JP2016126992A - Coil conductor wire and coil wire - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a conductor wire for coil capable of reducing an eddy current loss and obtaining a high space factor, and excellent in productivity, and to provide an electric wire for coil.SOLUTION: A conductor wire for coil comprises a plurality of conductor strands and a high resistance layer which sections each conductor strand in a state where the plurality of the conductor strands are integrally held. Among the plurality of the conductor strands, at least some of the conductor strands are subjected to X-ray diffraction in cross section. When the total sum of diffraction intensities of a (111) plane, a (200) plane, a (220) plane, a (311) plane, a (222) plane, and a (400) plane is S, and the ratio of the diffraction intensity I(200) of the (200) plane to the total sum S is I(200)/S, the I(200)/S satisfies 0.2 or more, and the high resistance layer includes a high conductive material of which the electric resistance is higher than that of a metal constituting the conductor strands.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a conductor wire and an electric wire used for a coil. In particular, the present invention relates to a coil conductor wire and a coil electric wire that can reduce eddy current loss and provide a coil with a high space factor, which is excellent in manufacturability.

  Conventionally, coil parts such as a motor, a transformer, and a reactor are used in various fields. An electric wire called an enameled wire is widely used for the coil provided in the coil component. An enameled wire is generally an electric wire including a linear conductor such as a copper wire and an insulating layer made of enamel (resin) provided on the outer periphery of the conductor. The coil is formed by winding such an electric wire in a spiral shape or a spiral shape. The insulating layer is peeled off at the end of the electric wire forming the coil, and a connecting member such as a terminal fitting is connected to the exposed conductor portion.

  As an electric wire used for a coil, there is a litz wire in which ultra-fine wires such as a plurality of ultra-fine enamel wires are bundled together with an insulating material (for example, Patent Document 1). In the litz wire, the conductors of adjacent electric wires are electrically separated by an insulating layer. In other words, a litz wire having a plurality of divided conductors with a single conductor subdivided is a coil having a single conductor that is not subdivided and having the same conductor cross-sectional area. In this case, eddy current loss generated in the coil can be reduced.

JP 2010-153069 A

  In addition to reducing eddy current loss, it is desired to develop a wire that can provide a coil with a high space factor.

  The above-mentioned litz wire can reduce the eddy current loss and has a portion (insulating layer) through which no current flows, so the cross-sectional ratio of the portion (conductor) through which the current flows is low. Accordingly, in the litz wire, the outer dimension (for example, the outer diameter in the case of a round wire) is increased in order to ensure a predetermined conductor cross-sectional area. In particular, the outer dimension of a litz wire used for a coil for high current applications is larger. When the coil is formed of a litz wire having a large outer dimension, the ratio of the coil occupying the predetermined space, that is, the space factor becomes small. Therefore, it is difficult to increase the space factor of the coil with the conventional litz wire.

  Furthermore, in the above-mentioned litz wire, it is difficult to handle an extremely fine wire when bundling an extremely thin wire having a wire diameter of less than 1 mm, and the workability is poor. Further, when an insulating layer such as enamel is formed on an extremely fine copper wire, it is necessary to repeat a plurality of operations such as resin application and baking (heat treatment) so that the insulating layer has a predetermined thickness. From these points, improvement in manufacturability is desired.

  Therefore, a wire rod used for the coil is desired to be able to reduce eddy current loss, to have a high ratio of a region where current can flow, and to be excellent in manufacturability.

  The present invention has been made in view of the above circumstances, and one of its purposes is to reduce eddy current loss, to obtain a coil with a high space factor, and to be excellent in manufacturability. And it is providing the electric wire for coils.

  A coil conductor wire according to an aspect of the present invention includes a plurality of conductor strands and a high resistance layer that partitions the conductor strands while holding the plurality of conductor strands integrally. Among the plurality of conductor strands, at least some of the conductor strands are subjected to X-ray diffraction with respect to a cross-section, and (111) plane, (200) plane, (220) plane, (311) plane, (222) ) Plane, (400) plane, the sum of diffraction intensities is S, and the ratio of the (200) plane diffraction intensity I (200) to the total sum S is I (200) / S. S satisfies 0.2 or more. The high resistance layer includes a conductive material having an electric resistance higher than that of a metal constituting the conductor wire.

  The coil electric wire which concerns on 1 aspect of this invention is equipped with said conductor wire for coils, and the insulating layer provided in the outer periphery of the said conductor wire for coils.

  The above-described coil conductor wire and the above-described coil wire can reduce eddy current loss, obtain a coil with a high space factor, and are excellent in manufacturability.

It is a schematic diagram which shows an example of the conductor wire for coils and the electric wire for coils of embodiment, and process explanatory drawing explaining an example of the manufacturing method which can manufacture these. It is a schematic block diagram which shows an example of the conform extrusion apparatus utilized for an integration process in the manufacturing method which can manufacture the conductor wire for coils of embodiment. It is explanatory drawing explaining the measuring method of an eddy current loss about a round wire. It is explanatory drawing explaining the measuring method of an eddy current loss about a flat wire.

[Description of Embodiment of the Present Invention]
The inventors of the present invention have studied a configuration in which a plurality of wires such as litz wires are bundled so that eddy current loss can be reduced and the space factor of the coil is increased. As a result, the following knowledge was obtained.

  A plurality of strands serving as conductors are not electrical insulators such as enamel, but are materials that have higher electrical resistance than the constituent metals of the strands and have conductivity (hereinafter referred to as high-resistance conductive materials). In this case, it is possible to sufficiently secure a region where current can flow while reducing generation of eddy current. Depending on the composition of the above-described high-resistance conductive material, both the strands and the regions that divide the strands can be regions where current can sufficiently flow. For example, each element wire may be a copper wire, and the high resistance conductive material constituting the partitioning region may be a metal such as aluminum or aluminum alloy. If it is a collective wire provided with such a high resistance conductive material, the whole can be made into a conductor.

  Furthermore, the high-resistance conductive material can be adhered without cracking or falling off, although the material can be plastically processed as described above (the plastic deformation amount is small when plastic processing is performed). (Including materials), it is excellent in the productivity of the assembly wire for the following reason. For example, a coating layer made of a high-resistance conductive material is formed on a metal wire having a large diameter, a plurality of the obtained coated wire materials are prepared and bundled, and integrated using a specific extrusion as described later. Thus, it is possible to easily manufacture an aggregate wire in which conductor wires derived from metal strands are partitioned by a high-resistance conductive material derived from a coating layer. That is, operations such as formation and integration of the coating layer can be performed on a thick wire that is easy to handle.

  In particular, if conform extrusion described later is used for the integration of the above-described plurality of coated wires, there is no need for equipment and processes for heating the high-resistance conductive material to a temperature at which it can be joined. Conform extrusion is a cold work, but the plastic workability of the object to be extruded can be enhanced by the processing heat, so that it can be firmly and well integrated, and the raw material can be supplied continuously, making it long. Assembly wire can be manufactured. From these points, the aggregate wire can be mass-produced with high productivity by using the high resistance conductive material.

  Furthermore, the aggregate wire obtained by conform extrusion is excellent in mechanical properties (particularly elongation), and excellent in workability and workability when wound or bent in a spiral or spiral shape. Therefore, it can be said that it can be suitably used for a coil wire. And when the assembly wire obtained through conform extrusion was investigated, the conductor strand had a specific orientation structure | tissue.

  Based on the above knowledge, eddy current loss can be reduced, and a coil with a high space factor can be obtained. Furthermore, in addition to excellent coil formability, the wire itself for the coil is also excellent in manufacturability of the wire. It is proposed that the conductor strand is partitioned by a conductive material having a higher resistance than the conductor strand, and that the conductor strand has a specific orientation. Hereinafter, embodiments of the present invention will be listed and described.

  (1) A coil conductor wire according to an aspect of the present invention includes a plurality of conductor wires and a high-resistance layer that partitions each conductor wire in a state where the plurality of conductor wires are integrally held. Among the plurality of conductor strands, at least some of the conductor strands are subjected to X-ray diffraction with respect to the cross section, so that (111) plane, (200) plane, (220) plane, (311) plane, (222) ) Surface and (400) plane, the sum of the diffraction intensities is S, and the ratio of the diffraction intensity I (200) of the (200) plane to the sum S is I (200) / S. S satisfies 0.2 or more. The high resistance layer includes a conductive material having an electric resistance higher than that of the metal constituting the conductor strand.

The conductive material is a material having a semiconductor electrical conductivity, specifically, 1 × 10 ⁻¹⁰ S / cm or more.
-The electrical resistance is a volume resistivity (μΩ · cm).
The electric conductivity and volume resistivity are values specific to the material, and can be specified by examining the composition of the constituent material through component analysis and referring to known data.

