JP2019075312A - Rectangular electric wire - Google Patents

Abstract

To provide a rectangular electric wire which can easily perform terminal treatment.SOLUTION: A laminated conductor part is formed by laminating a rectangular wire having a rectangular conductor of which an outer periphery is coated with a thermosetting resin layer. The laminated conductor part has the outer periphery covered with a thermoplastic resin layer. The rectangular wires in the laminated conductor part are not bonded to each other.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a flat wire.

  The miniaturization of electronic devices and electric devices is promoted, and along with this, coils mounted in these devices are also from conventional enamelled wire of circular cross-section (round enameled wire) to enameled wire of rectangular cross-section The use of (flat angle enameled wire) is becoming mainstream (see, for example, Patent Document 1).

  The flat enameled wire is obtained by coating and baking an insulating paint on a rectangular conductor having a rectangular cross section and providing an insulating film. By using the flat rectangular enameled wire, the gap between the enameled wires when wound around the coil can be reduced (that is, the space factor of the enameled wire can be increased), and the coil can be miniaturized. And, in recent years, in order to further reduce the size of the coil, thinning of the enameled wire is in progress.

  As a rectangular wire for high frequency used for a coil of an AC motor or a high frequency electric device, a rectangular wire in which an enamel coating or an oxide film for insulation is formed on the outer periphery of a plurality of rectangular enameled wires is used.

JP, 2009-245666, A

By the way, in the case of a conventional flat wire having a plurality of stacked flat enameled wires, when processing and wiring the end of the flat wire when assembling the motor, each of the plurality of flat enameled wires is connected to the connection target Work will occur.
In this work, in the case of conventional rectangular copper wire, a plurality of rectangular enameled wires are normally adhered to each other. Therefore, the rectangular enameled wire is used together with an insulating enamel coating or oxide film covering the outer periphery of the plurality of rectangular enameled wires. There is a problem that it takes time and effort to branch the wire suitably, and it takes time to assemble the motor.

  This invention is made in view of this point, and it aims at providing the flat angle electric wire which can perform terminal processing easily.

One aspect of the flat wire of the present invention is
A laminated conductor portion formed by laminating rectangular wires having a rectangular conductor whose outer periphery is covered with a thermosetting resin layer;
A thermoplastic resin layer covering the outer periphery of the laminated conductor portion;
Have
The flat wires of the laminated conductor portion are not bonded to each other.

  According to the present invention, terminal processing can be easily performed.

It is a sectional view showing the flat angle electric wire of one embodiment concerning the present invention.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a cross-sectional view showing a flat wire 10 according to an embodiment of the present invention.

  The rectangular electric wire 10 shown in FIG. 1 is, for example, a laminated conductor portion 60 in which rectangular wires 40, 50 having a rectangular conductor 20 and a layer of thermosetting resin (referred to as "thermosetting resin layer") 30 are laminated; And a layer (referred to as a “thermoplastic resin layer”) 70 covering the outer periphery of the laminated conductor portion 60.

[Flat wire 40, 50]
The flat wires 40, 50 have the same configuration in the present embodiment. Each of the rectangular wires 40 and 50 has a rectangular conductor 20 and a thermosetting resin layer 30 formed of a thermosetting resin covering the outer periphery of the rectangular conductor 20.
The rectangular wires 40 and 50 have, for example, a rectangular cross section whose width is larger than the thickness. Here, the rectangular cross section has a substantially rectangular cross-sectional shape in which a pair of opposing short sides overhang in an arc shape, that is, a pair of long sides opposing each other are opposed to each other, and each has a convex shape toward the outside And an elliptical cross section having a curved short side. In the present embodiment, the flat rectangular conductor 20 has a rectangular cross section having a pair of long sides facing each other and short sides facing each other.

Four corners 40 a in the rectangular cross section of the flat wire 40 are rounded. The corners 40a may not be rounded. The corner 40 a is not rounded (that is, the cross section is rectangular) or rounded in order to increase the space factor when wound around the coil. It is preferable that the radius (curvature radius R of the corner) of the roundness is 0.2 to 0.5 mm. In the case where the corner 40a is rounded, as compared with the case where the corner 40a is rounded (the corner 40a has a right-angled shape), the rectangular wires 40 and 50 which have the corner 40a on both sides and are in contact with each other. The surfaces in contact with each other are separated from each other in the cross-sectional view. As a result, the flat wires 40, 50 can be easily peeled off from their both sides. When the corner 40a is rounded, if the radius of curvature of the corner (curvature radius R of the corner) is larger than 0.5 mm, the contact surfaces of the flat wire 40 and 50 are also reduced, so lamination is preferable. It becomes difficult to do. As a result, the outer periphery of the laminated conductor portion 60 formed by laminating the rectangular wires 40 and 50 can not be suitably covered with the thermoplastic resin layer 70. Therefore, the flat wires 40, 50 can not be easily branched at the terminal of the flat wire 10, and the branching work, that is, the end processing operation of the flat wire 10 takes time and effort.
When the corner 40a is rounded, the radius of rounding (R) is preferably 0.3. In addition, since the flat wire 50 is the same as the flat wire 40, description is abbreviate | omitted.

