JP2016085846A - Assembled conductor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an assembled conductor which is formed by bundling a plurality of element wires consisting of rectangular wires, does not cause buckling of the element wires in the bent inside or crack of insulating films in the bent outside during edge-wise bending, and suppresses eddy current loss.SOLUTION: An assembled conductor 10 integrates a plurality of copper element wires 3 by bundling the plurality of copper element wires 3 consisting of a conductor 1 made of copper materials and its surrounding insulating film 2 to form a copper element wire assembly 4 and by forming an outermost insulating film 6 surrounding the copper element wire assembly 4. In the copper element wire assembly 4, copper plates 5 are each disposed between the inner side face which is the bent inside in edge-wise bending, the outer side face which is the bent outside in edge-wise bending, and the outermost insulating film 6.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a collective conducting wire composed of a plurality of strands.

  The stator constituting the motor is formed of a stator core formed by laminating an annular yoke, a plurality of teeth projecting radially inward from the yoke, and a steel plate having a slot formed between adjacent teeth. The stator is formed by being wound between the teeth while the coil is inserted into the slot. The coil winding has an insulating coating formed around the conductors to insulate the conductors in the coil, and an insulator such as an insulating bobbin or insulating paper is disposed between the teeth and the coil. Thus, insulation between the core and the coil is achieved. Further, for example, in a distributed winding type winding form, interphase insulation between different-phase coils is achieved by an insulator such as insulating paper.

  For example, a conventional coil forming winding is made by dissolving a thermosetting enamel resin in a solvent and applying it to a thickness of several μm around a copper conductor, and heat-treating it to harden the coating layer. The winding is manufactured by forming the enamel film having a desired thickness by repeating the process. In general, an amidoimide resin, a urethane resin, an esterimide resin, a polyimide resin, an oxide film, or the like is used as a material for the enamel coating. In addition to the winding having a circular cross section, a rectangular wire capable of increasing the coil space factor is applied.

  By the way, for example, when applying the above-described circular winding or rectangular wire as a winding for a coil constituting a drive motor of a hybrid vehicle or an electric vehicle, for the purpose of further improving the coil space factor and improving torque. Although the cross-sectional area of the winding tends to increase, eddy current loss increases as the cross-sectional area increases.

  As a countermeasure against this eddy current loss, the conductor cross-section is divided into small cross sections, an insulation coating is formed around the small cross-section conductors to form small cross-section strands, and the bundle formed by bundling these strands Attention has been focused on the method of applying conducting wires.

  For example, in Patent Document 1, a plurality of conductor wires (element wires) covered with an insulating film are arranged in parallel to each other to form an aggregate conductor, and an insulating film formed by an extrusion molding method is formed on the outermost layer of the aggregate conductor. A provided collective conductor (collective conductor) is disclosed.

  By applying the collective conducting wire in this way, eddy current loss can be reduced as compared with the case of using a round wire or a flat wire. By the way, in order to further reduce the eddy current loss in the collective conducting wire, measures such as using an organic insulating coating such as an enamel coating or a high-resistance metal element wire are taken. However, the bonding between the strands is insufficient, and there is a problem that the strands on the inner side of the bending are buckled during the edgewise bending process, and the insulating coating on the outer side of the bending is cracked. Here, “edgewise bending” refers to a case where a plurality of rectangular wires are bundled to form a collective conductor having a rectangular cross section, and the short side of the collective conductor is taken as the inner diameter side. The coil formed by bending in this manner is called an edgewise coil.

JP 2010-55806 A

  The present invention has been made in view of the above problems, and relates to a collective conductor formed by bundling a plurality of rectangular wires, and the inner wires of the bending are buckled during edgewise bending. An object of the present invention is to provide a collective conducting wire in which eddy current loss is further suppressed without causing a problem that a crack occurs in an insulating coating on the outside of the bend.

  In order to achieve the above-mentioned object, the assembly conductor according to the present invention is a copper element assembly formed by bundling a plurality of copper elements composed of a copper material conductor and an insulating coating around the conductor. An assembly conductor in which an outermost insulating film is formed around the body and a plurality of copper strands are integrated, and the inside of the copper strand assembly is bent when edgewise bending is performed. Copper plates are respectively interposed between the inner side surface, the outer side surface serving as the outer side of bending, and the outermost insulating coating.

