JP2001035718A - Normally wound high-conductor density coil - Google Patents

Abstract

PROBLEM TO BE SOLVED: To increase the current density of a normally wound high-conductor density coil through increase in the conductor density of the coil by normally winding an insulated wire manufactured by coating a copper wire having a specific diameter with a polyamide-imide resin coating having a specific film thickness proportional to the diameter of the copper wire. SOLUTION: A normally wound high-conductor density coil uses a copper wire, having a diameter of 0.5-0.04 mm as the conductor of the coil. The copper wires is coated with an insulating film, having a thickness which is 0.5-2.0% as thick as the diameter of the copper wire. In order to meet the electrical, mechanical, and heat-resistance requirements of the coil using the thin insulating film, the film is formed of a polyamide-imide resin or polyester-imide resin. Both the resins have main chains in their structural formulae. Therefore, the resins have very high heat resistances, high mechanical strengths, and good electrical characteristics and enable the copper wire to exhibit satisfactory performance as the electric wire of the normally wound coil, even if the films are thin. In addition, the conductor density of the coil can be improved to 75-86%, because the conductor ratio of the coil can be increased to 92-98%.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a high conductor density coil having a high magnetic flux per unit area.

[0002]

2. Description of the Related Art An insulated wire for converting electric energy into magnetic energy is generally called a magnet wire. In order to convert electric energy into magnetic energy using a magnet wire, it is wound into a coil. This type of coil is a coil with higher efficiency as the magnetic flux per unit area becomes stronger. Generally, the coil area ratio of a coil formed by winding a magnet wire is about 60%. However, in order to increase the line area ratio and obtain a highly efficient coil, an air core coil, an array winding coil, and the like have been devised. For example, in the case of an array winding coil, the alignment section 90%, the cross section 80
%, Which is a great improvement. However, it seems that the most advantageous way to improve the product area factor is to use square wires.
This is not always true. In the case of a round wire, a line area factor of 90% or more is impossible due to the gap between the lines, but in the case of a square wire, 95%
Percentage line area is possible. Further, in the case of a square wire, it is also convenient that the ratio of the length of the square to the length of the coil can be designed in accordance with required values such as a winding width, a stack thickness, and the number of turns of the coil. However, what is required as a characteristic of the coil is to increase the current density. The characteristic item for that purpose is not the line area ratio but the conductor density of the coil. The conductor density of the coil is a value determined by the product of the conductor ratio of the magnet wire itself and the coil area ratio. Magnet wires have evolved with the progress of synthetic resin chemistry technology, and various types of insulating coatings have been used, making it possible to assure electrical and mechanical properties with relatively thin coatings. According to JIS C 3202, 0
Species, 1 type, 2 types, and especially 3 types are specified.
The type and thickness of the insulating film are selected depending on the application, but the minimum thickness must be guaranteed due to factors such as electrical, mechanical, and thermal. Aligned winding coil is 63-22
No. 645.

[0003]

SUMMARY OF THE INVENTION The present invention provides a high conductor density coil having a high conductor density and a high current density.

[0004]

According to the present invention, there is provided a method for producing a copper wire having a wire diameter of 0.5 to 0.04 mm and a wire diameter of 0.5 to 0.04 mm.
An aligned-winding high conductor density coil formed by winding insulated wires provided with a polyamide-imide resin film having a thickness of 5 to 2.0%. 2. An aligned-winding high conductor density coil in which the polyamideimide resin coating described in claim 1 is replaced with a polyesterimide resin coating. 3. Item 1 or 2 in which the conductor ratio is 92% to 98%
Item 2. An array-wound high conductor density coil as described in the item. 4. Items 1 to 3 in which the conductor density is 75% to 86%
Item 25. An aligned-wound high conductor density coil according to any one of the preceding items. 5. For conductors with a wire diameter of 0.5 to 0.04 mm, a conductor diameter of 0.
A self-fusing insulated wire having a thickness of 0.5 to 3.0% of the conductor diameter is wound on an insulated wire provided with a polyamide-imide resin coating having a thickness of 5 to 2.0%. Self-fusing aligned winding high conductor density coil. 6. A self-fusing, aligned-winding, high conductor density coil in which the polyamideimide resin coating described in Item 5 is replaced with a polyesterimide resin coating. 7. Item 5 or Item 6, wherein the conductor ratio is 82% to 96%.
Self-fusing aligned winding high conductor density coil described in the paragraph. 8. Item 7. An aligned-winding self-fusing high conductor density coil according to item 5 or 6, wherein the conductor ratio is 75 to 86%. "
About.

