JP2007227266A - Assembled conductor - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent the occurrence of an eddy current and improve a conductor space factor in an assembled conductor. <P>SOLUTION: An assembled conductor 10 integrates many untwisted conductor wires 3 each of which has a rectangular cross-section as a divided part of a whole cross-section form area. Each of the conductor wires 3 has a conductor strand 1, and a coating layer 2 which is attached to the outer circumferential portion of the conductor strand 1 and is composed of a metal material or a metallic compound having an electrical resistance value greater than that of the conductor strand 1. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a collective conductor formed by integrating a plurality of conductor wires.

  Various conductors have been proposed as a collective conductor in which a plurality of conductor wires are bundled together.

  For example, in Patent Document 1, a plurality of enamel wires having a circular cross section are arranged and twisted so as to form two horizontal rows, and the entire cross section is a rectangular flat twisted wire. Litz wire is disclosed. And according to this, it is described that the space factor in a coil | winding can be improved.

  Patent Document 2 discloses a self-bonding assembly line in which a self-bonding layer is provided on the outside of an assembly line in which a plurality of insulating wires are bundled, and an insulating layer and a self-bonding layer are sequentially formed on a conductor. A plurality of fusion-insulated wires are bonded in parallel by bonding the self-bonding layers, and a thermoplastic self-bonding layer is formed on the outer periphery of the bundled assembly line. And according to this, when the outer self-bonding layer is formed, it is difficult for the insulation element wire to be scattered, and even when winding in a complicated shape such as a deflection coil, the insulation element wire does not protrude or break. It is described that the coil space factor can be ensured with a large conductor cross-sectional area.

Patent Document 3 discloses a self-bonding dislocation electric wire in which a plurality of self-bonding rectangular enamel wires are assembled, dislocated, and twisted and wound around an outer periphery of a stranded wire with an insulating tape spirally wound. What is disclosed is a self-lubricating / self-bonding flat enameled wire. And according to this, during manufacturing work of the dislocation wire and coil winding work, the strands of each other exhibit excellent mutual slipperiness, and the strands can be firmly heat-sealed when the coils are heat-sealed. Are listed.
Japanese Patent Laid-Open No. 2-242531 JP-A-9-161547 Japanese Patent Laid-Open No. 11-203948

  By the way, an induction motor (induction motor), a brushed DC motor, a brushless DC motor, and the like are often used for driving an electric vehicle.

  For example, the induction motor includes a stator core formed in a cylindrical shape, a coil attached to the stator core, and a rotor rotatably arranged with a certain gap on an inner peripheral wall of the stator core, and induction generated in the coil The rotor is rotated by a magnetic field to obtain a driving force.

  The stator core includes a plurality of concave portions (slots) and convex portions that are alternately formed in the circumferential direction on the inner peripheral wall or the outer peripheral wall. In each slot, a conductor wire such as an enamel wire constituting a coil is disposed.

  FIG. 14 is a cross-sectional view in which a plurality of conductor wires 103 having a circular transverse cross section are arranged in the slots 130b between the protruding strip portions 130a. Here, the conductor wire 103 includes a conductor wire 101 through which a current flows and a covering layer 102 covering the periphery thereof. In FIG. 14, since the conductor wire 103 having a circular cross section is disposed in the slot 130b, a dead space is formed between the conductor wires 103, and the filling rate of the conductor wire 103 inside the slot 130b is as follows. It is low.

  In recent years, motors for electric vehicles such as hybrid vehicles are often driven by high-frequency alternating current generated by an inverter. For example, in the case of FIG. 14, the current flowing through the conductor wire 103 is caused by the skin effect. The AC resistance increases due to concentration near the surface of the conductor wire 101.

  Therefore, in order to increase the filling factor of the conductor wire 103 inside the slot 130b, that is, the area of the conductor occupying a predetermined area (conductor space factor) and reduce the AC resistance due to the skin effect and eddy current, As the conductor to be inserted into the conductor, for example, an aggregate conductor as described in Patent Documents 1 to 3 can be used.