  As shown in FIG. 1, a ratio L / of the length L of the major axis formed between a pair of short sides of the cross section of the flat wire 40 and the length S of the minor axis formed between a pair of long sides S (aspect ratio) is preferably 2 to 5. When the ratio L / S is larger than 5 or smaller than 2, when connecting the terminal of the flat wire 10 to the connection target, the flat wires 40, 50 of the end portion are less likely to be peeled off. The length L of the major axis formed between the pair of short sides corresponds to the maximum value of the distance between the pair of long sides. The length S of the short axis formed between the pair of long sides corresponds to the distance between the pair of short sides. The major and minor axes are preferably orthogonal to one another. The major axis length L is substantially the same as the major axis length of the rectangular conductor 20 (width of the rectangular conductor 20 + thermosetting resin layer 30 × 2), and the minor axis length S is The length is substantially the same as the length of the minor axis (the thickness of the rectangular conductor 20 + the thickness of the thermosetting resin layer 30 × 2). When the ratio L / S (aspect ratio) of the major axis length L to the minor axis length S is 2 to 5, for example, the radius (R) of the roundness of the corner 40a is 0.3 mm. The ends of the flat wires 40, 50 at the end of the flat wire 10 are more easily peeled off when the radius (R) is 0.2 to 0.5 mm.

  Hereinafter, each layer which comprises the flat wire 40 and 50 is demonstrated.

[Flat conductor 20]
The rectangular conductor 20 has, for example, a rectangular cross section whose width is larger than its thickness. Here, the rectangular cross section has a substantially rectangular cross-sectional shape in which a pair of opposing short sides overhang in an arc shape, that is, a pair of long sides opposing each other are opposed to each other, and each has a convex shape toward the outside And an elliptical cross section having a curved short side. In the present embodiment, the flat rectangular conductor 20 has a rectangular cross section having a pair of long sides facing each other and short sides facing each other.

  The material of the rectangular conductor 20 may be copper, a copper alloy, aluminum, iron, silver, an alloy thereof, or the like, but copper or a copper alloy is preferable from the viewpoint of mechanical strength, conductivity and the like. The flat conductor 20 is a conductor subjected to wire drawing processing such as rolling.

  The four corners of the rectangular cross section of the flat conductor 20 may or may not be rounded. With regard to these corner portions, from the viewpoint of increasing the space factor when wound around the coil, even if it is not rounded (that is, the cross section is rectangular) or rounded, It is preferable that the radius (curvature radius R of the corner) of the roundness is 0.2 to 0.5 mm. In the present embodiment, the corners of the flat conductor 20 are rounded. The radius of the roundness of the corner of the flat conductor 20 is similar to that of the corners of the flat wires 40 and 50, and the thermosetting resin layer 30 is extremely thin. It can be said that the radius of curvature of the corners of the flat wires 40, 50 is similar.

  In the cross section of the flat rectangular conductor 20, the length between the pair of short sides, more specifically, the length (width L) of the major axis formed between the pair of short sides is 1.0 to 10.0 mm. Is preferred. The length between the pair of long sides, more specifically, the length (thickness S) of the short axis formed between the pair of long sides is preferably 0.5 to 5.0 mm.

[Thermosetting resin layer 30]
The thermosetting resin layer 30 is a layer provided on the outer periphery of the rectangular conductor 20 and covering the rectangular conductor 20. The thermosetting resin layer 30 has a function of providing the rectangular wires 40 and 50 with heat resistance and insulation. The thermosetting resin layer 30 can use what is used conventionally. For example, polyimide (PI), polyamide imide (PAI), polyester imide (PEsI), polyether imide (PEI), polyimide hydantoin modified polyester, polyamide (PA), formal, polyurethane (PU), polyester (PE), polyvinyl formal , Epoxy and polyhydantoin. Among these, polyimide (PI) which is excellent in heat resistance is preferable. In the present embodiment, the thermosetting resin layer 30 is a layer made of polyimide (PI), and the thermosetting resin layer of polyimide covers the rectangular conductor 20.

