JP2012209391A - Wiring component - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve such a problem that a compact wiring component having high reliability cannot be formed since a conventional lateral winding rectangular wire cannot be bent in the edgewise direction though a cross section area of a transformer coil can be enlarged by using a rectangular wire.SOLUTION: A rectangular insulated wire is used which is formed by heating and laterally winding a thin film insulation tape 10 formed of two layers of polyimide 11 and Teflon 12 around the outer periphery of a rectangular conductor 13 so as to be tightly adhered to each other. The rectangular insulated wire is bent in the edgewise direction to form a wiring component such as a bus bar and a bus ring.

Description

  The present invention relates to a wiring component formed by edgewise winding a flat insulated wire.

  Conventionally, as an insulated wire for coil winding, an enameled wire in which an insulating coating such as polyurethane resin or polyester resin is applied on a single wire conductor has been often used.

  However, there is a problem that pinholes occur in the enameled wire, and a serious problem occurs if the U phase and the V phase are short-circuited in the motor.

  Therefore, recently, as the insulated wires, linear copper conductors and aluminum conductors having a rectangular cross section are used. As the insulating materials, fiber materials such as kraft paper, amine-treated paper, aramid paper, polyimide (PI), etc. Horizontally wound rectangular wires obtained by winding an organic polymer film in a tape shape around a conductor are widely used (see, for example, Patent Document 1).

  Moreover, the cross-sectional area of the coil of a transformer can be enlarged by using a flat wire as an insulated wire.

JP 2001-67943 A

  However, since the conventional horizontal winding rectangular wire cannot be bent in the edgewise direction, it is impossible to form a small and highly reliable wiring component.

  In a horizontally wound rectangular wire using a fiber-based material as an insulating material, the size of a wiring component formed using the horizontally wound rectangular wire is increased depending on the thickness of the insulating paper.

  Further, a horizontal winding rectangular wire using polyimide as an insulating material can be bent in the flatwise direction, but will be wrinkled when bent in the edgewise direction. When a coil is formed by bending this horizontally wound flat wire in the edgewise direction, wrinkles are formed, and the thickness of the portion increases and the size of the formed coil increases. Moreover, since partial discharge occurs in the air layer where wrinkles are formed, the withstand voltage decreases.

  An object of the present invention is to provide a small and highly reliable wiring component formed by processing a flat insulated wire into edgewise winding in consideration of the above-described conventional problems.

In order to solve the above-described problem, the first aspect of the present invention provides:
A flat insulation wire wound in a horizontal winding so that the thin film insulating tape formed of two layers of polyimide and Teflon (registered trademark) is heated and adhered to the outer periphery of the flat conductor is wound edgewise. Wiring parts.

The second aspect of the present invention
The flat rectangular insulated wire is the wiring component according to the first aspect of the present invention, wound so that a width of 1/2 or more of the insulating tape overlaps.

  According to the present invention, it is possible to provide a small and highly reliable wiring component formed by processing a flat insulating wire into edgewise winding.

Schematic sectional view of an insulating film according to an embodiment of the present invention The figure explaining the creation method of the flat insulated wire of embodiment of this invention (A), (b) The cross-sectional schematic diagram of the flat-surface insulated wire surface part of embodiment of this invention The perspective view of the coil component formed with the flat insulated wire of embodiment of this invention The perspective view of the coil component formed with the flat insulated wire of embodiment of this invention The perspective view of the coil component formed with the flat insulated wire of embodiment of this invention

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

(Embodiment)
The flat insulated wire of the embodiment of the present invention is obtained by winding a tape-shaped insulating film around a flat copper wire in a horizontal winding.

  In FIG. 1, the schematic cross section of the insulating film 10 of this Embodiment is shown.

  The insulating film 10 of this embodiment has a two-layer structure in which a Teflon (registered trademark) layer is formed below a polyimide layer generally used as an insulating material.

  As shown in FIG. 1, the insulating film 10 has a polyimide layer 11 formed on a Teflon layer 12. For example, the thickness Tp of the polyimide layer 11 is 25 μm, and the thickness Tt of the Teflon layer 12 is 12. The insulating film 10 thickness Tf is 37.5 μm.

  FIG. 2 is a diagram illustrating a method for creating a flat insulated wire according to the present embodiment. FIG. 2 shows a view as viewed toward the wide surface of the flat insulated wire.

  The insulating film 10 is wound around the flat copper wire 13 so as to overlap at least partially. FIG. 2 shows an example in which winding is performed so that the overlap width Wd is Wd = 1/4 Wf with respect to the width Wf of the insulating film 10.

  The insulating film 10 corresponds to an example of the insulating tape of the present invention, and the flat copper wire 13 corresponds to an example of the flat conductor of the present invention.

  When the insulating film 10 is wound around the flat copper wire 13, it is wound while being heated to about 300 ° C. By heating, the Teflon layer 12 melts and adheres to the surface of the flat copper wire 13 and also adheres to the portion of the polyimide layer 11 to be overlaid.

  Instead of heating when the insulating film 10 is wound, the insulating film 10 may be wound around the flat copper wire 13 and then heated to be in close contact.