  In the collective conductor as described above, since the plurality of conductor wires are bundled, the skin current is divided and the eddy current is canceled between adjacent conductor wires, so that the AC resistance can be lowered. However, since the collective conductors of Patent Documents 1 to 3 are configured by bundling a plurality of conductor wires in a twisted state, the twisted structure forms a dead space and reduces the conductor space factor. As a result of the twisted aggregate conductor itself forming a local coil, it is inevitable that eddy currents are generated.

  The present invention has been made in view of such points, and an object thereof is to suppress the generation of eddy currents and improve the conductor space factor in the collective conductor.

  In order to achieve the above object, in the present invention, a plurality of conductor wires each having a partial cross-section obtained by dividing the overall cross-sectional shape are integrated in an untwisted state.

  Specifically, the collective conductor according to the present invention is an aggregate conductor in which a plurality of conductor wires each having a partial cross section obtained by dividing the overall cross sectional shape are integrated in an untwisted state, and each of the above conductor wires Comprises a conductor strand and a coating layer made of a metal or a metal compound provided on the outer periphery of the conductor strand and having an electrical resistance value larger than the electrical resistance value of the conductor strand. To do.

  According to said structure, while each conductor wire which comprises an aggregate conductor has the cross section of the shape of the part which divided | segmented the whole cross-sectional shape of the aggregate conductor, the conductor strands which comprise each conductor line are Since they are bundled through the covering layer, the conductor space factor in the collective conductor is improved. Moreover, since each conductor wire which comprises an assembly conductor is bundled in the untwisted state, the assembly conductor itself does not form a local coil, and generation | occurrence | production of an eddy current is suppressed. Therefore, it is possible to suppress the generation of eddy currents and improve the conductor space factor in the collective conductor.

  Further, since the potential difference between the conductor wires is relatively small, the insulation between the conductor wires of each conductor wire is achieved by a coating layer made of a metal having a larger electric resistance value than the conductor wires. It is possible to ensure necessary and sufficient.

  You may have a binding layer in the outermost periphery of the said conductor wire. As a result, the conductor wires can be reliably bonded to each other.

  The cross section of the conductor wire may be formed in a rectangular shape.

  According to said structure, since the cross section of the conductor strand which comprises a conductor wire is a rectangular shape, the cross section of a conductor wire also becomes a rectangular shape. Therefore, since the conductor lines are easily aligned in the width direction and the height direction by overlapping the side surfaces of the conductor lines, the conductor space factor in the collective conductor can be improved.

  The conductor strand may be formed of copper or a copper alloy, and the coating layer may be formed of nickel or a nickel alloy. Moreover, while the said conductor strand is formed with copper or a copper alloy, the said coating layer may be formed with tin or the tin alloy. The conductor wire may be formed of metal, and the covering layer may be formed of an oxide of the conductor wire.

  According to this structure, a coating layer can be comprised with a general and cheap material.

  In an electric vehicle using an inverter-driven motor, it is desired to improve a conductor space factor inside a slot of a stator core constituting the motor in order to increase the efficiency of the motor. Therefore, the present invention is particularly effective for an inverter-driven motor coil.

  According to the present invention, a plurality of conductor wires each having a partial cross-sectional shape obtained by dividing the overall cross-sectional shape are integrated in a non-twisted state, and the covering layer of each conductor wire is more electrically resistant than the conductor strand. Since it is made of a metal or metal compound having a large value, generation of eddy current can be suppressed and the conductor space factor in the collective conductor can be improved. Furthermore, the insulation between the conductor strands of these conductor wires can be ensured sufficiently and sufficiently by the coating layer made of a metal or a metal compound having a larger electric resistance value than the conductor strands.

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In addition, this invention is not limited to the following embodiment.

  FIG. 1 is a perspective view of the collective conductor 10 according to the present embodiment.

  As shown in FIG. 1, the collective conductor 10 includes a plurality of conductor wires 3 integrated so as to be aligned in the width direction (lateral direction in the figure) and the height direction (vertical direction in the figure) in an untwisted state. ing. The collective conductor 10 is preferably used as a coil of a motor driven by an inverter.