  In the coil conductor wire, a high resistance layer is interposed between the conductor wires, and each conductor wire is electrically separated to some extent by the high resistance layer. Therefore, the above-mentioned coil conductor wire is an electric wire having one conductor that is not subdivided, and is compared with an electric wire having the same conductor cross-sectional area as the total cross-sectional area of the conductor wires provided in the coil conductor wire. Thus, the generation of eddy current can be reduced. Therefore, the coil conductor wire can reduce eddy current loss, and by using the coil conductor wire, an increase in AC loss can be suppressed and a low loss coil can be obtained.

  In addition, since the high resistance layer has electrical conductivity higher than that of the conductor wire, the above-described coil conductor wire including the high resistance layer has higher conductivity and lower electrical resistance than the litz wire. It can be said that it is a wire. In particular, when each conductor wire and the high resistance layer are integrated by metallurgical bonding, the interface resistance between the conductor wire and the high resistance layer is small. It can be said that the wire is excellent in conductivity. Therefore, typically, the coil conductor wire can be used entirely as a region through which current flows, and compared with a litz wire having the same conductor cross-sectional area as that of the coil conductor wire. Sizes such as dimensions and cross-sectional areas can be reduced. Therefore, if the coil wire is used, the number of turns can be increased as compared with the case where the litz wire is used, so that a coil having a high space factor can be obtained.

  Or compared with the litz wire of the same outer dimension, the ratio of the area | region where an electric current can flow is large in said coil conductor wire. Therefore, if the coil wire is used, the number of turns can be reduced as compared with the case where the litz wire is used, so that a small coil can be obtained. That is, the coil wire described above contributes to the miniaturization of the coil.

  Furthermore, the above-described coil conductor wire is excellent in coil formability and workability for the following reasons, and can be suitably used as a coil wire. As described above, as a result of metallurgical bonding of each conductor wire and the high resistance layer, the conductor wires are firmly integrated by the high resistance layer. Therefore, a plurality of conductor wires are separated when the coil conductor wire is wound into a spiral shape or a spiral shape to form a turn, bend, or connect a terminal fitting or the like to the end. It is united without any problems, and it can perform operations such as coil forming and processing before and after that. The coil conductor wire described above is excellent in coil moldability, workability, and the like because it includes a conductor wire having a specific structure in which the (200) plane is oriented. For example, in the case of a copper wire or a copper alloy wire, when the (200) plane is oriented, mechanical properties such as elongation and yield strength are excellent.

In addition, the coil conductor wire is excellent in manufacturability from the following points by utilizing conform extrusion as described above.
1. 1. No heating equipment is required to integrate multiple conductor wires. 2. A plurality of conductor strands can be firmly integrated. 3. A wire having a high elongation that improves mechanical properties, particularly coil formability is obtained. 4. Because of its excellent mechanical properties, the extruded material can be used as a conductor as it is. Unlike the case of using a general extrusion device that extrudes billets, long materials can be manufactured.

  (2) As an example of the coil conductor wire, when the ratio of the diffraction intensity I (220) of the (220) plane to the sum S is I (220) / S, the I (220) / S is 0. A form satisfying more than 0.01 is mentioned.

  The said form is excellent by mechanical characteristics, such as elongation and yield strength, by having the structure | tissue which both (200) plane and (220) plane orientated.

  (3) As an example of said coil conductor wire, the form whose at least one part conductor wire is a copper wire among said several conductor strands is mentioned.

  In the above embodiment, since the conductor strand includes a copper wire having high electrical conductivity and conductivity, preferably all the conductor strands are copper wires, so that the conductor cross-sectional area can be easily reduced, and the outside of the coil conductor wire can be reduced. The size can be reduced. Therefore, the said form is easy to obtain a coil with a higher space factor.

  (4) As an example of the coil conductor wire, the conductive material includes an aluminum alloy, nickel (Ni), copper oxide, aluminum (Al), tin (Sn), iron (Fe), nickel alloy, The form which is at least 1 sort (s) selected from a tin alloy, an iron alloy, an iron oxide, and the intermetallic compound containing copper and aluminum is mentioned.

  Among the listed materials, metals such as pure metals (Al, Ni, Sn, Fe), alloys, and intermetallic compounds, for example, have a sufficiently high electrical resistance compared to copper, but have a high resistance because they are excellent in conductivity. In the form in which the constituent material of the layer includes the metal, a coil having a high space factor can be obtained while reducing generation of eddy current. Further, since the metal is excellent in plastic workability, this form also has advantages such as excellent coil formability, easy conform extrusion, and excellent manufacturability.

  Among the listed materials, non-metals such as metal oxides tend to have higher electrical resistance than the above metals. In addition, the metal oxide can be easily formed and can be easily formed thin, and a sufficient proportion of the conductor wire in the coil conductor wire can be secured. Therefore, the form in which the constituent material of the high resistance layer contains the metal oxide can further reduce eddy current loss, and can easily obtain a coil having a higher space factor, and is excellent in manufacturability.

  (5) As an example of said coil conductor wire, the form whose average crystal grain diameter of at least one part conductor wire is 30 micrometers or less among said several conductor strands is mentioned.

  Since the said form contains the conductor strand which has a fine crystal structure whose average crystal grain diameter is 30 micrometers or less, Since all the conductor strands preferably have such a fine crystal structure, it is especially excellent in elongation. Therefore, the said form is excellent in coil moldability, workability, etc., and can be suitably utilized for the wire for coils.

  (6) As an example of said coil conductor wire, the form in which the said high resistance layer surrounds the circumference | surroundings of each said conductor strand is mentioned.

  Since the high resistance layer exists around each conductor strand, the said form can partition more reliably each conductor strand, and it is easier to reduce generation | occurrence | production of an eddy current. Moreover, the said form can be easily manufactured by integrating the several covering wire material provided with the coating layer which consists of a high resistance conductive material in the outer periphery of a metal strand by conform extrusion, for example, and also a covering wire itself is easy Therefore, it is excellent in manufacturability.

  (7) As an example of the above-described coil conductor wire, a form including a twisted portion in which the plurality of conductor strands are twisted may be mentioned.

  It can be said that the said form was manufactured by twisting in the manufacturing process (the part twisted in the manufacturing process finally becomes a twisted part). Here, when integrating a plurality of wire rods by conform extrusion, it is easy to handle these wire rods in advance and to supply them to the conform extrusion device. As a result, the manufacturability of the coil conductor wire can be improved. Therefore, the said form which has a twist part is excellent in manufacturability. However, since it can be said that a twist part is a local coil, it is preferable that there are as few as possible. In other words, it is preferable that the pitch of the twisted portion is long.

  (8) A coil wire according to an aspect of the present invention is the coil conductor wire according to any one of (1) to (7) above, and an insulating layer provided on the outer periphery of the coil conductor wire. With.

  The coil electric wire uses a coil conductor wire having the above-mentioned specific orientation and a specific high-resistance layer as a conductor, so that it can be used for a coil to reduce eddy current loss and Improves the space factor and excels in manufacturability. Moreover, since the said coil electric wire is equipped with an insulating layer, when it uses for a coil, the insulation between turns and the insulation of a coil and its surrounding components are securable.

[Details of the embodiment of the present invention]
Hereinafter, a coil conductor wire, a coil wire, and a manufacturing method thereof according to an embodiment of the present invention will be described in more detail with reference to the drawings as appropriate.

-Coil conductor wire The coil conductor wire 1 which concerns on embodiment is provided with the some conductor strand 10, ..., and the high resistance layer 20, as shown in FIG. The conductor wire 10 is made of metal and mainly functions as a conductor. The high resistance layer 20 has a function of integrally holding the plurality of conductor wires 10. The high resistance layer 20 includes a material having a higher electrical resistance than the constituent metal of the conductor wire 10. From this point, the high resistance layer 20 also functions as a partition member that electrically separates the plurality of conductor strands 10 to some extent. Furthermore, the material of the high resistance layer 20 has conductivity. From this point, the high resistance layer 20 also functions as a region where current can flow. The outer shape, sectional shape, size, number, etc. of the conductor wire 10 such as the outer shape, sectional shape, size, etc. of the conductor wire 1 shown in FIG.

..Outline Examples of the outer shape of the coil conductor wire 1 include a circular wire having a circular cross section (conductor wire 1A), a rectangular wire having a rectangular cross section (conductor wire 1B), and the like. Other cross-sectional shapes include polygons such as hexagons and irregular shapes such as ellipses. The round wire (conductor wire 1A) is excellent in coil moldability and easy to manufacture a coil. The rectangular wire (conductor wire 1B) is easy to obtain a coil having a higher space factor than the round wire. In particular, a wide rectangular wire is more likely to generate eddy currents because magnetic flux easily passes than a round wire having the same cross-sectional area. From this point, the conductor wire 1B has a great effect of reducing eddy current loss. Be expected.