  The polyimide is not particularly limited, and a common polyimide such as a wholly aromatic polyimide and a thermosetting aromatic polyimide can be used. For example, a commercially available product (manufactured by Toray Industries, Inc., trade name: Torenice # 3000) is used, or a tetracarboxylic acid component unit and a diamine component unit are reacted in a solvent and imidized by heat treatment at the time of coating. It is also possible to use one obtained by

  The tetracarboxylic acid component unit constituting the polyimide preferably contains, for example, a biphenyl tetracarboxylic acid anhydride (BPDA) unit and the like. Moreover, you may further include another aromatic tetracarboxylic acid unit and aliphatic tetracarboxylic acid unit as needed. Moreover, it is preferable that the diamine component unit which comprises a polyimide contains an aromatic diamine unit or an aliphatic diamine unit.

  The thickness of the thermosetting resin layer 30 of polyimide or the like is, for example, preferably 5 μm to 50 μm, and more preferably 5 μm to 20 μm. Due to this thickness, the flat wires 40, 50 having the thermosetting resin layer 30 can be easily peeled from the end.

  The thickness of the thermosetting resin layer 30 is preferably 5 to 50 μm. If the thickness of the thermosetting resin layer 30 is thinner than 5 μm, or if it is thicker than 50 μm, the thermosetting resin layers 30 which abut each other at the flat wire lines 40 and 50 preferably become branched. It takes time to branch work.

[Thermoplastic resin layer 70]
The thermoplastic resin layer 70 is a layer which is provided on the outer periphery of the laminated conductor portion 60 formed by laminating the flat wires 40 and 50 and covers the laminated conductor portion 60. The thermoplastic resin layer 70 contains a thermoplastic resin, and has a function of providing the rectangular wires 40 and 50 with heat resistance and insulation. The thermoplastic resin layer 70 preferably has a melting point of 200 ° C. or more and 450 ° C. or less. Thereby, the thermoplastic resin layer 70 is also excellent in adhesive strength with the laminated conductor portion 60 and solvent resistance. The melting point of the thermoplastic resin can be analyzed and measured using a differential scanning calorimeter (DSC). The thermoplastic resin layer 70 can be extrusion molded, and in the present embodiment, the thermoplastic resin layer 70 is provided on the outer periphery of the laminated conductor portion 60 by extrusion molding of a thermoplastic resin.
The thermoplastic resin layer 70 has a rectangular or elliptical cross-sectional outer shape.
When the thermoplastic resin is provided on the outer periphery of the laminated conductor portion 60, the primer resin is not used. This is because the flat wires 40, 50 of the laminated conductor portion 60 are bonded to each other.

  The thermoplastic resin of the thermoplastic resin layer 70 is, for example, polyetheretherketone (PEEK), modified polyetheretherketone (modified-PEEK), polyetherketoneketone (PEKK), polyetherketone (PEK), polyetherketone Ether ketone ketone (PEKEKK) and polyphenylene sulfide (PPS). In the present embodiment, polyetheretherketone (PEEK) is used as the thermoplastic resin, and the outer periphery of the laminated conductor portion 60 is covered with the thermoplastic resin layer 70 containing PEEK.

  The polyether ether ketone has a continuous use temperature of 260 ° C. as defined in UL 746 B, and is excellent in heat resistance. Furthermore, polyetheretherketone is excellent in bending characteristics, and suppresses the generation of cracks and wrinkles in the thermoplastic resin layer 70 when bent. Further, since the polyetheretherketone is relatively hard, the rectangular wires 40 and 50 are laminated when the extrusion is performed so as to surround the laminated conductor portion 60, that is, the thermosetting resin layer 30 of the rectangular wire 40. The contact state is maintained without affecting the contact state of the flat wire 50 with the thermosetting resin layer 30. Polyether ether ketone is also superior to other general resins in flame retardancy, abrasion resistance, chemical resistance, electrical insulation and the like.

  The thickness of the thermoplastic resin layer 70 made of polyetheretherketone or the like is, for example, preferably 50 μm to 150 μm, and more preferably 50 μm to 100 μm. In addition, the flat wire 40, 50 has the thermosetting resin layer 30 with a thickness of 5 μm to 50 μm, and the flat wire 40, 50 has a radius of 0.1 to 0.5 mm at the corner 40a (R ). Thereby, flat wire 40, 50 becomes easy to exfoliate from an end.