  The conductor wire 3 includes a linear conductor wire 1 having a rectangular cross section and a covering layer 2 provided so as to cover the conductor wire 1. The rectangular cross-sectional shape of the conductor wire 3 (conductor wire 1) is a partial shape obtained by dividing the rectangular overall cross-sectional shape of the collective conductor 10, respectively.

  Here, the rectangular shape which is the cross-sectional shape of the conductor wire 3 (conductor wire 1) is a shape as shown in FIGS. That is, the rectangular shape has a square cross section with a right corner as shown in FIG. 6, a cross section rectangle with a right corner as shown in FIG. 7, and a corner as R as shown in FIG. A cross-section square, a cross-section rectangle having a rounded corner as shown in FIG. 9, and a shape in which a pair of opposing sides are parallel and the other is arc-shaped as shown in FIG. Etc.).

  Each of the shapes shown in FIGS. 6 to 10 can be formed by forming a conductor bus as a wire drawn by a die, or by a processing molding apparatus such as roller rolling.

  Moreover, what is necessary is just to process and shape the rolling shape of the round-shaped bus-bar from one direction in the track-like thing of the cross section of FIG.

  And each conductor wire 3 is mutually joined through the coating layer 2, and is integrated. The coating layer 2 may be made of a material having the binding property itself or a material having the binding layer on the outermost periphery of the coating layer. For example, what has sectional structure as shown in FIGS. 11-13 which is sectional drawing is mentioned.

  That is, as shown in FIG. 11, the covering layer 2 may be formed by the insulating layer 5 and the binding layer 6 laminated on the insulating layer 5. In addition, as shown in FIG. 11, the insulating layer 5 may be sandwiched between a pair of binding layers 6. Furthermore, as shown in FIG. 13, the covering layer 2 may be formed by the binding layer 6 itself.

  The cross-sectional shape of the conductor wire 3 (conductor wire 1) is preferably the above rectangular shape from the viewpoint of space factor and productivity, but may be a polygon such as a triangle or a hexagon. In addition, the conductor wire 1 having a rectangular cross section can easily reduce the dead space (space where no conductor exists) with respect to the entire cross section of the collective conductor 10, and collective conductors of various sizes. 10 can be adapted.

  Further, in the conductor wire 1 having a rectangular cross section, the length of the long side is set to 1 to 1.5 times (preferably 1 to 1.2 times) the short side, so that m rows × n columns (for example, m and n are integers, and m ≧ 1, preferably n ≧ 2. More preferably, 1 ≦ m ≦ 4, 5 ≦ n ≦ 20. m <1, n If it is <5, the advantage as a collective conductor (difference from a single wire) is reduced, and if 4 <m and 20 <n, it tends to be difficult to integrate in an untwisted state. Etc. (3 rows and 6 columns in FIG. 1), the space factor of the conductor wire 1 with respect to the entire assembly conductor 10 can be improved and the surface area of the conductor wire 1 can be increased. Miniaturization and light weight of motors (including conductor wires through which high-frequency AC flows) used in electric vehicles such as hybrid vehicles It can be realized.

  Note that the cross-sectional shapes of the conductor wires 1 constituting the assembly conductor 10 may not all be the same.

The size of the conductor wire 1 may be, for example, a size having a side of 0.05 mm to 2 mm (preferably 0.05 mm to 1 mm) and corresponding to a round wire of 0.03 mmφ to 2.0 mmφ. The cross-sectional area is 0.0007 mm ² to ⁴ mm ² .

  For example, copper, aluminum, silver, iron, gold, or an alloy thereof can be applied as the material of the conductor wire 1.

  The covering layer 2 is made of a metal or a metal compound having a larger electric resistance value than the conductor wire 1. Here, the electrical resistance value means the electrical resistance values of the conductor wire 1 and the coating layer 2 at 20 ° C.

  For example, when the conductor wire 1 is copper or a copper alloy, it is preferable that nickel or a nickel alloy is applied to the coating layer 2 in order to ensure insulation.

