JP4060557B2 - Manufacturing method and manufacturing apparatus for laminated flat rectangular enameled wire for high frequency - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method and an apparatus for manufacturing a high-frequency laminated rectangular enameled wire, and more particularly to a method and an apparatus for manufacturing a high-frequency laminated rectangular enameled wire that can reduce high-frequency loss.
[0002]
[Prior art]
FIG. 11 is a cross-sectional view showing an example of a conventional high frequency enamel litz wire.
The high-frequency enamel Litz wire 500 is obtained by twisting a plurality of strands 51 (51-1 to 51-7 in the illustrated example) in which an enamel coating 53 for insulation is formed on the outer periphery of a central conductor 52. . The outer diameter of the strand 51 is, for example, about 0.3 mm.
At high frequencies, the current distribution concentrates on the surface of the conductor due to the skin effect, so a litz wire in which a plurality of strands 51 are twisted is used.
[0003]
When the enamellitz electric wire 500 for high frequency as described above is used as, for example, a heating coil of an electromagnetic cooker, the vibration sound accompanying electromagnetic induction is removed from the audible range, and the high frequency around 10 kHz is taken from the viewpoint of increasing the calorific value. Current often flows.
[0004]
[Problems to be solved by the invention]
In the conventional high-frequency enamel Litz wire 500, as shown in FIG. 12, the current distribution i ′ is concentrated on the surface of the central conductor 52 of each element wire 51 due to the skin effect. There is a problem that the ratio of the above becomes small and the high frequency loss becomes large.
Accordingly, an object of the present invention is to provide a method and apparatus for manufacturing a high-frequency laminated enameled wire that can reduce high-frequency loss.
[0005]
[Means for Solving the Problems]
In a first aspect, the present invention provides a rectangular wire feeding step of feeding out a plurality of flat strands in which the outer periphery of the center conductor is covered with an enamel coating in a posture in which the longitudinal direction of the rectangular cross section is laid horizontally. A bonding paint application process for applying a bonding paint to each flat wire, and each flat wire after the application is inserted into a vertically long and slender slit in a posture in which the longitudinal direction of the rectangular cross section is substantially vertical. A flat rectangular wire laminating step for laminating and a forming step of adjusting the overall cross-sectional shape by vertically inserting the flat rectangular wire bundle after lamination into a long and slender groove. A manufacturing method is provided. In the method for producing a laminated rectangular enamel wire for high frequency according to the first aspect, each rectangular element wire in a substantially horizontal position is fixed to a substantially vertical position and then inserted into a vertically elongated slit. Even when the distance between the application portion and the slit is shortened, it is possible to finely adjust the joining state while preventing the inconvenience that the rectangular strands adhere to each other with an extra joining paint before lamination. Therefore, the entire manufacturing apparatus can be reduced in size.
Moreover, since the cross-sectional shape is adjusted by inserting the flat wire bundles laminated by the slits into the groove, each flat wire can be aligned in a horizontal row with a simple configuration to improve the characteristics of the finished electric wire. I can do it.
As a result of the above, it becomes possible to produce a high-frequency laminated rectangular enameled wire having characteristics that can reduce the high-frequency loss and increase the output at a low cost.
[0006]
In a second aspect, the present invention provides a rectangular wire feeding means for feeding out a plurality of flat strands in which the outer periphery of the center conductor is covered with an enamel coating in a posture in which the longitudinal direction of the rectangular cross section is laid substantially horizontally. Bonding paint applying means for applying a bonding paint to each flat wire, and each flat wire after the application is inserted into a vertically long and slender slit in a posture where the longitudinal direction of the rectangular cross section is substantially vertical. A high-frequency laminated rectangular enamel wire, comprising: a rectangular wire laminating means for laminating and a forming means for adjusting the overall cross-sectional shape by vertically inserting the laminated rectangular wire bundle into a long and narrow groove. A manufacturing apparatus is provided.