.. Size The cross-sectional area of the coil conductor wire 1 can be selected as appropriate according to the application. The smaller the coil, the easier it is to obtain a coil with less eddy current. For example, the cross-sectional area is about 0.005 mm ² or more and 500 mm ² or less, and further about 0.5 mm ² or more and 50 mm ² or less. For example, in the case of a round wire (conductor wire 1A), a diameter of about 0.1 mmφ (100 μmφ) or more and about 5 mmφ or less can be mentioned. For example, in the flat wire (conductor wire 1B), the length (width or thickness) of one side is about 0.5 mm (500 μm) or more and about 15 mm or less.

.. Content of conductor strands The higher the total area ratio of the conductor strands 10 in the coil conductor wire 1, the more preferably a region where current can sufficiently flow can be secured, and a coil with a high space factor can be easily obtained. The total area ratio is preferably 65 area% or more, more preferably 70 area% or more, 75 area% or more, further 80 area% or more, particularly 90 area% or more in the cross section of the conductor wire 1.

  As the number of conductor wires 10 in the coil conductor wire 1 is increased, the number of conductor wires 10 is reduced. Therefore, the generation of eddy currents can be reduced, which is preferable. For example, the number is 4 or more, and further 9 or more.

.. Arrangement state of conductor wire and high resistance layer The high resistance layer 20 is intended to electrically isolate the conductor wire 10 to some extent as described above. It has the part 22 and is arrange | positioned so that the conductor strands 10 may not contact. Typically, as shown in the coil conductor wire 1 of FIG. 1, the high resistance layer 20 exists in a mesh shape so as to surround the outer periphery of each conductor wire 10. This configuration is preferable because each conductor wire 10 is surely separated by the high resistance layer 20, so that generation of eddy currents can be easily reduced. In addition, at least some of the plurality of conductor wires 10 are not covered by the high resistance layer 20 at all of the conductor wires 10, some are in contact with the high resistance layer 20, and other portions are high resistance. The form which does not contact the layer 20 is mentioned. In this embodiment, for example, the high resistance layer 20 exists in a cross shape or a lattice shape, and a part of the outer peripheral surface of each conductor element wire 10 located on the outermost side constitutes the outer peripheral surface of the conductor wire 1.

.. Twisted portion As an example of the coil conductor wire 1, a form including a twisted portion (not shown) in which a plurality of conductor strands 10 are twisted is mentioned. The twisted portion is a position of the above-mentioned position when a position in one cross section is different from a position in another cross section when one conductor strand 10 is viewed in the longitudinal direction of the conductor wire 1. The switching part. The circular conductor wire 1A shown in FIG. 1 will be described as an example. When the conductor wire 10 located at the upper left in the cross section shown in FIG. 1 is located at the lower right in another cross section, both the cross sections shown in FIG. It can be said that the position of the conductor wire 10 is switched between the two. This switching portion is a twisted portion. It is preferable that the number of twisted portions is small in order to reduce loss. That is, it is preferable that the pitch of the twisted portion is longer. The twisted portion is a trace of the wire being twisted in the manufacturing process as described above, and the pitch of the twisted portion in the conductor wire 1 is affected by the twist (twisting pitch) in the manufacturing process. Typically, the pitch of the twisted portion tends to be longer than the twist pitch in the manufacturing process. This is because the twist pitch in the manufacturing process is extended by undergoing plastic processing such as conform extrusion.

.. Mechanical characteristics Since the coil conductor wire 1 is wound in a spiral shape or a spiral shape and used for a coil, it is desired to have excellent plastic workability. Therefore, an example of the conductor wire 1 is a form in which the breaking elongation at room temperature (hereinafter sometimes simply referred to as elongation) satisfies 30% or more. Alternatively, as an example of the conductor wire 1, a form in which a 0.2% proof stress at room temperature (hereinafter sometimes simply referred to as proof stress) satisfies 80 MPa or more is given. If the elongation is 30% or more or the proof stress is 80 MPa or more, the processability such as coil formability and bending is excellent. The higher the elongation, the better the coil formability, etc., so 35% or more, further 40% or more can be mentioned. If the proof stress is 90 MPa or more, it is more excellent in workability. Depending on the constituent material of the conductor wire 10 and the constituent material of the high resistance layer 20, a form with higher elongation and yield strength can be mentioned.

.. Conductor strand ... Constituent material The constituent metal of the conductor strand 10 includes, for example, one selected from copper (pure copper), copper alloy, aluminum (pure aluminum), and aluminum alloy. These metals generally have high electrical conductivity (S / cm) and electrical conductivity (% IACS). Therefore, the conductor wire for coil 1 including at least one kind of wire material of copper wire, copper alloy wire, aluminum wire, and aluminum alloy wire as the conductor wire 10 has high conductivity as a whole, Easy to reduce the area. As a result, the outer dimension and cross-sectional area of the conductor wire 1 can be reduced (the conductor wire 1 can be made thinner), and a coil with a high space factor can be easily formed. In particular, if at least some of the plurality of conductor wires 10 are copper wires, preferably all are copper wires, it is easy to obtain a coil with excellent conductivity and a higher space factor. Since the electrical resistance is low, Joule loss can be reduced. If at least a part of the plurality of conductor wires 10 is a copper alloy wire, an aluminum wire, or an aluminum alloy wire, since the conductivity is inferior to copper, the generation of eddy currents can be easily reduced.

  A configuration in which the constituent metals of the conductor strands 10 included in the coil conductor wire 1 are the same type (for example, a configuration in which all the conductor strands 10 are copper wires), and a configuration including conductor strands 10 having different constituent metals ( For example, it may be a form including a copper wire and a copper alloy wire. If the constituent metals of all the conductor wires 10 in the conductor wire 1 are of the same type, the conductor wire 1 can be easily prepared from the point that it is easy to prepare a metal wire 100 as a raw material and to be uniformly deformed at the manufacturing stage. Excellent manufacturability. Depending on the composition of the constituent metals, it is possible to further obtain an effect that it is easy to obtain a coil with a high space factor, that it is easily deformed uniformly and is excellent in coil formability. On the other hand, in the case where the conductor wire 1 includes the conductor strands 10 made of a plurality of types of constituent metals, the electrical resistivity of each conductor strand 10 is different and may include the high-resistance conductor strand 10, so eddy current loss Is easy to reduce. In this case, the constituent material of the high resistance layer 20 is a material having an electric resistance higher than that of the conductor wire 10 made of a metal having the highest electric resistance.

  The constituent metal and the number of each conductor wire 10 and the constituent material of the high resistance layer 20 described later substantially maintain the raw materials (metal strand 100, high resistance material 200, etc.) prepared in the manufacturing process. Therefore, the composition and number of the metal strands 100 to be prepared and the composition of the high resistance material 200 may be selected so that the conductor wires 10 and the high resistance layer 20 have a desired composition and number.

... External shape Each conductor strand 10 with which the conductor wire 1 for coils can take various external shapes. This is because plastic deformation can occur during the manufacturing process. For example, when the round metal wire 100 is used in the manufacturing process, in the round coil conductor wire 1A, the outer peripheral side region of each conductor wire 10 positioned on the outermost side is a curved surface along the round wire. In the flat wire coil conductor 1B, each conductor wire 10 tends to be rectangular like a flat wire.

... Size The smaller the cross-sectional area of each conductor wire 10 provided in the coil conductor wire 1, the more preferable it is to suppress the generation of eddy currents. For example, the cross-sectional area is about 0.05 mm ² or more and 1 mm ² or less, and further about 0.1 mm ² or more and 0.5 mm ² or less. Even if the cross-sectional area of each conductor wire 10 is small, the conductivity is excellent if the total area ratio is high as described above. A typical example is a form in which the cross-sectional areas of the respective conductor wires 10 are substantially the same. Depending on the size or the like of the metal strand 100 prepared in the manufacturing process, the conductor strand 10 having a different cross-sectional area may be included.

... Structure The coil conductor wire 1 includes a conductor wire 10 having a specific orientation. Specifically, when X-ray diffraction is performed on the cross section of the conductor wire 1, the (200) plane of the crystal is oriented. Specifically, diffraction intensity of (111) plane, diffraction intensity of (200) plane, diffraction intensity of (220) plane, diffraction intensity of (311) plane, diffraction intensity of (222) plane, and (400) plane Taking the diffraction intensity, let S be the sum of these diffraction intensities. Further, the diffraction intensity of the (200) plane is I (200), and the ratio of the diffraction intensity I (200) to the total diffraction intensity S is I (200) / S. The conductor wire 1 includes a conductor wire 10 that satisfies I (200) / S of 0.2 or more.