  Moreover, when the conductor strand 1 is copper or a copper alloy, the solder process to the edge part of the assembly conductor 10 can be performed favorably by applying tin or a tin alloy as a coating layer.

  Nickel or nickel alloy, tin or tin alloy, etc. can be formed on the outer periphery of the conductor wire 1 by plating, vapor deposition or the like.

  Moreover, when applying a metal compound as the coating layer 2, for example, an oxide of the conductor wire 1 can be applied as the coating layer. That is, when the conductor wire 1 is copper or a copper compound, the copper oxide film becomes the coating layer 2, and when the conductor wire 1 is aluminum or an aluminum alloy, the aluminum oxide film or the like becomes the coating layer 2. These oxide films can be formed by continuously passing the conductor wire 1 through an oxidizing atmosphere.

  In addition to the oxide film, a sulfide film, a nitride film, and the like can be applied to the coating layer 2, and the coating layer 2 can be formed by vapor deposition, chemical treatment, or the like.

  The layer thickness (film thickness) of the coating layer 2 is preferably, for example, about 0.01 to 10 μm, but varies depending on the forming method and type of the coating layer 2.

  Since the coating layer 2 can be formed thinner than a known insulating layer (insulating layer formed by dipping or electrodeposition), it is preferable in that the proportion of the conductor wire 1 in the aggregated conductor 10 can be increased.

  Moreover, it is preferable to provide the outermost layer of the conductor wire 3 with a binding layer that binds the adjacent conductor wires 3 together. Thereby, the conductor wires 3 can be integrated with each other through the binding layer.

  As the material of the binder, the fusion material is a resin having a heat fusion property such as polyvinyl butyral, polyamide, epoxy, or polyester, or alcohol fusion such as polyamide soluble in alcohol. And adhesives include EVA, acrylic, urethane, epoxy, chloroprene, cyanoacrylate, silicone, nitrile, PVC, and vinyl acetate resins. In addition, since the binder is comprised with the above resin, the insulation between each conductor strand 1 can also be improved.

  The layer thickness of the binder is 0.5 μm to 3 μm. In addition, the binding material may not be uniformly formed on the outermost periphery of the conductor wire 3 as long as each conductor wire 3 can be fixed in the collective conductor 10, and the portion where the binding material exists or does not exist unevenly. However, it is preferable to form a binder on the entire outermost surface of the conductor wire 3 from the viewpoint that the conductor wires 3 will not be scattered even if the assembly conductor 10 is processed (bending, twisting, etc.). .

  When pressure resistance is required for the outermost layer of the collective conductor 10, a tape having insulating properties such as polyimide, aramid, polyester, and nylon is wound around the surface of the collective conductor 10, or polyamide Resins such as imides, polyesterimides, polyesters, urethanes, acrylics, epoxies, polyimides, and polyvinyl formals may be dip coated.

  As shown in FIG. 2, the assembly conductor 10 having the above configuration is arranged in a plurality of layers (for example, four layers) inside each slot 30 b of the stator core 30 constituting the motor. According to this, it is possible to suppress the formation of a dead space inside the slot as in the case where a plurality of conductor wires 103 having a normal circular cross section are arranged (see FIG. 14).

  Here, the stator core 30 is formed in a cylindrical shape as a whole, and includes a plurality of protrusions 30a and recesses (slots 30b) formed alternately in the circumferential direction on the inner peripheral wall or outer peripheral wall thereof. In FIG. 2, the curved stator core 30 is schematically replaced with a flat surface, but the slot 30b has, for example, a bottom portion width of about 4 mm and an opening portion width of about 6 mm. Yes, the depth is about 30 mm.

  Next, an example of the manufacturing apparatus and the manufacturing method of the assembly conductor 10 having the above configuration will be described. Here, the collective conductor 10 is manufactured using the collective conductor manufacturing apparatus 50 shown in the top view of FIG. 3 and the side view of FIG.

  The assembly conductor manufacturing apparatus 50 includes a plurality of unwinding rolls 20, a first guide roll 21, a first die 22a, a binding treatment chamber 23, a second die 22b, a second guide roll 24, The winding roll 25 is provided so as to be connected in a row.