In the apparatus for manufacturing a high-frequency laminated flat enameled wire according to the second aspect, the method for manufacturing a high-frequency laminated flat enameled electric wire according to the first aspect can be suitably implemented.
[0007]
In a third aspect, the present invention provides the high-frequency laminated rectangular enamel wire manufacturing apparatus having the above-described configuration, wherein an angle in a longitudinal direction of the slit is 45 ° or more and 135 ° or less with respect to a horizontal direction. An apparatus for manufacturing a laminated rectangular enamel wire for high frequency is provided.
In the high frequency laminated flat enamel wire manufacturing apparatus according to the third aspect, since the slits are suspended in the angular range, it is possible to reduce the inconvenience that excess bonding paint hangs down due to gravity before lamination.
[0008]
In a fourth aspect, the present invention provides the high-frequency laminated rectangular enameled wire manufacturing apparatus having the above-described configuration, wherein the horizontal width of the slit is [the thickness of the rectangular wire + margin width of 10 μm or less] × the number of laminated layers. An apparatus for producing a high-frequency laminated flat rectangular enameled wire is provided.
In the apparatus for manufacturing a high-frequency laminated flat enameled wire according to the fourth aspect, it is possible to obtain a pressure contact force suitable for lamination by adjusting the margin width.
[0009]
In a fifth aspect, the present invention provides the apparatus for manufacturing a high-frequency laminated flat enameled wire having the above-described configuration, wherein the horizontal width of the groove is [the thickness of the flat wire + margin width of 10 μm or less] × the number of laminated layers, and The vertical depth of the groove is 1 to 5 times the width of the flat wire, and a high-frequency laminated flat enamel wire manufacturing apparatus is provided. In the apparatus for manufacturing a high-frequency laminated flat rectangular enameled wire according to the fifth aspect, a pressing force suitable for shape correction can be obtained by adjusting the margin width. In addition, since the vertical depth of the groove is set to be 1 to 5 times the width of the rectangular wire, the groove depth can be reduced and the forming means can be made compact as long as the flat wire bundle can be inserted stably. I can do it.
[0010]
In a sixth aspect, the present invention provides the apparatus for manufacturing a high-frequency laminated flat enameled wire having the above-described configuration, wherein the load applied to the flat wire bundle by the forming means is 0.2 times or more the safety tension of the flat wire bundle. Provided is an apparatus for producing a laminated flat rectangular enameled wire for high frequency, characterized in that it is 1 time or less.
In the apparatus for manufacturing a laminated rectangular enamel wire for high frequency according to the sixth aspect, the lower limit of the load applied by the forming means to the flat wire bundle is 0.2 times the safety tension of the flat wire bundle. The molding performance can be increased by increasing the molding force. In addition, since the upper limit of the load applied by the forming means to the flat wire bundle is set to be one times the safety tension of the flat wire bundle, it is possible to prevent inconvenience that excessive stress is applied to the flat wire bundle.
[0011]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings. Note that the present invention is not limited thereby.
[0012]
FIG. 1 is a configuration diagram showing a high-frequency laminated flat enameled wire manufacturing apparatus 1000 according to an embodiment of the present invention.
First, a long and flexible rectangular element wire α1 (α1-1, α1-2,..., Α1-n) is connected to the wire feeder 1 (1-1, 1-2,..., 1-n). It is drawn out in a posture in which the longitudinal direction of the rectangular cross section is laid almost horizontally. As shown in FIG. 2, the rectangular wire α <b> 1 has a structure in which the outer periphery of the center conductor 22 is covered with an enamel coating 23 for insulation. If the example of the dimension of the flat wire α1 is shown, the width w is 1.6 mm and the thickness d is 0.03 mm. The material of the center conductor 22 is, for example, copper, copper alloy, aluminum, aluminum alloy, or a combination of these metals. The material of the enamel coating 23 is, for example, polyamide-imide or polyester-imide. The film thickness of the enamel film 23 is, for example, about 1 to 3 μm.