  As described above, the conductor wire 10 composed of the metal with the (200) plane oriented tends to be excellent in mechanical properties such as elongation and yield strength. Specifically, the elongation satisfies 30% or more, or the proof stress satisfies 80 MPa or more. The coil conductor wire 1 including such a conductor wire 10 can also satisfy an elongation of 30% or more, a proof stress of 80 MPa or more, excellent coil formability, workability, and the like, and a coil wire. It is suitable for. As an example of the conductor wire 1, a form in which a part of the plurality of conductor wires 10 has the above-described specific orientation and the other part does not satisfy the above-described orientation. However, in consideration of mechanical characteristics and the like, it is preferable that all of the plurality of conductor strands 10 included in the conductor wire 1 satisfy the above-described orientation.

  Further, when the diffraction intensity of the (220) plane is I (220) and the ratio of the diffraction intensity I (220) to the total diffraction intensity S is I (220) / S, the coil conductor wire 1 is I (220). 200) / S satisfies 0.2 or more and I (220) / S includes a conductor wire 10 that exceeds 0.01. The conductor strand 10 composed of a metal in which both the (200) plane and the (220) plane are oriented tends to be more excellent in mechanical properties such as elongation and yield strength. The form is more suitable for the coil wire.

  The more the (200) plane and (220) plane are oriented, that is, the larger I (200) / S and I (220) / S are, the better the mechanical properties such as elongation and proof stress are. There is no particular upper limit. I (200) / S is preferably 0.25 or more, more preferably more than 0.28, and I (220) / S is preferably 0.02 or more, more preferably 0.03 or more.

  As an example of the coil conductor wire 1, a form including a conductor wire 10 having a fine crystal structure can be given. Specifically, the form containing the conductor strand 10 whose average crystal grain diameter is 30 micrometers or less is mentioned. The conductor wire 10 having such a fine structure is as follows. 1. Excellent elongation and yield strength, for example, the elongation satisfies 30% or more, or the yield strength satisfies 80 MPa or more. There is a tendency to increase the terminal fixing force. From these points, the coil conductor wire 1 including the conductor wire 10 having the above-described fine structure is excellent in coil formability, workability, characteristics when using the coil, and the like, and can be suitably used as a coil wire. As an example of the conductor wire 1, some of the plurality of conductor wires 10 are made of a metal having the above-described microstructure, and the other portion is made of a metal not having the above-mentioned microstructure. Form. However, considering the coil application as described above, it is preferable that all of the plurality of conductor strands 10 included in the conductor wire 1 are made of the metal having the above-described microstructure.

  The finer the crystal, that is, the smaller the above-mentioned average crystal grain size, the better the properties such as elongation, yield strength and terminal fixing force, and no lower limit is particularly provided. The average crystal grain size is preferably 25 μm or less, more preferably 20 μm or less, and further preferably 18 μm or less. Details of the method of measuring the average crystal grain size will be described later.

..High resistance layer: the constituent material The constituent material of the high resistance layer 20 includes a conductive material (high resistance conductive material) having a higher electrical resistance than that of the constituent metal of the conductor wire 10. . If the constituent material of the high resistance layer 20 is only an electrical insulator such as enamel, the ratio of the area (electrical insulator) where current does not flow in the coil conductor wire 1 is high, and the ratio of the area where current can flow is Lower. As a result, the outer dimension of the conductor wire 1 is increased, and the space factor of the coil is reduced. In the case where the entire constituent material of the high resistance layer 20 is a high resistance conductive material, the ratio of the region through which current can flow can be sufficiently increased, and such a conductor wire 1 makes it easy to obtain a coil with a high space factor.

As a specific example of the high resistance conductive material, for example, if it is an inorganic material, a metal such as aluminum, nickel, tin, iron, aluminum alloy, nickel alloy, tin alloy, iron alloy, and an intermetallic compound containing copper and aluminum, Non-metals such as copper oxide (eg, copper (I) oxide: Cu ₂ O), iron oxide (eg, triiron tetroxide: Fe ₃ O ₄ ), and the like can be given. The intermetallic compound containing copper and aluminum is, for example, when the conductor wire 10 is a copper wire and the high resistance layer 20 made of aluminum or an alloy thereof is provided on the outer periphery of the copper wire, at the interface between the two in the manufacturing process. Includes generated ones. In the case of an organic material, examples of the high resistance conductive material include a conductive polymer (however, a material that can be subjected to conform extrusion described later). Table 1 shows typical values of volume resistivity (specific resistance, μΩ · cm) of each material.

  If the high-resistance conductive material is the metal described above, for example, when the conductor wire 10 is a copper wire, the electrical resistance is sufficiently higher than that of the conductor wire 10 (copper) and the conductivity is sufficiently high. . Therefore, when the high resistance layer 20 contains the above metal, it has a sufficient area where current can flow as compared with the litz wire while reducing the generation of eddy current to some extent, so that a coil with a high space factor can be obtained. easy. Further, when the high resistance layer 20 includes the above metal, the above metal is excellent in plastic workability, so that it is excellent in coil moldability, workability, and the like, and can be suitably used as a coil wire. Furthermore, when the above-mentioned metal is used as a raw material in the production of the high resistance layer 20, the above-mentioned metal is excellent in plastic workability. 1. The coating layer 210 can be easily formed. 2. Good plastic working such as conform extrusion, wire drawing and rolling; Since the plurality of conductor strands 10 can be satisfactorily integrated by conform extrusion, it is excellent in manufacturability of the coil conductor wire 1. In addition, when the high-resistance conductive material is a magnetic material such as nickel, iron, or an alloy thereof, reduction of eddy current loss generated in the conductor wire 10 due to an alternating magnetic field around the coil can be expected. The alternating magnetic field is generated by a leakage magnetic flux from another electric wire arranged close to the coil or a magnetic core where the coil is arranged.

  If the high-resistance conductive material is the above-described non-metallic inorganic material, the electrical resistance is higher although the conductivity is inferior to that of the above-described metal. Further, when the high resistance layer 20 is manufactured, the high resistance layer 20 can be easily manufactured by using the covered wire 110 obtained by oxidizing the metal strand 100 or the like. Furthermore, it is easy to form the coating layer 210 very thin by oxidation treatment. As a result, the high resistance layer 20 present in the coil conductor wire 1 is also very thin (for example, the thickness is less than 10 μm, 5 μm or less, and further 1 μm or less), and the ratio of the conductor wire 10 in the conductor wire 1 can be easily increased. Therefore, when the high resistance layer 20 includes the metal oxide, generation of eddy current can be further reduced, and a coil having a higher space factor can be easily obtained, and the manufacturability of the conductor wire 1 is excellent.

  If the high-resistance conductive material is an organic material such as a conductive polymer, the electrical resistance is higher although the conductivity is inferior to that of the metal described above. Therefore, when the high resistance layer 20 includes the organic material, generation of eddy current can be further reduced.

... Thickness of the interposition part The high resistance layer 20 may be thin as long as the conductor wire 10 can be partitioned. Further, the thickness may not be uniform. For example, the minimum thickness of the interposition part 22 is about 0.01 μm to 100 μm, further about 0.01 μm to 10 μm, and further about 1 μm.

.. Other inclusions In addition to the plurality of conductor wires 10 and the high-resistance layer 20, the coil conductor wire 1 includes an electrical insulator (for example, copper (II) oxide: CuO, iron monoxide: FeO, trioxide) Diiron: Fe ₂ O ₃ etc.). The electrical insulator is formed in a layered form on the outer periphery of the conductor wire 10 (directly above, or an intermediate layer of the high resistance layer 20 or an outer layer of the high resistance layer 20), or is granular in the high resistance layer 20. The form which exists in dispersion | distribution is mentioned. For example, when an electrical insulator is provided in a layered manner on the outer periphery of the conductor wire 10, the conductor wire 10 can be electrically separated, and generation of eddy current can be effectively reduced. However, since the inclusion of the electrical insulator causes a decrease in the region where current can flow, the content of the electrical insulator is preferably 10 area% or less, more preferably 5 area% or less in the cross section of the conductor wire 1.

-Coil electric wire The coil electric wire 2 which concerns on embodiment uses the above-mentioned coil conductor wire 1 as a conductor, and is equipped with the insulating layer 30 on the outer periphery of this conductor. Examples of the outer shape of the electric wire 2 include a round wire having a circular cross section (electric wire 2A) and a rectangular wire having a rectangular cross section (electric wire 2B). The above-described conductor wire 1 can be used for a coil as it is, but when the electric wire 2 including the insulating layer 30 is used for the coil, the insulating layer 30 provides insulation between the turns of the coil, and the coil and surrounding components arranged in the vicinity of the coil. And insulation can be achieved. The specifications (composition, structure (orientation / crystal grain size, etc. of conductor wire 10), shape, size, etc.) of the conductor wire 1 provided in the electric wire 2 are substantially the same as the specification of the conductor wire 1 before the insulating layer 30 is formed. To maintain.