[0005]

DESCRIPTION OF THE PREFERRED EMBODIMENTS In order to increase the current density of a coil, the conductor density of the coil must be increased.
Since the conductor density is determined by the product of the conductor ratio and the line area ratio of the coil, it is necessary to increase the conductor ratio and the line area ratio of the coil after all. In order to increase the wire area ratio, it is preferable that there is no gap between the windings of the coil. For example, a wire area ratio of 90% or more is not possible with a round wire, but it is 95% with a square wire.
Although a square wire seems to be advantageous since a line area ratio of about% can be obtained, a round wire is advantageous for improving current density because a round wire is excellent in conductor ratio.

[0006] The conductor ratio can be increased by reducing the insulating coating. One of the means for that is to reduce the surface area of the conductor in comparison with the volume. If the area is the same, the circumference of the circle is shorter than that of the square. Therefore, in the coil conductor, the round wire has the same volume and the conductor surface area is smaller than the square wire, and the amount of the insulating coating is smaller. Round wires are advantageous over square wires. Another means of increasing the conductor ratio is to reduce the amount of insulating coating by thinning the insulating coating.

According to the present invention, the conductor of the coil has a wire diameter of 0.5 to 0.5 mm.
A 0.04 mm copper wire is used. Neither polyamide imide nor polyester imide is practically applicable to a wire having a wire diameter of less than 0.05φ because it has no solderability like a polyurethane wire. Also, as the wire diameter increases, the coating increases in proportion to the thickness. Therefore, for a thick wire of 0.5φ or more, a general coating such as polyester can be used. However, 0.04-0.5m
When a film of polyesterimide or polyamideimide is provided on a wire having a wire diameter of m, a coil having a high conductor density can be formed. An insulating film having a film thickness of 0.5 to 2.0% of the wire diameter is formed on the copper wire having a wire diameter of 0.5 to 0.04 mm. Target,
Resins such as polyurethane and vinyl formal which are conventionally used cannot satisfy the requirements at all in order to satisfy the heat resistance and requirements.

In the present invention, in order to satisfy the electrical, mechanical and heat resistance requirements of a coil with such a thin insulating film, the insulating film is formed of a polyamideimide resin or a polyesterimide resin. The polyamide-imide resin had a main chain of the general formula (I), and the weight-average molecular weight of the used polyamide-imide resin was about 15,000. Further, the polyesterimide resin had a main chain represented by the general formula (II), and the weight average molecular weight of the used polyesterimide resin was about 2,000. General formula (I)

[0009]

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Formula (II)

[0011]

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As described above, since it has a special main chain, it has excellent heat resistance, high mechanical strength, and good electrical characteristics. Also, the performance of the aligned winding coil as an electric wire is good, and the conductor ratio can be remarkably improved to 92% to 98%.
And the conductor density of the coil can be made 75% to 86%. There is also a problem in the way the coils are wound. The voltage per turn of a coil formed by winding an insulated wire is
It is 1 / the total number of turns of the voltage applied to both ends of the winding start and end of the coil. In order to minimize the maximum value of the potential difference between adjacent insulated wires, it is necessary to form aligned windings in which the order of winding is not disordered in each layer. In this way, it is possible to obtain an array winding coil having the maximum conductor density and the minimum line-to-line potential difference. A self-fusing insulated wire having a self-fusing film provided on the insulated wire at a thickness of 0.5 to 3% of the conductor diameter is wound while being treated with hot air or a solvent during coil formation. The self-fusing coating melts and fills the gap of the insulated wire wound in a line. The outer diameter of the coil depends on the outer diameter of the self-insulating wire of the base. 0.5 of self-adhesive coating
%, The fusion force is poor, and if it is more than 3%, the volume becomes larger than the gap between the wires, and the coil outer diameter becomes larger.