[0013]
Next, as shown in FIG. 3, each rectangular wire α <b> 1 is laminated by the felt 2, the coating roll 3 a of the bonding paint tank 3, the vertical slit jig 4, and the forming jig 5.
[0014]
That is, each rectangular wire α1 is inserted through the gap between the felts 2 facing up and down, and then the coating material is applied to the surface of the rectangular wire α1 by the application roll 3a. The material of the bonding paint is, for example, a nylon resin, an epoxy resin, or a phenol resin. As a result, as shown in FIG. 4, the rectangular wire α <b> 3 in which the bonding coating 24 is formed on the outer periphery of the enamel coating 23 is obtained.
[0015]
Then, each rectangular element wire α3 is adjusted to a posture in which the longitudinal direction of the rectangular cross section is substantially vertical, and is inserted into a vertical slit jig 4 having a slit S that is elongated in the vertical direction and stacked. FIG. 5 illustrates a cross section of the flat rectangular wire bundle α4 after the lamination. The horizontal width τs of the slit S is [the thickness of the flat wire α1 + the margin width of 10 μm or less] × the number n of stacked layers. For example, if d = 30 μm, the margin width = 5 μm, and n = 15, τs = 525 μm. The width of the margin is adjusted so as to have a pressing force suitable for stacking. Further, the angle θ in the longitudinal direction of the slit is 45 ° or more and 135 ° or less with respect to the horizontal direction, and is particularly preferably 90 °. In addition, the maximum angle φ in the section where the flat wire α3 enters the slit S is set to 10 ° or less with respect to the horizontal plane from the viewpoint of preventing an excessive twisting force from being applied to each flat wire α3. It is preferable.
[0016]
In this way, the rectangular strands α3 are vertically set up and then inserted into the slit S, so that the rectangular strands α3 are bonded to each other by the bonding paint hanging down from each of the rectangular strands α3 by gravity before lamination. It is possible to finely adjust the joining state while preventing inconvenience, and the distance L between the coating roll 3a and the vertical slit jig 4 can be shortened. For example, L = 0.3 m (On the other hand, when the flat wire α3 is laminated in the horizontal position, the distance needs to be 2 m or more, for example. End up).
[0017]
Then, the flat wire bundle α4 is inserted into a vertically elongated groove M engraved in the forming jig 5 to adjust the overall cross-sectional shape. As shown in FIG. 6, in the flat rectangular wire bundle α5 after forming, the flat rectangular wires α1 are aligned in a horizontal row. The horizontal width τm of the groove M is [the thickness of the flat wire α1 + the margin width of 10 μm or less] × the number of stacked layers. For example, if d = 30 μm, the margin width = 2 μm, and n = 15, τm = 480 μm. The width of the margin is adjusted so as to have a pressing force suitable for shape correction. The vertical depth h of the groove M is not less than 1 and not more than 5 times the width w of the rectangular wire α1. For example, when h is three times w = 1.6 mm, h = 4.8 mm.
The load applied to the flat wire bundle α4 (weight of the forming jig 5) G is obtained from the viewpoint of preventing an excessive stress from being applied to the flat wire bundle α4 while obtaining sufficient forming performance. The safety tension is preferably 0.2 times or more and 1 time or less of the safety tension of α4.
[0018]
Next, returning to FIG. 1, the flat wire bundle α <b> 5 is inserted into the baking machine 6 to bake and harden the bonding coating 24. Thereby, the film thickness of the bonding coating 24 is, for example, 2 to 3 μm.