  In addition to the polyether ether ketone, the thermoplastic resin layer 70 may further contain other components as necessary. Examples of other components include antioxidants, lubricants and the like.

  The antioxidant may have a function of preventing thermal deterioration of the thermoplastic resin contained in the thermoplastic resin layer 70. Examples of the antioxidant include phenol based antioxidants, sulfur based antioxidants, phosphorus based antioxidants, amine based antioxidants and the like.

  Examples of lubricants include synthetic lubricants such as polyethylene wax, silicone resin and fluorine resin, and natural lubricants such as beeswax, carnauba wax and candelilla wax.

  The thickness of the thermoplastic resin layer 70 is 50 to 150 μm. When the thickness of the thermoplastic resin layer 70 is thinner than 50 μm, or when the thickness of the thermoplastic resin layer 70 is thicker than 150 μm, preferably, the flat wire 40, 50 is branched at the end of the flat wire. It is difficult, it takes time to branch work. In particular, when the thickness of the thermoplastic resin layer 70 is outside the range of 50 to 150 μm and the thickness of the thermosetting resin layer 30 is outside the range of 5 to 50 μm, the flat wire at the end of the flat wire 10 It becomes more difficult to branch 40 and 50 suitably in a similar shape, and it becomes difficult to perform branching operation.

  The flat wire 10 may further include other layers as necessary. In addition, the rectangular electric wire 10 can be preferably used as a winding of an electric coil for which heat resistance is required, for example, for industrial and automobile motors, and a generator.

[Method of manufacturing flat wire 10]
The flat wire 10 of the present embodiment is 1) a flat wire of the flat wires 40, 50 for obtaining the flat wires 40, 50 in which the outer periphery of the flat conductor 20 is covered with the thermosetting resin layer 30 containing the above-mentioned polyimide or the like. And 2) laminating the rolled flat wire, and forming a thermoplastic resin layer 70 on the outer periphery thereof.

1) Flat wire manufacturing process A thermosetting resin layer 30 containing the above-mentioned polyimide is formed on the outer periphery of the conductor to obtain flat wires 40, 50.
The thermosetting resin layer 30 is formed by applying a polyimide precursor varnish (a solution in which a polyamic acid is dissolved) or a polyimide varnish (a solution in which a polyimide is dissolved) to the outer periphery of a flat conductor as a raw material and baking it. be able to. The application of the polyimide precursor varnish or the polyimide varnish can be performed by, for example, a coating method, an immersion method, an electrodeposition method, or the like. After applying the polyimide precursor varnish or the polyimide varnish, the baking operation may be performed only once or may be performed multiple times. The baking temperature may be at least a temperature at which the solvent in the varnish can be removed (a temperature at which the polyimide precursor can be cured when using a polyimide precursor varnish), and can be, for example, 200 to 500 ° C., preferably 300 to 400 ° C. .
The softening temperature of the thermosetting resin layer 30 by polyimide is higher than the softening temperature of the thermoplastic resin layer 70.

  The polyimide precursor varnish or the polyimide varnish is a polyimide precursor or a polyimide dissolved in a solvent.

  Before the thermoplastic resin coating step 2) after the rectangular wire manufacturing step 1), the cross-sectional shapes of the rectangular wires 40, 50 obtained by the rectangular wire manufacturing step of 1) are predetermined. Roll to the shape of. Specifically, in the rolling of the flat wire 40, 50, the obtained flat wire 40, 50 has the cross-sectional shape as shown in FIG. 1, and the long axis length L of the cross section of the flat wire 40, 50 And the ratio (aspect ratio) L / S of the length S of the minor axis to the length S is 2 to 5.

2) Thermoplastic Resin Coating Step Flat rectangular wires 40 and 50 formed at a predetermined aspect ratio are laminated to form a laminated conductor portion 60. In the laminated conductor portion 60, the flat wires 40, 50 are not adhered to each other, and in detail, they are laminated in a state of point contact with each other.
A thermoplastic resin (polyether ether ketone in this embodiment) is extruded on the outer periphery of the laminated conductor portion 60 in this state. As a result, a thermoplastic resin layer 70 having a rectangular cross-sectional shape or a cross-sectional elliptical shape covering the outer periphery of the laminated conductor portion 60 is formed.

  According to the rectangular electric wire 10 of the present embodiment, since the heat resistance (polyimide layer) of the rectangular wires 40 and 50 is higher than the heat resistance of the thermoplastic resin layer (polyether ether ketone layer) 70, the rectangular electric wire 10 Even when the outer side of the flat wire is deteriorated, the rectangular wires 40, 50 are maintained normally and do not conduct each other.

