JP4079312B2 - Manufacturing method of flat insulated wire - Google Patents
Manufacturing method of flat insulated wire Download PDFInfo
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- JP4079312B2 JP4079312B2 JP2002135440A JP2002135440A JP4079312B2 JP 4079312 B2 JP4079312 B2 JP 4079312B2 JP 2002135440 A JP2002135440 A JP 2002135440A JP 2002135440 A JP2002135440 A JP 2002135440A JP 4079312 B2 JP4079312 B2 JP 4079312B2
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Description
【０００１】
【発明の属する技術分野】
本発明は平角絶縁電線の製造方法に関する。更に詳しくはスピーカのボイスコイル、ビデオテープレコーダ（VTR）用小型モータコイル、チョークコイル、光ピックアップ用リニアボイスコイル、フロッピディスク用モータコイル、ノイズフィルタ等に用いられる平角絶縁電線の製造方法に関するものである。
【０００２】
【従来の技術】
平角絶縁電線の製造方法は断面円形の丸導体を圧延して平角導体とし、その外周に常法に従って絶縁塗料を塗布焼付する方法、もう一つは丸導体の外周に絶縁塗料を塗布焼付後これを圧延して平角絶縁電線に変形する方法がある。
【０００３】
【発明が解決しようとする課題】
前記した平角絶縁電線の製造方法では、何れの方法にも次のような問題点がある。即ち、前者の方法では平角導体の外周に絶縁塗料を塗布焼付する際、塗料の温度上昇に伴いその流動性が増大し、焼付後の角部の皮膜が薄くなり厚さの均一な皮膜を得ることが困難である。そのため、角部の皮膜が薄く甚だしくは導体表面が露出した平角絶縁電線を電気機器コイル巻線に用いた場合、絶縁不良の原因となり機器の信頼性が著しく低下してしまう。
一方後者の方法では、厚さの均一な皮膜を得ることができる反面、圧延による導体の加工硬化と絶縁皮膜の加工劣化による特性低下の問題がある。前記加工硬化した導体は熱処理することによって軟らかさを与えることができるが、加工劣化した皮膜は耐熱衝撃性が劣り、亀裂が発生したり剥がれが起こってしまう。この現象は平角絶縁電線の厚さと幅の比が大きくなるに従って顕著になるが、特にその比が1:5以上の高圧延比になると亀裂や剥がれが無数に発生して導体表面が露出し、絶縁特性は大幅に低下してしまう。このため前記コイルには適用し得なかった。
【０００４】
本発明は、上記従来技術が有する各種問題点を解決するためになされたものであり、従来の第１の方法である平角導体の外周に絶縁塗料を複数回塗布焼付する平角絶縁電線の製造方法に大幅な変更をすることなく、焼付後に角部を含む全面に渡って均一な皮膜が形成され、導体表面が露出することのない平角絶縁電線の製造方法を提供することを目的とする。
【０００５】
【課題を解決するための手段】
第１の観点として本発明は、平角導体の外周に絶縁塗料を複数回塗布焼付して所定皮膜厚さの絶縁皮膜を設けて平角絶縁電線とする平角絶縁電線の製造方法であって、
断面円形の丸導体を圧延して平角導体とする圧延工程；と、前記平角導体にプラズマ処理することにより導体全面または選択的に導体角部の濡れ性を向上させるプラズマ処理工程；と、前記プラズマ処理した平角導体の外周に絶縁塗料を複数回塗布焼付して所定皮膜厚さの絶縁皮膜を設ける塗料塗布焼付け中、平角導体の外側に薄絶縁皮膜が形成された中間体（以下、中間体と略記する）に紫外線を照射処理することにより、中間体全面または選択的に中間体角部の濡れ性を向上させる塗料塗布焼付け・紫外線照射処理工程；とにより絶縁性に優れた平角絶縁電線を製造することを特徴とする平角絶縁電線の製造方法にある。
上記第１観点の平角絶縁電線の製造方法では、前記プラズマ処理工程を行うことにより、平角導体全面または選択的に平角導体角部の濡れ性が向上するため、導体角部と塗料の親和性が大きくなり、導体角部に皮膜形成性が付与される。次いで塗料塗布焼付け・紫外線照射処理工程において、中間体に紫外線照射処理を行うことにより絶縁皮膜に打撃を与えることなく、中間体全面または選択的に中間体角部の濡れ性を向上させる。その結果、角部を含む全面に渡って密着の優れた絶縁皮膜が均一に形成され、導体表面が露出することがなく、絶縁性に優れた平角絶縁電線を製造することが可能となる。
【０００６】
第２の観点として本発明は、前記平角導体が銅、アルミニウム、または銅クラッドアルミニウムである平角絶縁電線の製造方法にある。
上記第２観点の製造方法では、前記平角導体として、銅、アルミニウム、または銅クラッドアルミニウムを好ましく用いることができる。
【０００７】
第３の観点として本発明は、前記プラズマ処理した平角導体の全面または角部の濡れ性が、表面張力で60mN/m以上である平角絶縁電線の製造方法にある。