..Insulating layer The constituent material of the insulating layer 30 is a resin. Specific examples of the resin include polyimide, polyamideimide, polyesterimide, polyetherimide, H-type polyester, polyolefin, polyamide, polyethersulfone, polyphenylene sulfide, polyetheretherketone, and polytetrafluoroethylene. Other resins can also be applied. The insulating layer 30 may have either a single layer structure or a multilayer structure. The insulating layer 30 is typically formed in a uniform thickness over the circumferential direction and the longitudinal direction of the coil conductor wire 1. As for the thickness of the insulating layer 30, about 10 micrometers or more and 150 micrometers or less are mentioned, for example.

.. Other layers A lubricating layer can be provided as the outermost layer of the insulating layer 30 or on the outer periphery of the insulating layer 30. By having the lubrication layer, it is possible to improve the coil formability and the insertability when the obtained coil is accommodated in a slot or a case. The lubricating layer is, for example, a form composed of surface lubricating oil applied to the outer periphery of the insulating layer 30, a resin in which the outermost layer of the insulating layer 30 has lubricity, for example, a resin blended with additives such as a lubricity improver The form formed by etc. is mentioned. As an example of the constituent material of the lubricating layer, an amidoimide resin to which paraffin or wax is added may be mentioned.

  An adhesion layer may be provided as the innermost layer of the insulating layer 30 or between the coil conductor wire 1 and the insulating layer 30. By having the adhesion layer, the adhesion between the conductor wire 1 and the insulating layer 30 can be improved. The adhesion layer can be formed of a resin containing an additive such as an adhesion improver. As an example of the adhesion improver, mercaptans, particularly 2-mercaptoimidazole and 5-amino-1,3,4-thiadiazole-2-thiol have a high adhesion effect.

Coil conductor wire manufacturing method / coil wire manufacturing method The coil conductor wire 1 described above includes, for example, a coil conductor wire manufacturing method including the following preparation process, covering process, and integration process. Can be manufactured.
Preparation step Step of preparing a plurality of metal wires Covering step A coating layer made of a conductive material having a higher electrical resistance than the metal constituting the metal strands is formed on the outer periphery of each metal strand. The step of preparing the coated wire material of the integration step of integrating the plurality of coated wire materials by means of conform extrusion while bundling the plurality of coated wire materials, or the step of producing the aggregated wire material, The plurality of metal strands and the plurality of covered wires are bundled and integrated by conform extrusion so as to be partitioned from each other by the covered wire, and the assembly wire can be produced.

As another manufacturing method, the manufacturing method of the conductor wire for coils provided with the following strand preparation processes and a strand integration process is mentioned, for example.
Wire preparation step A step of preparing a plurality of metal wires and a plurality of high resistance wires made of a conductive material having an electric resistance higher than that of the metal constituting the metal wires. A process of producing a collective wire by integrating the metal wires in a bundled state so as to be partitioned by the plurality of high resistance wires by conform extrusion

  In the above-described method for manufacturing a coil conductor wire, it is possible to extrude at the same time in a state in which a covered wire is bundled, a state in which a metal wire and a covered wire are bundled, or a state in which a metal wire and a high-resistance wire are bundled. A plurality of metal wires (conductor wires) can be easily integrated by the high resistance conductive material constituting the covering layer or the high resistance wire. Further, the high resistance layer 20 can be easily formed by the plastic deformation of the coating layer or the plastic deformation of the high resistance strand and the joining to the metal strand. Therefore, according to the manufacturing method described above, it is possible to easily manufacture an aggregate wire in which a plurality of conductor wires 10 are partitioned by the high resistance layer 20. The obtained assembly wire can be used as the coil conductor wire 1 as it is. Furthermore, according to the manufacturing method using conform extrusion, as described above, 1. 1. Omission of heating equipment for integrating multiple wires. 2. Strong integration of multiple wires; 3. Realization of excellent mechanical properties (elongation, yield strength, etc.) of the assembly wire; 4. Omission of post-processing (drawing, heat treatment, etc.) From the viewpoint of continuous production of long materials (details will be described later) and the like, the coil conductor wire 1 can be manufactured with high productivity. As an advantage of using conform extrusion, a structure having a specific orientation can be obtained (at least the (200) plane is oriented), and the crystal can be made fine (for example, the average crystal grain size of the conductor wire 10 is 30 μm or less), and excellent surface properties can be obtained.

The above-described method for manufacturing a coil conductor wire can further include the following processing steps and a heat treatment step.
Processing step A step of drawing the assembly wire to produce a workpiece Heat treatment step A step of applying heat treatment to the workpiece to produce a coil conductor wire

  By the above-described processing steps, the dimensional accuracy and shape accuracy of the assembly wire can be further increased. In addition, the above-described heat treatment step removes the processing strain introduced in the processing step, thereby obtaining a coil conductor wire having excellent elongation and the like. Therefore, according to the manufacturing method including the above-described processing step and heat treatment step, it is possible to manufacture a coil conductor wire having excellent dimensional accuracy, shape accuracy, and mechanical characteristics.

In addition to each process (preparation process, coating process, and integration process, or strand preparation process and strand integration process) of the above-described coil conductor wire manufacturing method, the above-described coil wire 2 is as follows. It can manufacture with the manufacturing method of the electric wire for coils provided with this insulation process.
Insulating step A step of forming an electric wire for a coil by forming an insulating layer on the outer periphery of the assembly wire or the coil conductor wire.

  In the above-described method for manufacturing a coil wire, the coil wire can be easily manufactured by forming an insulating layer on the above-described assembly wire or coil conductor wire.

Hereinafter, each process will be described in detail.
-Preparation process / element preparation process In a preparation process, the metal element wire 100 which finally becomes the conductor element wire 10 is prepared as a raw material. Examples of the metal strand 100 include a wire made of a metal having excellent conductivity and low electrical resistance described in the section of the constituent material of the conductor strand. The shape, size, and number of the metal strands 100 can be selected as appropriate. The larger the number of metal strands 100 used, the better the conductor can be subdivided. Although the size of the metal strand 100 depends on the size of the coil conductor wire 1 finally obtained, for example, when the metal strand 100 is a round wire, the diameter thereof is 0.1 mmφ to 10 mmφ. Degree. The size of the metal strand 100 and the high-resistance strand described later is often different from the final size (the size of the conductor strand 10 in the conductor wire 1) due to plastic processing such as conform extrusion. Typically, the conductor wire 10 is smaller.

  In the strand preparation process, as a raw material, a metal strand 100 (see the above preparation process) that finally becomes the conductor strand 10 and a high resistance strand (not shown) that finally becomes the high resistance layer 20 are used. prepare. This step does not require a coating step described later, and the number of steps can be reduced.

  Examples of the high-resistance strand include the high-resistance conductive material described in the section of the constituent material of the above-described high-resistance layer, particularly a wire composed of the above-described metal from the viewpoint of excellent plastic workability. The shape, size, and number of high resistance strands may be selected so that the conductor strands 10 can be partitioned after plastic deformation. In particular, the size of the high-resistance strand is such that if the cross-sectional area is smaller than that of the metal strand 100 (having a small diameter), the high-resistance strand can be easily interposed between the metal strands 100 without gaps, and the conductor in the coil conductor wire 1 It is easy to increase the ratio of the strand 10 and is preferable. For example, the cross-sectional area (or wire diameter) of the high-resistance strand is 50% or less, further 25% or less, and further 10% or less of the metal strand 100.

  Both the metal wire 100 and the high-resistance wire can be manufactured using a known metal wire manufacturing method.

In this step, the covering wire 210 is formed by forming a covering layer 210 that finally becomes the high resistance layer 20 on the outer periphery of the bare metal wire 100. The following various methods can be used for forming the coating layer 210. In any of these methods, the thinner the covering layer 210 is, the higher the resistance layer 20 finally obtained can be made thin, and the coil conductor wire 1 with a high proportion of the conductor wire 10 can be obtained, which is preferable. For example, the thickness of the coating layer 210 is 3 mm or less, further 2 mm or less, and further 1 mm or less. In a film forming method or an oxidation method described later, a very thin layer having a thickness of 10 μm or less, further 5 μm or less, 1 μm or less, or 0.1 μm or less can be easily formed.

1. A method of fitting the pipe 200 made of the above-described high-resistance conductive material to the metal strand 100 (hereinafter sometimes referred to as a fitting method).
2. A method of preparing a sheet (not shown) made of a high resistance conductive material, winding the sheet around the metal wire 100 and fixing it by welding or brazing (hereinafter sometimes referred to as a winding method).
3. A method (hereinafter sometimes referred to as a film forming method) of plating (high-resistance conductive material) on the metal wire 100 (electroplating, electroless plating, etc.), vapor deposition, application (paste application, etc.).
4). A method of performing an oxidation treatment on the metal element wire 100 (hereinafter sometimes referred to as an oxidation method).