  In the rectangular wires 40 and 50, a thermosetting resin layer 30 is provided on the outer periphery of the rectangular conductor 20 by applying a solvent such as polyimide precursor or polyimide. For this reason, the thickness of the insulating film becomes uneven in the circumferential direction as a conventional common problem in the production of the flat wires 40, 50 (the thickness of the insulating film can not be formed uniformly in the circumferential direction). Specifically, the uneven thickness phenomenon (so-called dog bone) in which the thickness of the insulating film is selectively reduced at the rectangular corner, and the insulating film thickness is increased in the region sandwiching the corner accordingly. The shape called) occurs. Dock bone is said to be a phenomenon caused by the surface tension of the applied insulating paint, and is considered to be an unavoidable phenomenon in flat wire. For this reason, the flat wire 40, 50 to be laminated is laminated in a state of point contact without surface contact. The flat wires 40 and 50 are not bonded to each other using an adhesive.

  Therefore, when extruding a thermoplastic resin on the outer periphery of the laminated conductor portion 60, the rectangular wires 40, 50 are not bonded to each other even when heated at a high temperature during the extrusion. In addition, the lamination surface (thickness) at the flat wire 40, 50 in the case where the thickness 0.5 to 5.0 mm, the width 1.0 to 10.0 mm, and the thickness 5 to 50 μm of the thermosetting resin layer 30 In the case of the uneven thickness of a), the usual thickness: the thickness of the uneven thickness portion = 1: 1.about.2.0.

  As described above, according to the present embodiment, the thermoplastic resin layer 70 has the outer periphery of the laminated conductor portion 60 in which the rectangular wires 40 and 50 each having the rectangular conductor 20 whose outer periphery is covered with the thermosetting resin layer 30 are laminated. It is covered. The flat wires 40, 05 of the laminated conductor portion 60 are not bonded to each other. The thermosetting resin is a polyimide, and the thermoplastic resin is a polyetheretherketone. The radius of curvature of the corners of the flat wires 40 and 50 is 0.1 to 0.5, the thickness of the thermosetting resin layer is 5 to 50 μm, and the thickness of the thermoplastic resin layer is 50 to 150 μm. . Furthermore, the width / length of the cross section of the flat wire 40, 50 is 2 to 5.

  Therefore, when the terminal processing of the rectangular electric wire 10 is performed for wiring etc., the rectangular wires 40, 50 can be easily peeled and branched to each other, whereby the wiring can be easily performed and the terminal processing is easily performed. Can.

  Further, according to the rectangular electric wire 10 of the present embodiment, the thermosetting resin for covering the rectangular conductor 20 is polyimide, and the thermoplastic resin for covering the outer periphery of the laminate of the rectangular conductor 20 covered with polyimide is polyether. Since the ether ketone is used, this combination contributes to the low dielectric constant of the rectangular electric wire 10, and the partial discharge inception voltage can be increased.

  It should be understood that the embodiments disclosed herein are illustrative and non-restrictive in every respect. The scope of the present invention is indicated not by the above description but by the claims, and is intended to include all the modifications within the meaning and scope equivalent to the claims.

  The present invention can provide an insulated wire in which cracking of the insulating layer is suppressed and which has high heat resistance and good adhesion with the conductor and in-layer adhesion.

Reference Signs List 10 rectangular wire 20 rectangular conductor 30 thermosetting resin layer 40, 50 rectangular wire 60 laminated conductor portion 70 thermoplastic resin layer 40 a corner portion

Claims (5)

A laminated conductor portion formed by laminating rectangular wires having a rectangular conductor whose outer periphery is covered with a thermosetting resin layer;
A thermoplastic resin layer covering the outer periphery of the laminated conductor portion;
Have
The flat wires of the laminated conductor portion are not bonded to each other,
Flat wire characterized in that. The thermosetting resin is polyimide,
The thermoplastic resin is polyetheretherketone.
The flat wire according to claim 1, characterized in that: The radius of curvature of the corner of the flat wire is 0.2 to 0.5 mm.
The flat wire according to claim 1 or 2, characterized in that: The thickness of the thermosetting resin layer is 5 to 50 μm,
The thickness of the thermoplastic resin layer is 50 to 150 μm,
The flat wire according to any one of claims 1 to 3, characterized in that: The width / length of the cross section of the flat wire is 2 to 5,
The flat wire according to any one of claims 1 to 4, characterized in that:

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