[0019]
Next, the rectangular wire bundle α5 after the bake hardening is inserted into the winding machine 70. In the winding machine 70, the motor 7 directly drives the bobbin 8, and winds the long object 9 spirally along the traveling direction of the flat wire bundle α5. The long object 9 is a thread (for example, a nylon thread or a tetron thread) or a tape (a nylon polyester tape or a Kapton tape). FIG. 7 illustrates a cross section of the rectangular wire bundle α9 after the winding. Winding of the long object 9 prevents the inconvenience that the cross-sectional shape of the flat wire bundle α9 collapses and the arrangement position of each flat wire α1 shifts, and the finished wire (high-frequency laminated flat enamel wire for high frequency described later) 100) can be further reduced.
[0020]
Next, the insulating paint is applied to the outer periphery of the flat wire bundle α9 by the application roll 10a of the insulating paint tank 10. Examples of the material for the insulating paint include polyamideimide and polyesterimide. As a result, as shown in FIG. 8, the rectangular wire bundle α <b> 10 in which the insulating coating layer 25 is formed on the outer periphery of the long object 9 is obtained.
[0021]
Next, the rectangular wire bundle α10 is inserted into the gap of the felt 11 to remove excess insulating paint, and then inserted into the baking machine 12 to bake and harden the insulating coating layer 25.
[0022]
Next, the fusion paint is applied to the outer periphery of the rectangular wire bundle α10 after the bake hardening by the application roll 13a of the fusion paint tank 13. The material of the fusion paint is, for example, a thermosetting resin such as urethane or polyester. As a result, as shown in FIG. 9, a high-frequency laminated rectangular enameled wire 100a in which a protective fusion layer 26 is formed on the outer periphery of the insulating coating layer 25 is obtained.
[0023]
Next, the high-frequency laminated rectangular enameled electric wire 100 a is inserted into the baking machine 14, the fusion layer 26 is baked and cured, and the high-frequency laminated rectangular enameled electric wire 100 is finished and wound around the winder 15.
[0024]
The material of each member (enamel coating 23, bonding coating 24, insulating coating layer 25, fusion layer 26) formed on the outer periphery of the central conductor 22 is a material that can be melted by soldering heat of about 180 ° C., for example. This is advantageous from the viewpoint of improving the usability of the electric wire. Moreover, it is preferable that the material of each member is determined in consideration of heat resistance, flexibility, and price.
[0025]
In the high-frequency laminated rectangular enameled electric wire 100 manufactured as described above, the current distribution i spreads over the entire central conductor 22 as shown in FIG. That is, since the thickness d of the central conductor 22 is extremely small (less than 0.03 mm in the above example), there is almost no portion where no current flows even if the skin effect is present, and the current portion is smaller than the conductor cross-sectional area. The ratio can be increased. As a result, high-frequency loss can be reduced to cope with higher output.
[0026]
【The invention's effect】
According to the method and apparatus for producing a high-frequency laminated flat enamel wire of the present invention, a low-loss electric wire having a structure in which flat wire is laminated is efficiently produced in an in-line production process. I can do it. Therefore, for example, a heating coil for an electromagnetic cooker that can cope with heating of a cooking utensil such as aluminum or copper can be suitably manufactured.
[0027]
In addition, since a plurality of rectangular strands drawn out in a posture in which the longitudinal direction of the rectangular cross section is horizontal is corrected to a vertical posture and then inserted into the slit, even when the bonding paint application part and the lamination slit are brought close to each other This makes it possible to avoid inconveniences such as the fact that the flat strands are displaced and adhere to each other, and the overall size of the apparatus can be reduced.
[Brief description of the drawings]
FIG. 1 is a configuration diagram showing an apparatus for manufacturing a laminated rectangular enamel wire for high frequency according to an embodiment of the present invention.
FIG. 2 is a cross-sectional view showing a rectangular wire.
3 is a perspective view showing a main part of the manufacturing apparatus of FIG. 1. FIG.
FIG. 4 is a cross-sectional view showing a rectangular wire after the formation of a bonding film.
FIG. 5 is a cross-sectional view showing a flat wire bundle after lamination.
FIG. 6 is a cross-sectional view showing a flat rectangular wire bundle after molding.