  In the case of horizontal winding using a general polyimide film, an adhesive is used for bonding to the flat copper wire 13, but in the insulating film 10 of the present embodiment, the Teflon layer 12 is heated and melted. Since it adheres to the flat copper wire 13, it is not necessary to use an adhesive.

  3A and 3B show the AA cross section in FIG. 2 of the surface portion of the flat insulated wire of the present embodiment. FIG. 3A shows a cross section when the overlap width Wd is wound so that Wd = 1/4 Wf, that is, a cross section when wound as shown in FIG. FIG. 3B shows a cross section when wound so that Wd = 1/2 Wf.

  As shown in FIG. 3A, the insulating film 10 to be wound next is wound so that at least a part of the insulating film 10 overlaps, so that the Teflon layer 12 and the polyimide layer 11 in the overlapping part are in close contact with each other. The surface of 13 can be insulated without a gap. Therefore, the insulating film 10 of the first embodiment may be so-called “choi wrap winding”.

  As shown in FIG. 3B, the Teflon layer 12 and the polyimide are wound over the entire flat copper wire 13 by winding the overlap width Wd so as to be 1/2 or more of the width Wf of the insulating film 10. In a state where the layer 11 is in close contact, the thickness becomes two sheets of the insulating film 10, and a more reliable insulating film is formed.

  In a flat insulation wire in which a conventional polyimide film is wound horizontally as an insulating material, when it is bent in the edgewise direction, wrinkles occur due to low adhesion at the overlapping portion of the film. In the film 10, the adhesiveness between the polyimide layer 11 and the Teflon layer 12 is high, and no wrinkle is produced even when bent in the edgewise direction.

  Therefore, it is possible to form a highly reliable and compact wiring component by using edge-wise winding using the flat insulated wire of the present embodiment.

  In addition, the thickness Tp of the polyimide layer 11 and the thickness Tt of the Teflon layer 12 described above are examples, and these thicknesses are not limited. By making the thickness of each layer the range of the thickness Tp = 7.5 to 75 μm of the polyimide layer 11 and the thickness Tt = 1 to 25 μm of the Teflon layer 12, the rectangular film in which the insulating film 10 is wound horizontally. The insulated wire can be bent in the edgewise direction without wrinkles.

  In the above description, the flat copper wire 13 is used as the conductor of the flat insulated wire. However, a flat insulated wire using another metal conductor such as an aluminum conductor may be used.

  4 to 6 respectively show perspective views of examples of wiring components formed using the flat insulated wires of the present embodiment.

  FIG. 4 shows a rectangular coil component (rectangular coil 20) in which the rectangular insulated wire of the present embodiment is edgewise wound, and FIG. 5 is a cylindrical coil component (cylindrical coil 21) in which edgewise winding is performed. ). FIG. 6 shows an alpha-wound coil component (alpha-wound coil 22).

  Since the flat insulation wire of this embodiment does not cause wrinkles even when edgewise winding is performed, as shown in FIGS. 4 to 6, the size in the direction in which the flat insulation wires overlap does not increase, and reliability is improved. High coil parts can be formed.

  In addition, when the direction to bend edgewise with respect to the flat insulation wire is only one direction, such as the rectangular coil 20, the cylindrical coil 21, and the alpha winding coil 22 shown in FIGS. It is preferable to work by bending only in the edgewise direction that can be more stably bent with respect to the oblique direction in which the insulating film 10 is wound around the copper wire 13.

  Further, in the case of a member having two directions of edgewise bending with respect to the rectangular insulated wire, the portion bent in the edgewise direction with respect to the oblique direction in which the insulating film 10 is wound around the rectangular copper wire 13 is What is necessary is just to process so that the bending direction of many may become the direction which can be bent more stably.

  Further, the rectangular insulated wire of the present embodiment can be applied to bus bars and bus rings having a portion bent in the edgewise direction besides these, and a highly reliable bus bar and bus ring can be formed. .

  As described above, the flat insulated wire of this embodiment does not generate wrinkles even when edgewise winding is performed. Therefore, by using the flat insulated wire of this embodiment, coils, bus bars, and buses processed into edgewise winding are used. Wiring parts such as rings can be formed.

  Therefore, by using the wiring component of the present invention, the thickness of the component can be reduced, so that the mounting space can be saved, and the drive motor can be reduced in size and increased in output.

  Since the wiring component according to the present invention is formed by a rectangular insulating wire that does not cause wrinkles even when bent in the edgewise direction, the wiring component is small and highly reliable. Therefore, the wiring is formed by winding the rectangular insulating wire edgewise. Useful as parts.

DESCRIPTION OF SYMBOLS 10 Insulation film 11 Polyimide layer 12 Teflon layer 13 Flat copper wire 20 Rectangular coil 21 Cylindrical coil 22 Alpha winding coil

Claims (2)

  A flat insulating wire wound in a horizontal winding so that the thin film insulating tape formed of two layers of polyimide and Teflon (registered trademark) is heated and adhered to the outer periphery of the flat rectangular conductor is edgewise wound. Wiring parts.   The wiring component according to claim 1, wherein the flat insulated wire is wound so that a width of ½ or more of the insulating tape overlaps.

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