上記第３観点の製造方法では、前記プラズマ処理した平角導体の全面または角部の濡れ性が、表面張力で60mN/m以上であるので、平角導体の全面または角部の濡れ性の向上がより計れ、特に導体角部と絶縁塗料の親和性を大きくすることができ、導体角部に皮膜形成性が十分付与される。
【０００８】
第４の観点として本発明は、前記紫外線照射処理に使用するランプが低圧紫外線ランプであり、該ランプから出ている波長は１８４．９ｎｍ、２５３．７ｎｍがピークとなる平角絶縁電線の製造方法にある。
上記第４観点の平角絶縁電線の製造方法では、前記紫外線照射処理に使用するランプとして低圧紫外線ランプが好ましく、また該ランプから出ている波長は１８４．９ｎｍ、２５３．７ｎｍがピークとなるものが好ましい。
【０００９】
第５の観点として本発明は、前記紫外線照射処理した中間体の全面または角部の濡れ性が、固体表面張力で５０dyne/cm2以上である平角絶縁電線の製造方法にある。
上記第５観点の平角絶縁電線の製造方法では、前記紫外線照射処理した中間体の全面または角部の濡れ性が、固体表面張力で５０dyne/cm2以上であるので、中間体の全面または角部の濡れ性の向上がより計れ、特に中間体角部と絶縁塗料の親和性を大きくすることができ、中間体角部に皮膜形成性が十分付与される。
【００１０】
【発明の実施の形態】
以下、本発明の内容を、図に示す実施の形態により更に詳細に説明する。なお、これにより本発明が限定されるものではない。
図１は、本発明の平角絶縁電線の製造方法の１実施形態を示すチャートである。
【００１１】
−第１の実施の形態（実施例１）−
実施例１の平角絶縁電線の製造方法について、図１のチャートを用いて説明する。
先ず、丸銅線（φ0.70mm）を圧延して導体厚0.30 mm、導体幅1.30mmの平角導体を製造した。（圧延工程 ｆ１）
上記平角導体を焼鈍後、プラズマ照射器 ST-7000（キーエンス社製製品名）を用い、平角導体全面にプラズマ処理を行った。（プラズマ処理工程 ｆ２）
次いで、線速8m/min、炉温360℃の電熱焼付炉を用い、ポリウレタン系絶縁塗料WD4307-30%（日立化成社製製品名）を複数回塗布焼付する工程において、平角導体上に皮膜厚が0.004mmとなった中間体に紫外線表面改質装置ＳＳＰ−８（センエンジニアリング社製製品名）を用い、選択的に中間体角部に紫外線照射処理を行い、さらに皮膜厚さが0.012mmとなるように複数回紫外線照射処理と塗布焼付を行い、平角絶縁電線を製造した。（塗料塗布焼付け・紫外線照射処理工程ｆ３）
前記平角絶縁電線の製造の際、プラズマ処理した平角導体のサンプルを採取し、平角導体全面および角部の濡れ性を測定したところ、表面張力で60mN/m以上であった。また、前記紫外線照射処理した中間体のサンプルを採取し、中間体の全面および角部の濡れ性を測定したところ、固体表面張力で５０dyne/cm2以上であった。また、前記紫外線照射処理に用いたランプは低圧紫外線ランプであり、該ランプから出ている波長は１８４．９ｎｍ、２５３．７ｎｍがピークとなるものである。
【００１２】
−比較例１−
丸銅線（φ0.70mm）を圧延した導体厚0.30 mm、導体幅1.30mmの平角導体を用い、焼鈍後、プラズマ処理および紫外線照射処理は行わず、その他は実施例１と同一条件で塗料塗布焼付を行い、平角絶縁電線を製造した。
【００１３】
−特性試験−
上記実施例１及び比較例１により得られた平角絶縁電線について、JIS C3003 エナメル銅線及びエナメルアルミ線試験方法に従い、ピンホール試験及び絶縁破壊電圧試験（金属シリンダ法）を行った。その結果を下記表1に示す。
【００１４】
【表１】
上記表1から明らかなように、本発明の平角絶縁電線の製造方法により得られた平角絶縁電線は、比較例の平角絶縁電線と比較して、絶縁皮膜厚が薄いにも関わらずピンホール、絶縁破壊電圧値が非常に優れていることが分かる。
【００１６】
【発明の効果】
本発明の平角絶縁電線の製造方法によれば、丸導体を圧延して平角導体とした後、プラズマ処理を行うことで、平角導体全面または選択的に平角導体角部の濡れ性が向上するため、導体角部と塗料の親和性が大きくなり、導体角部に皮膜形成性が付与される。また、塗布焼付け工程時において、中間体に紫外線を照射することにより絶縁皮膜に打撃を与えることなく中間体全面または選択的に角部の濡れ性を向上させる。これらにより角部を含む全面に渡って密着の優れた絶縁皮膜が均一に形成され、導体表面が露出することがなく、絶縁性に優れた平角絶縁電線が得られるようになった。そのため、本発明により得られた平角絶縁電線を用いて巻線されたコイル等の信頼性も大幅に向上するようになった。従って、本発明は産業上に寄与する効果が極めて大である。
【図面の簡単な説明】
【図１】本発明の平角絶縁電線の製造方法の１実施形態を示すチャートである。[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a flat insulated wire. More specifically, the present invention relates to a method for manufacturing a rectangular insulated wire used for a voice coil of a speaker, a small motor coil for a video tape recorder (VTR), a choke coil, a linear voice coil for an optical pickup, a motor coil for a floppy disk, a noise filter, and the like. is there.