FIG. 7 is a cross-sectional view showing a rectangular wire bundle after winding a long object.
FIG. 8 is a cross-sectional view showing a rectangular wire bundle after an insulating coating layer is formed.
FIG. 9 is a cross-sectional view showing a high-frequency laminated flat rectangular enameled wire.
10 is an explanatory diagram showing a current distribution in the laminated rectangular enamel wire for high frequency shown in FIG. 9;
FIG. 11 is a cross-sectional view showing an example of a conventional high frequency enamel litz wire.
12 is an explanatory diagram showing a current distribution in the high-frequency enamellit wire of FIG. 11. FIG.
[Explanation of symbols]
1000 High Frequency Laminated Flat Square Enamel Wire Manufacturing Equipment 1 Line Machine 2, 11 Felt 3 Bonding Paint Tank 3a, 10a, 13a Coating Roll 4 Vertical Slit Jig 5 Molding Jig 6, 12, 14 Baking Machine 7 Motor 8 Bobbin 9 Long Scale 10 Insulating paint tank 13 Fusing paint tank 15 Winder 22 Central conductor 23 Enamel coating 24 Bonding coating 25 Insulating coating layer 26 Fusing layer 70 Winding machine 100a, 100 High-frequency laminated rectangular enamel wire α1, α2, α3 Flat wire α4, α5, α9, α10 Flat wire bundle i Current distribution S Slit M Groove

Claims (6)

A flat wire drawing process in which a plurality of flat wires whose outer periphery is covered with an enamel coating is placed in a posture in which the longitudinal direction of the rectangular cross section is laid substantially horizontally, and a bonding paint is applied to each flat wire. A bonding paint coating step, and a rectangular wire laminating step for laminating each rectangular wire after the application into a vertically elongated slit in a posture in which the longitudinal direction of the rectangular cross section is substantially vertical, and laminating And a forming step of adjusting the overall cross-sectional shape by vertically inserting the flat wire bundle after lamination into a long and narrow groove, and a method for producing a laminated rectangular enamel wire for high frequency. A rectangular wire feeding means for feeding out a plurality of rectangular wires in which the outer periphery of the central conductor is covered with an enamel coating in a posture in which the longitudinal direction of the rectangular cross section is laid substantially horizontally, and a bonding paint is applied to each of the rectangular wires. Bonding paint application means, and rectangular wire lamination means for inserting and laminating each rectangular wire after application to a posture in which the longitudinal direction of the rectangular cross section is substantially vertical, and being vertically inserted into an elongated slit. An apparatus for producing a high-frequency laminated rectangular enameled wire, comprising: a forming means for adjusting the overall cross-sectional shape by inserting the laminated rectangular wire bundle vertically into an elongated groove. 3. The apparatus for producing a laminated flat enameled wire for high frequency according to claim 2, wherein the longitudinal angle of the slit is 45 ° or more and 135 ° or less with respect to the horizontal direction. Manufacturing equipment. The apparatus for manufacturing a high-frequency laminated flat enameled wire according to claim 2 or 3, wherein the horizontal width of the slit is [the thickness of the flat wire + margin width of 10 μm or less] x the number of laminated layers. Manufacturing equipment for laminated flat rectangular enameled wires for high frequencies. 5. The high-frequency laminated flat enameled wire manufacturing apparatus according to claim 2, wherein the horizontal width of the groove is [thickness of flat wire + margin width of 10 μm or less] × number of laminated layers, and An apparatus for producing a laminated rectangular enameled wire for high frequency, wherein the vertical depth of the groove is 1 to 5 times the width of the rectangular wire. 6. The apparatus for manufacturing a high-frequency laminated flat rectangular enameled wire according to claim 2, wherein the load applied by the forming means to the flat wire bundle is 0.2 times or more the safety tension of the flat wire bundle. An apparatus for producing a laminated flat rectangular enameled wire for high frequency, characterized in that it is 1 time or less.

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