  1. In the fitting method, for example, the metal strand 100 is housed in a metal pipe 200 and wire drawing is performed at the same time, thereby eliminating a gap between the metal strand 100 and the pipe 200 and making them metallurgical. The coated wire 110 can be easily manufactured. In addition, the fitting method is preferable because it does not require the step of joining the sheet seam, which is essential in the winding method, and the covering layer 210 can be easily formed. In addition, when the metal strand 100 is a copper wire, for example, when pure aluminum and an aluminum alloy are compared, a hard aluminum alloy is easier to bite into copper than a soft pure aluminum, and the coating layer 210 tends to be formed. It is in.

  2. The winding method can be easily applied to the metal strand 100 having an arbitrary size and composition. Moreover, the winding method can form the coating layer 210 of uniform thickness similarly to the fitting method.

  3. In the film forming method, it is easy to form the coating layer 210 having excellent adhesion to the metal wire 100 and also to form the relatively thin coating layer 210 as described above.

  4). The oxidation method can easily form the covering layer 210 (finally the high resistance layer 20) made of an oxide (for example, copper oxide) of the constituent metal of the metal wire 100. In addition, since the constituent metal of the metal strand 100 and the constituent metal of the base coating layer described later are used as the constituent elements of the coating layer 210, the coating layer 210 is excellent in adhesion to the metal strand 100.

In order to manufacture a form in which the high resistance layer 20 includes an iron oxide, for example: Fitting method, 2. Winding method, 3. 3. After forming the base coating layer made of iron by any of the film forming methods, By performing the oxidation method, it is possible to form the coating layer 20 in which at least a part (particularly the surface side region) is made of an iron oxide. The oxidation conditions may be selected according to the constituent metal of the metal strand 100 and the constituent metal of the underlying coating layer so that a desired metal oxide can be generated. For example, when the metal strand 100 is a copper wire, Cu ₂ O is contained by setting the atmosphere to air, the heating temperature to about 300 ° C. to 1000 ° C., and the holding time to about 0.1 seconds to 10 hours. Copper oxide can be formed.

.. Integration process / element integration process In the integration process, a plurality of coated wire rods 110 are integrated in a bundled state. In this case, the bundled wire 120 always has a coating layer 210 that eventually becomes the high resistance layer 20 around the metal strand 100. Therefore, this form can easily manufacture an assembly wire in which the components constituting the metal strand 100 are surely partitioned by the high resistance conductive material constituting the coating layer 210.

  On the other hand, when the metal wire 100 is bundled by surrounding the metal wire 100 with the covered wire 110 so that the plurality of metal wires 100 are partitioned from each other by the covered wire 110, the bundled wire (not shown) A covering layer 210 that finally becomes the high resistance layer 20 exists around the strand 100. Thus, even if the covered wire 110 is appropriately disposed, it is possible to manufacture an aggregate wire in which the components constituting the metal strand 100 are partitioned by the high-resistance conductive material forming the cover layer 210.

  On the other hand, in the strand integration process, both strands are bundled by surrounding the metal strand 100 with a high resistance strand so that the plurality of metal strands 100 are separated from each other by the high resistance strand. Integrate in state. In this bundled wire (not shown), there is a high-resistance element wire that finally becomes the high-resistance layer 20 around the metal element wire 100. By appropriately arranging the high-resistance strands in this way, the components constituting the metal strand 100 can be made by the high-resistance conductive material constituting the high-resistance strand without forming the covering layer 210. A partitioned assembly wire can be manufactured. For example, it is easy to handle if a wound wire in which a high resistance wire is wound around the outer periphery of the metal wire 100 is prepared. Both strands can be bundled by surrounding the metal strand 100 with a winding wire so that the metal strand 100 is partitioned from each other by the winding wire.

  And in the above-mentioned manufacturing method, conform extrusion is utilized for integration. A known conform extrusion apparatus can be used. Hereinafter, an example of the conform extrusion apparatus will be described with reference to FIG.

  The conform extrusion apparatus 80 includes a cylindrical wheel 81 that is rotatably supported, a groove 82 that is provided in the circumferential direction of the wheel 81 and in which an object to be extruded (here, the bundled wire 120 and the like) is disposed, and a groove 82. A shoe 83 that covers a part of the opening of the slab and functions as a lid, an abutment 85 that is attached to the groove 82 and dams the material, a die 86 that pushes out the dammed material, and a die chamber that houses the die 86 84.

  When an object to be extruded is inserted into the groove 82 of the rotating wheel 81, the object to be extruded is sequentially drawn by the frictional force between the wheel 81 and the object to be extruded. When the object to be pushed out is blocked by the abutment 85 and the groove 82 is closed by the shoe 83, an extrusion pressure is generated. This extrusion pressure causes the extrusion target to flow into the material accumulation location of the die chamber 84, and the extrusion target is extruded into a desired shape by the die 86 to form the extrusion material (here, the aggregate wire (coil conductor wire 1)). Can be manufactured.

  One advantage of using conform extrusion is that the degree of freedom in processing and the degree of freedom in shape are high. For example, the degree of workability (cross-sectional reduction rate) is substantially 0%, that is, the degree of workability is 50% or more, further 60% or more, 70% or more, from a low workability such as substantially joining the bundled wire 120 or the like. , 80% or more, and 90% or more can be easily processed. Also, for example, even if the object to be extruded is a round line, a polygonal line such as a flat line or an irregular line such as an ellipse can be easily and accurately formed. Since such a high degree of processing is possible and the degree of freedom of shape is high, the final shape and the final size aggregate wire can be easily manufactured, and the productivity is excellent.

  One of the advantages of using conform extrusion is that a continuous infinite length wire can be manufactured because continuous extrusion is possible by continuing to supply raw materials. Here, an integrated assembly wire can be manufactured by a general extrusion method of extruding a billet (which may be cold, warm, or hot). However, in this case, the length of the extruded material is restricted by the size of the billet, and it is difficult to increase the length. This is because if the billet itself is a long material, stable extrusion is difficult. In addition, in general extrusion methods, it is difficult to stably perform extrusion with a large degree of processing. Therefore, when manufacturing aggregated wires with a small cross-sectional area, the degree of processing of extrusion is reduced and the total degree of processing after extrusion is reduced. It is considered preferable to perform wire drawing or rolling with a large. When wire drawing or the like having a large total processing degree is performed, elongation and the like are lowered by work hardening. Therefore, heat treatment such as softening is indispensable after drawing with a large total workability. From the above points, when a general extrusion method is used, it is considered difficult to produce a collective wire such as the coil conductor wire 1 with high productivity. In contrast, the above-described manufacturing method using conform extrusion is preferable because the coil conductor wire 1 can be mass-produced with high productivity.

・ ・ Pre-process of integration process Before performing conform extrusion, the process which can maintain the state which bundled several strands can be provided. As this process, the following twist process or the accommodation process is mentioned, for example. As described later, by twisting together a plurality of strands or storing them in a single metal tube, the variation between the strands can be reduced, and it is easy to insert into the conform extrusion device 80 and has excellent workability. Moreover, it is easy to stick the strands after extrusion.

... Twist process This process bundles and twists a plurality of coated wire rods 110, or bundles and twists a plurality of metal strands 100 and a plurality of coated strands 110, or a plurality of metal strands 100 and a plurality of strands. It is possible to prevent loosening by bundling and twisting the high resistance strands. When the twisting process is performed, the coil conductor wire 1 having the above-described twisted portion is obtained. The pitch for twisting (twisting pitch) may be such that the variation can be reduced, and is preferably longer from the viewpoint of reducing the twisted portion described above, for example, 100 mm or more, and further 500 mm or more.

・ ・ ・ Accommodating step This step accommodates a plurality of covered wire rods 110 in one metal tube, or a plurality of metal wire wires 100 and a plurality of covered wire rods 110 in a single metal tube, or a plurality of metal wire elements. The wire 100 and the plurality of high resistance strands are accommodated in one metal cylinder. If the metal tube is made of, for example, the metal of the high-resistance conductive material described in the section of the material for the high-resistance layer, the high-resistance layer 20 can be finally formed. Reduction effect can be enhanced. Alternatively, if the metal tube is made of a metal having excellent conductivity such as the metal wire 100, for example, it can be a region where current can finally flow, and a coil with a high space factor can be formed. A coil conductor wire 1 suitable for formation is obtained.

  When a metal cylinder is used, the coil conductor wire 1 having no twisted portion is obtained. The metal cylinder may be thin as long as the fluctuation can be reduced. For example, the thickness is about 3 mm or less, and further about 1 mm or less. When a thin metal cylinder is used, the proportion of the high resistance layer 20 in the conductor wire 1 can be reduced when the high resistance layer 20 is finally obtained.