[0013]

Next, the present invention will be described specifically with reference to examples and comparative examples. Example 1 A polyamideimide paint was applied to a 0.17φ copper wire and baked to obtain a coating thickness of 0.0015 mm and a finished outer diameter of 0.17.
Create 3φ insulated wire. A 90-turn aligned-winding coil is manufactured on the bobbin of FIG. a is the core diameter, b is the winding width, and c is the winding height.

Example 2 A polyesterimide paint was applied to a 0.17φ copper wire and baked to form an insulated wire having an insulation coating thickness of 0.0015 mm, and a nylon-based self-fusing paint having a coating thickness of 0.15 mm was further formed thereon. A self-fusing insulated wire with a finished outer diameter of 0.176φ was created by coating and baking to a thickness of 002 mm. A 90-turn winding coil shown in FIG. 2 is manufactured while injecting hot air at 230 ° C. onto the bobbin shown in FIG. In the hot air jet coil diagram of Example 2, reference numeral 1 denotes an insulated wire, and reference numeral 3 denotes a self-fusing coating melted by hot air. The thickness of the self-fusing coating is 3% of the conductor diameter
Within this range, the fusion coating is melted by hot air injection or solvent treatment during winding work to fill gaps between wires, and the outer diameter of the coil depends on the finished outer diameter of the insulating coating.

COMPARATIVE EXAMPLE 1 A 0.17φ copper wire was coated with a polyurethane coating and baked to form an insulating coating having a thickness of 0.0015mm and a finished outer diameter of 0.173φ.
Create insulated wires. A 90-turn aligned winding coil was manufactured on the bobbin shown in FIG. Comparative Example 2 An insulating paint was baked on a flat copper wire having a minor axis of 0.027 mm and a major axis of 0.80 mm to a coating thickness of 0.0015 mm, and a self-fusing coating was baked thereon to a coating thickness of 0.0015 mm to reduce the finished outer diameter. 0.033mm diameter, 0.820mm long diameter
Made self-fusing insulated rectangular copper wire. 230 on the bobbin of FIG.
The coil was manufactured so as to wind the belt 90 times while spraying hot air at ℃. Table 1 shows the results of the examples.

[0016]

[Table 1]

In each of the examples, the conductor density and the magnetic force density are higher than those of the comparative example 2. Since the rectangular wire is made by rolling a round wire, it is inevitable that the conductivity is reduced by work hardening at that time. Therefore, in the magnetic force density shown in Table 1, the value of Comparative Example 2 is about 10% smaller than that of Example. Embodiment 2 can be directly soldered.

[0018]

According to the present invention, the manufacturing cost is lower than that of a flat wire,
Using a round wire with stable quality and low work hardening, it is possible to provide a coil with an unprecedented high conductor density and high magnetic force density at low cost.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of a bobbin on which an insulated wire is wound.

FIG. 2 is an explanatory view showing a state where a self-fusing electric wire is wound around a winding frame and fused.

[Explanation of symbols]

 1 winding frame a core diameter b winding width c winding height 2 insulated wire 3 fusion coating

Claims (8)

[Claims] An insulated wire comprising a conductive wire having a wire diameter of 0.5 to 0.04 mm and a polyamide-imide resin coating having a thickness of 0.5 to 2.0% of the wire diameter, which is wound in an aligned manner. Wound high conductor density coil. 2. An aligned-wound high conductor density coil in which the polyamide imide resin coating according to claim 1 is replaced by a polyester imide resin coating. 3. The coil according to claim 1, wherein the conductor ratio is 92% to 98%. 4. The aligned conductor high conductor density coil according to claim 1, wherein the conductor density is 75% to 86%. 5. An insulated wire having a conductor diameter of 0.5 to 0.04 mm and a polyamide-imide resin coating having a thickness of 0.5 to 2.0% of the conductor diameter provided on an insulated wire having a conductor diameter of 0.5 to 2.0%. A self-fusing aligned winding high conductor density coil formed by winding a self-fusing insulated wire having a thickness of about 3.0% in an aligned manner. 6. A self-bonding aligned-winding high conductor density coil in which the polyamide imide resin coating according to claim 5 is replaced with a polyester imide resin coating. 7. The self-fusing aligned wound high conductor density coil according to claim 5, wherein the conductor ratio is 82% to 96%. 8. The aligned winding self-fusing high conductor density coil according to claim 5, wherein the conductor ratio is 75 to 86%.