  Each of the unwinding rolls 20 is wound with a conductor wire 3 formed by covering the conductor element wire 1 with a coating layer 2 such as a nickel plating film. A binder is provided on the surface of the conductor wire 3 in advance.

  The first guide roll 21 is configured to guide the conductor wire 10 unwound from each unwinding roll 20 to the first dice 22a.

  As shown in FIG. 5, which is a cross-sectional view taken along the line VV of FIG. 3, the first die 22 a is configured by a cylindrical body having a rectangular cross section, and a plurality of conductor wires 3 supplied from each first guide roll 21. The arrangement is corrected and aligned in the width direction and the height direction.

  The binding processing chamber 23 is for binding the aligned conductor wires 3 to each other. Here, the binding processing chamber 23 in the case of using a heat-fusible bonding material as the binding material includes a heater for heating the aligned conductor wires 3. Further, the binding processing chamber 23 in the case of using a fusion material having an alcohol fusion property as the binder is provided with a coater for applying alcohol to the aligned conductor wires 3. Further, in the case where an adhesive is used as the binding material, the binding processing chamber 23 includes a coater for applying the adhesive to the aligned conductor wires 3 and a heater for drying (curing) the applied adhesive. I have.

  Similar to the first die 22a, the second die 22b is a correction jig for correcting the plurality of conductor wires 3 to be aligned in the width direction and the height direction. That is, the plurality of conductor wires 3 are bonded to each other by the first die 22a, the binding processing chamber 23, and the second die 22b to form a single collective conductor 10.

  The second guide roll 24 is configured to guide the collective conductor 10 supplied from the second die 22 b to the take-up roll 25. The take-up roll 25 takes up the collective conductor 10 guided by the second guide roll 24.

  Below, the manufacturing method of the assembly conductor 10 at the time of using the fusion | melting material which has heat sealing | fusion property as a binder is demonstrated.

  First, the surface of the conductor wire 1 having a rectangular cross section is subjected to, for example, nickel metal plating to form the conductor wire 3 having the coating layer 2 on the surface.

  Subsequently, a binder is provided on the surface of the conductor wire 3 by dip-coating an epoxy varnish. At this time, each of the conductor wires 3 coated with the binder is wound around a plurality of unwinding rolls 20.

  Furthermore, each unwinding roll 20 is set in the collective conductor manufacturing apparatus 50, the conductor wire 3 is unwound from each unwinding roll 20, and the first guide roll 21 is passed through, as shown in FIG. The conductor wire 3 is arranged in an aligned state inside the first die 22a and the second die 22b.

  Next, the binding processing chamber 23 is operated to heat the conductor wires 3 arranged in an aligned state. At this time, the adjacent conductor wires 3 are fused and integrated with each other, and the collective conductor 10 is obtained.

  Finally, the assembly conductor 10 is wound around the winding roll 25 via the second guide roll 24.

  As described above, the assembly conductor 10 can be manufactured.

  As described above, according to the collective conductor 10 of the present embodiment, each conductor wire 3 constituting the collective conductor 10 is a partial shape obtained by dividing the rectangular overall cross-sectional shape of the collective conductor 10 without a gap, that is, Since it has a rectangular cross section and the side surfaces of each conductor wire 3 are tightly bound via a binding material, the conductor space factor in the collective conductor 10 can be improved. In addition to this, since the conductor wires 3 constituting the assembly conductor 10 are bundled in a non-twisted state, the assembly conductor 10 itself does not form a local coil, thereby suppressing the generation of eddy currents. it can. Therefore, according to the collective conductor 10 of the present embodiment, the generation of eddy currents can be suppressed and the conductor space factor in the collective conductor 10 can be improved.

  Furthermore, since the assembly conductor 10 is formed by bundling a plurality of conductor wires 3 in a non-twisted state, the surface current can be increased by increasing the surface area of the conductor wire 1 in the assembly conductor 10. Furthermore, since the eddy currents cancel each other between the adjacent conductor wires 3, the AC resistance can be lowered and the current loss can be reduced. Therefore, when the collective conductor 10 is applied to a motor, the motor efficiency can be increased.

