the first embodiment of the present invention.

FIG. 4 is a photograph showing a cross section of the composite lightweight ribbon wire obtained in the second embodiment of the present invention.

FIG. 5 is a photograph showing a cross section of the composite lightweight ribbon wire obtained in the third embodiment of the present invention.

FIG. 6 is a comparison diagram of the space factor between the round wire and the ribbon wire.

[Explanation of symbols]

 1 Aluminum conductor or aluminum alloy conductor 2 Zinc thin film 3 Copper coating 3a Strike copper plating film 3b Thick copper plating film 4 Composite lightweight ribbon wire 4a Copper-coated aluminum conductor 4b Copper-coated aluminum wire

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) H01B 13/16 H01B 13/16 (72) Inventor Etsuro Tsukada 1788 Kamiko, Maruko-cho, Kogun-gun, Nagano Prefecture Tokyo Special 4K024 AA09 AB01 AB02 BA06 BC03 DA04 DA07 DA08 DA09 DB06 DB07 GA14 GA16 5G307 BA04 BB03 BC03 BC07 5G311 CA01 CB02 5G325 KC02 LA02

Claims (7)

[Claims] 1. A zinc thin film (2) is formed on the surface of an aluminum conductor or an aluminum alloy conductor (1) having an outer diameter of 1.0 mm or less by zinc substitution on the surface thereof, and the outer periphery of the zinc thin film (2) is formed by electrolytic copper plating. After the copper-coated aluminum conductor (4a) on which the copper coating (3) is formed is adjusted to a copper-coated aluminum wire (4b) of the desired size by cold plastic working, composite weight reduction of the desired size is further performed by cold rolling. Ribbon wire
(4) A composite lightweight ribbon wire characterized by being adjusted to (4). 2. The method according to claim 1, wherein said aluminum conductor or aluminum alloy conductor (1) is made of pure aluminum for stretching having an aluminum purity of 90% or more, or aluminum-magnesium (Al-Mg) alloy for stretching which has an aluminum purity of 90% or more. Magnesium-silicon (Al-M
The composite lightweight ribbon wire according to claim 1, comprising a g-Si) alloy. 3. The composite lightweight ribbon wire according to claim 1, wherein the ratio of the thickness to the width of the conductor of the composite lightweight ribbon wire is 1: 3 or more. 4. The copper-coated aluminum conductor (4a) has a copper coverage of 20% or less.
Or the composite lightweight ribbon wire according to 3. 5. An insulated composite lightweight ribbon wire, further comprising an insulating film and / or a fusion coating formed on the outer periphery of the composite lightweight ribbon wire according to claim 1. 6. A zinc substitution step of forming a zinc thin film (2) on the outer periphery of an aluminum conductor or an aluminum alloy conductor (1) having an outer diameter of 1.0 mm or less by zinc substitution, and applying an electric current to the outer periphery of the zinc thin film (2). 20% copper coverage by copper plating
Copper coated aluminum conductor (4a) with the following copper coating (3)
Electroplating process, and said copper-coated aluminum conductor
(4a) cold plastic working to adjust the copper-coated aluminum wire of the desired size by cold plastic working (4b), and, by cold rolling the copper-coated aluminum wire (4b), the thickness and width of the conductor Composite lightweight ribbon wire with a ratio of 1: 3 or more (4)
And a cold rolling process step of adjusting the temperature of the ribbon wire. 7. A method for manufacturing a composite lightweight ribbon wire according to claim 6, wherein an insulating paint and / or a fusion paint is further applied to the outer periphery of the composite lightweight ribbon wire and baked. A method for producing an insulated composite lightweight ribbon wire, comprising a paint application and baking step of forming an insulating film and / or a fusion film by heating.