.. Machining step This step performs plastic working for the purpose of dimensional correction or shape correction of the aggregate wire obtained by conform extrusion, specifically, at least one of wire drawing and rolling. This processing can be performed with a small processing degree (for example, about 20% or less, and further 5% or less) for the above-mentioned purpose. Processing with a high degree of processing can be performed on the aggregated wire after extrusion of the conform. However, in this case, the productivity of the coil conductor wire 1 is reduced due to an increase in the number of passes and the subsequent heat treatment time is increased, the crystal grains are coarsened due to the prolonged heat treatment, and further, the wire machine It causes deterioration of the physical characteristics. Considering these, it is preferable that the degree of plastic working performed after the conform extrusion is small. When plastic working is performed after conform extrusion, the orientation and crystal grain size immediately after conform extrusion are substantially maintained if the degree of processing is low, although it depends on the degree of processing.

-Heat treatment process Heat treatment can be performed after the conform extrusion. By performing the heat treatment, softening and removal of processing strain can be performed. As described above, the aggregate wire immediately after the extrusion of the conformation is excellent in elongation and the like, and thus this heat treatment can be omitted. However, it is preferable to perform the heat treatment when the above processing steps are performed. The heat treatment conditions are, for example, a heating temperature of about 250 ° C. or more and about 500 ° C. or less, a holding time of about 1 second or more and about 10 hours or less, and an atmosphere is preferably a low oxygen atmosphere for preventing oxidation. Examples of the low oxygen atmosphere include a reducing gas atmosphere such as a hydrogen-containing gas and a carbon dioxide gas-containing gas, a vacuum atmosphere (a reduced pressure atmosphere), and an inert gas atmosphere such as nitrogen and argon. In the case of conform extrusion, the orientation and crystal grain size are hardly affected under the above heat treatment conditions. Easy to maintain.

.. Insulating step This step repeats the step of applying a resin varnish obtained by dissolving the resin described in the above-mentioned insulating layer in an organic solvent and the step of baking the resin varnish on the outer periphery of the conductor. 30 is formed. Examples of the conductor include aggregate wires that have undergone conform extrusion, and wires that have been subjected to the above-described plastic processing and heat treatment after conform extrusion (any wire corresponds to an example of the coil conductor wire 1).

  A publicly known method utilized in manufacture of electric wires, such as an enamel wire, can be applied to the process of applying and the process of baking. As an example, after applying a resin varnish to a conductor or a coated conductor having one or more baked layers, the inside of the furnace having a set temperature of about 350 ° C. to 500 ° C. is about 5 seconds to 10 seconds per pass. The insulating layer 30 is formed by repeating baking for several times several times.

Hereinafter, more specific embodiments will be described with reference to test examples.
[Test Example 1]
Using a plurality of metal strands, an assembly wire (samples No. 1 to No. 3, No. 100, No. 200) integrated by various methods is produced, and the obtained assembly wire is mechanical. The characteristics were measured, the eddy current loss was measured, and the structure was observed. The results are shown in Table 2.

  Sample No. 1 is a pipe (outer diameter 17 mmφ, thickness) made of an oxygen-free copper wire (electric resistance 1.7 μΩ · cm) having a diameter of 12.5 mmφ and an aluminum alloy (5052, electric resistance 4.9 μΩ · cm). 2 mm) is prepared to produce a coated wire, and a plurality of coated wires are integrated by conform extrusion (see FIG. 1). The production procedure is as follows. An oxygen-free copper wire is disposed in the pipe, and the pipe is tightened through a wire drawing die having a hole diameter of 15 mmφ to produce a coated wire. The obtained coated wire is drawn to a diameter of 7.3 mmφ. Four obtained 7.3 mmφ coated wire-drawing materials are bundled and twisted at a twist pitch of 200 mm. The twisted bundled wire is subjected to swaging to form a diameter of 12.5 mmφ. The obtained 12.5 mmφ shaped wire was extruded with a conform extrusion device to obtain a round wire (diameter 3 mmφ) extrudate and a flat wire (thickness 2 mm × width 4 mm) extrudate. In each of the obtained extruded materials, the conductor wire composed of oxygen-free copper is surrounded and surrounded by the aluminum alloy, and the plurality of conductor wires are integrated through the aluminum alloy. . Each extruded material has a twisted portion. The total area ratio of the conductor wires in the extruded material is about 95 area%.

  Sample No. The aggregate wire No. 2 is prepared by preparing a nickel-plated copper wire (plating thickness 20 μm) having a diameter of 3.2 mm as a coated wire, and integrating a plurality of plated wires by conform extrusion (electricity of an oxygen-free copper wire). Resistance 1.7 μΩ · cm, nickel electrical resistance 6.9 μΩ · cm). Nineteen nickel-plated copper wires were bundled and twisted at a twist pitch of 200 mm. In the same manner as in No. 1, swaging (diameter: 12.5 mmφ) ⇒ conform extrusion was performed to obtain a round wire (diameter 3 mmφ) extruded material and a flat wire (thickness 2 mm × width 4 mm) extruded material. In each of the obtained extruded materials, a conductor wire made of oxygen-free copper is surrounded and surrounded by nickel, and a plurality of conductor wires are integrated via nickel. In any of the extruded materials, the average thickness of the nickel 74 portion in the cross section is about 9 μm. Moreover, all the extrusion materials have a twist part. The total area ratio of the conductor wires in the extruded material is about 97.5 area%.

Sample No. The aggregated wire 3 is prepared by preparing a copper wire subjected to surface oxidation as a coated wire, and integrating a plurality of surface oxidized copper wires by conform extrusion. An oxygen-free copper wire (electric resistance: 1.7 μΩ · cm) having a diameter of 3.2 mmφ was subjected to oxidation treatment (atmospheric atmosphere, 950 ° C. × 10 seconds) to form copper oxide on the surface of the wire. When component analysis of the obtained surface copper oxide wire was performed, an oxide layer (thickness of about 1 μm) containing copper (I) oxide: Cu ₂ O (electric resistance of about 1 × 10 ⁸ μΩ · cm) on the surface of the wire rod was obtained. ) Existed. Nineteen surface copper oxide wires were bundled and twisted at a twist pitch of 200 mm. In the same manner as in No. 1, swaging (diameter: 12.5 mmφ) ⇒ conform extrusion was performed to obtain a round wire (diameter 3 mmφ) extruded material and a flat wire (thickness 2 mm × width 4 mm) extruded material. In each of the obtained extruded materials, the conductor wire composed of oxygen-free copper is surrounded by copper oxide and partitioned, and a plurality of conductor wires are integrated via copper oxide. . In each of the extruded materials, the average thickness of the copper oxide portion in the cross section is about 0.5 μm. Moreover, all the extrusion materials have a twist part. The total area ratio of the conductor wires in the extruded material is about 99.9 area%.

  Sample No. 100 aggregate wires are obtained by integrating only a plurality of oxygen-free copper wires by conform extrusion. 19 oxygen-free copper wires (diameter: 3.2 mmφ) were bundled and twisted at a twist pitch of 200 mm. In the same manner as in No. 1, swaging (diameter: 12.5 mmφ) ⇒ conform extrusion was performed to obtain a round wire (diameter 3 mmφ) extruded material and a flat wire (thickness 2 mm × width 4 mm) extruded material. In each of the obtained extruded materials, an oxygen-free copper wire is plastically deformed and integrated.

Sample No. The assembly wire 200 is formed by bundling a plurality of oxygen-free copper bars into a billet, extruding the billet, performing at least one of wire drawing and rolling, and then performing heat treatment. The production procedure is as follows. Nineteen oxygen-free copper bars (cross-sectional area 100 mm ² ) are bundled and packed in an extruder container (inner diameter 50 mmφ) and extruded while heating at 450 ° C. to form an extruded material having a diameter of 13 mmφ. A 13 mmφ extruded material is drawn to obtain a round wire (diameter 3 mmφ). A 13 mmφ extruded material is drawn and rolled to obtain a rectangular wire (thickness 2 mm × width 4 mm). Each of the obtained round wire and flat wire is subjected to vacuum heat treatment (350 ° C. × 3 hours). Both the round wire and the flat wire obtained after the heat treatment are integrated by plastic deformation.

  The prepared sample No. 1-No. 3, no. 100, no. Ten aggregate wires were subjected to a tensile test under the following conditions to measure elongation (breaking elongation) and yield strength (0.2% yield strength).

(Measurement conditions for tensile test)
Length between chucks 250mm, crosshead speed 50mm / min

  The prepared sample No. 1-No. 3, no. 100, no. Eddy current loss was measured under the following conditions using an eddy current displacement meter (controller: LS-500-2 manufactured by Sentech Co., Ltd., sensor head: HA-80S manufactured by Sentech Co., Ltd.) on 200 aggregate wires.