  In addition, in the collective conductor 10, since the coating layer 2 can be formed thinly by plating, vapor deposition, or the like, the conductor space factor in the collective conductor 10 and each conductor wire 3 is improved, and the motor efficiency is further increased. preferable.

  Furthermore, since the conductor conductors 3 are fixed to each other by the binder, the conductor assembly 3 can hold the conductor conductors 3 in an aligned state even by deformation such as bending. And since the assembly conductor 10 can be easily formed rather than forming directly from a single conductor wire, it can be adapted to coils of various shapes.

  Furthermore, since the potential difference between the adjacent conductor strands 1 is relatively small, each covering layer 2 is made of a metal such as nickel having a larger electrical resistance than the conductor strand 1 made of copper, for example. The insulation between the conductor strands 1 can be ensured sufficiently and sufficiently. Moreover, it is preferable at the point which can endure use conditions of comparatively high temperature.

  Furthermore, since each conductor wire 3 is bound by a binding material made of resin, the assembly conductor 10 can be released from the bound state by solvent treatment, heating, or the like. Moreover, since the collective conductor 10 is a rectangular wire having a rectangular cross section, it is easy to handle.

  As described above, the present invention can improve the conductor space factor in the collective conductor, and thus is useful as a coil conductor for a motor driven by an inverter.

It is a perspective view which shows the collective conductor of embodiment. It is sectional drawing which shows the state which has arrange | positioned the assembly conductor inside the slot of a stator core. It is a top view of the assembly conductor manufacturing apparatus which manufactures an assembly conductor. It is a side view of the assembly conductor manufacturing apparatus which manufactures an assembly conductor. FIG. 5 is a cross-sectional view of the first die along line VV in FIG. 4. It is sectional drawing which expands and shows the rectangular cross section of a conductor wire. It is sectional drawing which expands and shows the rectangular cross section of a conductor wire. It is sectional drawing which expands and shows the rectangular cross section of a conductor wire. It is sectional drawing which expands and shows the rectangular cross section of a conductor wire. It is sectional drawing which expands and shows the rectangular cross section of a conductor wire. It is sectional drawing which expands and shows the cross-section of a coating layer. It is sectional drawing which expands and shows the cross-section of a coating layer. It is sectional drawing which expands and shows the cross-section of a coating layer. It is sectional drawing which shows the state which has arrange | positioned the conductor wire which has a circular cross section inside the slot of a stator core.

Explanation of symbols

1 Conductor Wire 2 Covering Layer 3 Conductor Wire 5 Insulating Layer 6 Binding Layer 10 Collective Conductor

Claims (7)

Each is a collective conductor in which a plurality of conductor wires having a cross-section of a part of a shape obtained by dividing the overall cross-sectional shape are integrated in an untwisted state,
Each of the conductor wires includes a conductor wire and a coating layer made of a metal or a metal compound provided on the outer periphery of the conductor wire and having an electric resistance value larger than the electric resistance value of the conductor wire. An aggregate conductor characterized by that. In the collective conductor according to claim 1,
An assembly conductor comprising a binder layer on an outermost periphery of the conductor wire. In the collective conductor according to claim 1 or 2,
The conductor assembly is characterized in that a cross section of the conductor wire is formed in a rectangular shape. In the collective conductor as described in any one of Claims 1-3,
The conductor assembly is formed of copper or a copper alloy, and the covering layer is formed of nickel or a nickel alloy. In the collective conductor as described in any one of Claims 1-3,
The conductor assembly is formed of copper or a copper alloy, and the covering layer is formed of tin or a tin alloy. In the collective conductor as described in any one of Claims 1-3,
The conductor assembly is formed of a metal, and the covering layer is formed of an oxide of the conductor strand. In the assembly conductor as described in any one of Claims 1-6,
A collective conductor characterized by being used for a coil of a motor driven by an inverter.

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