  The assembly conductor of the present invention is formed between a copper strand assembly formed by bundling a plurality of copper strands and an outermost insulating coating around the assembly, and more specifically, when the assembly conductor is edgewise bent. The copper plate is interposed between the inner side surface of the copper wire assembly that is the inner side of the bend and the outer side surface of the copper wire assembly that is the outer side of the bend and the outermost insulating coating. The copper plate can effectively suppress buckling that can occur during bending of the inner copper wire, and the outer copper plate can effectively suppress cracks that can occur in the insulating film of the outer copper wire. .

  In addition, of the copper wire assembly, the side surface that is the inner side of the bend and the side surface that is the outer side of the bend when edgewise bending is performed are the “edgewise surface”, and the side surface that is perpendicular to these side surfaces is wide. When referred to as a “flatwise surface”, it has been found that in an edgewise coil formed by edgewise bending the collective conducting wire, the flatwise surface is the main eddy current loss generation surface. According to the collective conducting wire of the present invention, the copper plate is interposed between the edgewise surfaces on the inner and outer sides of the bend and the outermost insulating coating, in other words, there is no copper plate on the flatwise surface, Since the copper plate exists only on the edgewise surface, the magnetic flux does not hit the flatwise surface, which is an eddy current loss generation surface, which leads to suppression of eddy current loss.

  Here, the copper plate used is a thin plate made of copper. In addition, the term “copper plate” in the present specification is meant to include a thin plate made of a copper material, a thin plate made of a copper alloy, and a thin plate made of a conductive metal similar to copper.

  The insulating film around the copper conductive wire is formed from copper oxide obtained by oxidizing copper, or is formed from an insulating resin material such as enamel.

  The copper strands may simply be in contact with each other and may not be coupled to each other, or may be coupled to each other with an insulating adhesive such as an epoxy resin.

  In addition, the outermost insulating coating around the copper wire assembly can be formed from, for example, a high heat resistant thermoplastic resin such as polyphenylene sulfide (PPS). Molded by the method.

  As can be understood from the above description, according to the collective conducting wire of the present invention, when the collective conducting wire is edgewise bent, the inner side surface of the copper wire assembly that becomes the inside of the bend and the copper that becomes the outside of the bend By interposing the copper plates between the outer side surface of the wire assembly and the outermost insulating coating, the inner copper plate effectively suppresses the buckling that can occur when bending the inner copper wires. The crack which the outer copper plate may produce in the insulating film of an outer copper strand can be suppressed effectively. In addition, there is no copper plate on the flatwise surface, and the presence of the copper plate only on the edgewise surface prevents the magnetic flux from hitting the flatwise surface, which is the eddy current loss generation surface. Eddy current loss that can occur in the assembly conductor can be effectively suppressed.

It is the schematic diagram which showed embodiment of the assembly conducting wire of this invention. It is the schematic diagram which showed the assembly conducting wire at the time of carrying out the edgewise bending process of the assembly conducting wire shown in FIG.

  Hereinafter, embodiments of the collective conducting wire of the present invention will be described with reference to the drawings. Needless to say, the number of wires constituting the assembly conducting wire is not limited to the illustrated example.

(Embodiment of collective conducting wire)
FIG. 1 is a schematic diagram showing an embodiment of the collective conducting wire of the present invention, and FIG. 2 is a schematic diagram showing the collective conducting wire when the collective conducting wire shown in FIG. 1 is edgewise bent.

  The structure of the collective conducting wire 10 shown will be described in order. First, eight copper strands 3 composed of a copper conductive wire 1 and a surrounding insulating coating 2 are used, and are arranged in a 2 × 4 arrangement to form a copper strand assembly 4. .

  The insulating coating 2 around the copper conductive wire 1 is formed of a metal having higher electrical resistance than copper, such as copper oxide or aluminum formed by oxidizing the conductive wire 1, or an insulating resin material such as enamel resin. The

  Each copper strand 3 is a rectangular wire having a rectangular cross section (more specifically, a substantially rectangular shape because the corner portion is slightly curved), and a set of copper strands formed of eight copper strands 3. Similarly, the body 4 has a substantially rectangular cross section.

  The copper strands 3 constituting the copper strand assembly 4 may be in contact with each other without being bonded, or may be bonded to each other with an insulating adhesive such as an epoxy resin. .