(Eddy current loss measurement conditions)
As shown in FIG. 3, ten specimens (round line) 3A having a diameter of 3 mmφ and a length of 30 mm are prepared, and are arranged in a plane by contacting them so that the axes of the round lines 3A are parallel. Alternatively, as shown in FIG. 4, ten samples (flat wire) 3B having a thickness of 2 mm and a width of 4 mm are prepared, and are arranged in a planar shape in contact with the width direction of each flat wire 3B. A spacer 92 made of thick paper having a thickness of 0.6 mm is placed on the arranged samples, and the sensor head 90 is pressed onto the spacer 92 to measure the output voltage. The obtained output voltage is converted into eddy current loss. In this test, a sample No. made of only copper was used. 100, no. The output voltage (eddy current loss) of 200 is set to 100. 1-No. 3 shows an output voltage (eddy current loss) as a relative value. The smaller the relative value, the less eddy current loss.

The prepared sample No. 1-No. 3, no. 100, no. Take the transverse cross section of the assembly wire of 200, X-ray diffraction is performed under the following conditions for the copper component (conductor wire in samples No. 1 to No. 3, arbitrary region in No. 100 and No. 200), The diffraction intensity was examined.
(Measurement conditions for X-ray diffraction)
Measuring device: SmartLab-2D-PILATUS (manufactured by Rigaku Corporation)
X-ray used: Cu-Kα
Excitation conditions: 45 kV 200 mA
Collimator diameter: 0.3mm
Measurement method: θ-2θ method Measurement surface: transverse section The diffraction intensity corresponding to the copper diffraction surface (nml) is defined as I (nml), and the main surfaces, specifically, (111) surface, (200) surface, ( 220), (311), (222), and (400) plane diffraction intensities I (111), I (200), I (220), I (311), I (222), I (400) And the sum is S. Then, the ratio I (200) / S of I (200) to the sum S and the ratio I (220) / S of I (220) to the sum S were obtained.

The prepared sample No. 1-No. 3, no. 100, no. The cross-section of the assembly wire of No. 200 was taken, and the average crystal grain size was determined under the following conditions for the copper component (conductor wire in samples No. 1 to No. 3 and arbitrary region in No. 100 and No. 200). Examined.
(Average crystal grain size)
The cross section of each sample was etched with a chemical solution to obtain a crystal structure of the copper component, a micrograph was taken at a magnification selected based on JIS H 0501 (1986), and the micrograph was measured using a cutting method.

  As shown in Table 2, the sample No. 1 in which the conductor wire is partitioned by a high resistance layer containing a conductive material having an electric resistance higher than that of the conductor wire. 1-No. 3 is a sample No. 3 composed only of copper. 100, no. It can be seen that eddy current loss can be reduced compared to 200. Sample No. 1-No. In all cases 3, the eddy current loss can be effectively reduced because the copper wire as the conductor wire is surrounded by the high resistance layer. Sample No. 1-No. As can be seen from FIG. 3, the higher the electric resistance of the constituent material of the high resistance layer (here, aluminum alloy <nickel <copper oxide), the eddy current loss can be reduced. Sample No. containing copper oxide 3 sample No. 3 100, no. It can be seen that the eddy current loss can be reduced to about half of 200. Sample No. 100, no. Since 200 is made of only copper, the relative values of eddy current loss are equal.

  For these reasons, the coil conductor wire in which the conductor wire is partitioned by a high resistance layer containing a conductive material having a higher electric resistance than the conductor strand is more vortex than a conventional conductor made of a single metal. It can be said that generation of current can be suppressed. Sample No. 1-No. In all cases 3, all the conductor wires are copper wires having excellent conductivity, the total area ratio of the conductor wires is high (90 area% or more), and current flows through at least a part of the high resistance layer. Available for gaining area. Therefore, sample no. 1-No. It can be said that all 3 can be suitably used as a wire for a coil from which a coil with a high space factor can be obtained.

  Sample No. 1-No. No. 3 is a sample No. 3 using a general extrusion method. Compared to 200, it can be seen that the (200) plane is oriented and the (220) plane is also oriented. Specifically, Sample No. 1-No. In all cases, I (200) / S is 0.29 or more, almost all samples are 0.30 or more, and I (220) / S is 0.03 or more. By having such a specific orientation, the sample No. It can be seen that the mechanical properties are excellent as compared with 200. Specifically, Sample No. 1-No. In all cases, the elongation is 40% or more and the proof stress is 90 MPa or more. In this way, the sample No. 1-No. It can be said that all 3 are excellent in coil moldability and can be suitably used as a coil wire.

  Furthermore, sample no. 1-No. No. 3 is a sample No. 3 using a general extrusion method. It can be seen that the average grain size is smaller than 200. Specifically, Sample No. 1-No. In all cases 3, the average crystal grain size is 16 μm or less, and the general sample is 15 μm or less. By having such a fine crystal structure, sample no. It can be seen that the mechanical properties are also superior to 200 (details regarding the mechanical properties are as described above).

  In addition, the wire that can reduce the eddy current loss and obtain a coil with a high space factor as well as the wire that also has excellent mechanical properties can be easily manufactured with high productivity by using conform extrusion. I understand that I can do it. In particular, sample no. 1-No. All 3 have a high elongation of 30% or more (here, 40% or more) even without heat treatment after conform extrusion. Therefore, by utilizing conform extrusion, a separate heating step is not necessary for integrating a plurality of wires, and a heat treatment step after extrusion can be omitted. In this way, the coil in which the conductor wire is partitioned by the high resistance layer containing a conductive material having a higher electric resistance than the conductor wire in that it can be easily and continuously manufactured by a manufacturing method using conform extrusion. It can be said that the conductor wire is excellent in manufacturability. In addition, in this example, it can be said that it is excellent in manufacturability because it is easy to handle and supply to the conform extrusion apparatus by forming a bundled wire by twisting a plurality of wires before conform extrusion.

  The present invention is not limited to the above-described embodiment, and can be appropriately changed without departing from the gist of the present invention. The present invention is shown by the scope of claims and is equivalent to the scope of claims. All changes within the meaning and scope are intended to be included.

  The coil conductor wire of the present invention and the coil electric wire of the present invention can be suitably used for the coil material of various coil parts such as a motor, a transformer, and a reactor.

1 Coil conductor wire 2 Coil wire 1A Coil conductor wire (round wire) 2A Coil wire (round wire) 3A Sample (round wire)
1B Coil conductor wire (flat wire) 2B Coil wire (flat wire)
3B sample (flat wire)
DESCRIPTION OF SYMBOLS 10 Conductor strand 20 High resistance layer 22 Interposition part 30 Insulation layer 100 Metal strand 200 High resistance material (pipe) 210 Coating layer 110 Covering wire 120 Bundling wire 80 Conform extrusion apparatus 81 Wheel 82 Groove 83 Shoe 84 Die chamber 85 Abutment 86 Die 90 Sensor head 92 Spacer

Claims (8)

A plurality of conductor wires;
A high resistance layer that partitions each conductor wire in a state in which the plurality of conductor wires are integrally held,
Among the plurality of conductor strands, at least some of the conductor strands are subjected to X-ray diffraction with respect to a cross-section, and (111) plane, (200) plane, (220) plane, (311) plane, (222) ) Plane, (400) plane, the sum of diffraction intensities is S, and the ratio of the (200) plane diffraction intensity I (200) to the total sum S is I (200) / S. S satisfies 0.2 or more,
The high resistance layer is a coil conductor wire including a conductive material having an electric resistance higher than that of a metal constituting the conductor wire.   2. The coil according to claim 1, wherein when the ratio of the diffraction intensity I (220) of the (220) plane to the total sum S is I (220) / S, the I (220) / S satisfies more than 0.01. Conductor wire.   The coil conductor wire according to claim 1, wherein at least a part of the plurality of conductor strands is a copper wire.   The conductive material is selected from aluminum alloy, nickel, copper oxide, aluminum, tin, iron, nickel alloy, tin alloy, iron alloy, iron oxide, and intermetallic compounds including copper and aluminum. It is at least 1 sort, The conductor wire for coils of any one of Claims 1-3.   The coil conductor wire according to any one of claims 1 to 4, wherein an average crystal grain size of at least a part of the plurality of conductor strands is 30 µm or less.   The said high resistance layer is a conductor wire for coils of any one of Claims 1-5 surrounding the circumference | surroundings of each said conductor strand.   The coil conductor wire according to any one of claims 1 to 6, further comprising a twisted portion in which the plurality of conductor wires are twisted.   The coil electric wire provided with the conductor wire for coils of any one of Claims 1-7, and the insulating layer provided in the outer periphery of the said conductor wire for coils.

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