  As shown in FIG. 2, when the collective conducting wire 10 is edgewise bent, the side surface 10 a that is the inner side of the bending and the side surface 10 b that is the outer side of the bending are “edgewise surfaces”, The side surfaces 10c and 10d are “flatwise surfaces”. Returning to FIG. 1, a thin copper plate 5 is disposed on two side surfaces corresponding to the edgewise surface among the four side surfaces constituting the copper strand assembly 4, and the copper strand assembly 4 and the two copper plates 5 are arranged. By forming the outermost insulating coating 6 so as to surround it, the collective conducting wire 10 is formed.

  The copper plate 5 is a copper material plate, but a metal material plate having the same conductivity as copper is also included in the copper plate 5.

  The outermost insulating film 6 is a film that integrates the eight copper wires 3 and imparts heat resistance to the collective conducting wire 10. From this viewpoint of high heat resistance, polyphenylene sulfide (PPS) or polyether is used. It is preferable to apply a thermoplastic resin such as ether ketone (PEEK), polyimide (PI) or polyamideimide (PAI).

  The outermost insulating coating 6 can be formed by a method in which the outermost insulating coating 6 is formed by an extrusion molding method in which eight copper wires 3 and two copper plates that are disposed mutually are temporarily fixed, or by enamel baking. Molding is carried out by various molding methods such as the method of electrodeposition, electrodeposition coating, and vacuum deposition.

  The collective conducting wire 10 includes an inner side surface of the copper strand assembly 4 that becomes the inner side of the bending when the collective conducting wire 10 is edgewise bent, and an outer side surface and the outermost side of the copper strand assembly 4 that becomes the outer side of the bending. Since the thin copper plate 5 is interposed between the insulating coating 6 and the inner copper plate 5, the inner copper plate 5 effectively suppresses buckling that may occur during bending of the inner copper wire 3. 5 can effectively suppress cracks that may occur in the insulating coating 2 of the outer copper wire 3.

  Further, in the collective conductor 10, the copper plate 5 is not present on the flatwise surfaces 10c and 10d, and the copper plate 5 is present only on the edgewise surfaces 10a and 10b. As a result, magnetic flux is no longer applied to the flat-wise surface, which is the collective conducting wire 10 in which eddy current loss is effectively suppressed.

  A bare rectangular wire with a cross-section of 0.8mm x 0.8mm is oxidized in the atmosphere at 320 ° C for 10 minutes to form an insulating film made of copper oxide around the conductor wire to create a copper wire. A copper wire assembly is manufactured by bundling in a 2-row, 4-column arrangement, and a thin copper plate having a thickness of 0.3 mm and a width of 1.6 mm is disposed on two side surfaces on the edgewise side of the copper wire assembly. In the fixed state, polyphenylene sulfide was extruded around it by extrusion molding to produce an outermost insulating film having a thickness of 50 to 150 μm, and a collective conductor was produced.

  As a result of comparing the eddy current loss of the collective conducting wire thus manufactured and the rectangular wire of the same size, the eddy current loss of the collective conducting wire of the example can be reduced by 80% than that of the rectangular wire of the same size. Proven.

  This is considered to be due to the fact that the flat conductor is a collective conducting wire with a small section and that a thin copper plate is present on the side edge on the edgewise side.

  The embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and there are design changes and the like without departing from the gist of the present invention. They are also included in the present invention.

  DESCRIPTION OF SYMBOLS 1 ... Conductive wire, 2 ... Insulation coating, 3 ... Copper wire, 4 ... Copper wire assembly, 5 ... Copper plate, 6 ... Outermost insulation coating, 10 ... Collective conducting wire, 10a ... Edgewise surface (inner side surface of bending) 10b: Edgewise surface (bending outer surface), 10c, 10d ... Flatwise surface

Claims (1)

A copper wire assembly is formed by bundling a plurality of copper wires composed of a copper-based conductive wire and a surrounding insulating coating, and an outermost insulating coating is formed around the copper strand assembly. An assembly conductor in which copper strands are integrated,
A copper plate is interposed between the inner side surface that becomes the inner side of the bending and the outer side surface that becomes the outer side of the bending, and the outermost insulating film, in the copper wire assembly. Assembly wire.

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