[0002]
[Prior art]
A method for producing a flat insulated wire is a method of rolling a round conductor having a circular cross section into a flat conductor, and applying and baking insulating paint on the outer periphery of the round conductor according to a conventional method. There is a method of rolling the wire to deform into a flat insulated wire.
[0003]
[Problems to be solved by the invention]
In the above-described method for manufacturing a rectangular insulated wire, each method has the following problems. That is, in the former method, when insulating paint is applied and baked on the outer periphery of a flat rectangular conductor, the fluidity increases as the temperature of the paint increases, and the film at the corner after baking becomes thin and a film having a uniform thickness is obtained. Is difficult. For this reason, when a flat rectangular insulated wire having a thin film at the corners and a heavily exposed conductor surface is used for the coil winding of an electric device, it causes insulation failure and the reliability of the device is significantly reduced.
On the other hand, in the latter method, a film having a uniform thickness can be obtained, but on the other hand, there is a problem of deterioration in characteristics due to work hardening of the conductor by rolling and work deterioration of the insulating film. The work-cured conductor can be softened by heat treatment, but the work-deteriorated film is inferior in thermal shock resistance, causing cracks or peeling. This phenomenon becomes more prominent as the ratio of the thickness and width of the flat insulated wire increases.In particular, when the ratio becomes a high rolling ratio of 1: 5 or higher, numerous cracks and peeling occur and the conductor surface is exposed. Insulation characteristics are greatly reduced. For this reason, it could not be applied to the coil.
[0004]
The present invention has been made to solve the various problems of the prior art, and is a first conventional method for producing a rectangular insulated wire in which an insulating paint is applied and baked a plurality of times on the outer periphery of a rectangular conductor. An object of the present invention is to provide a method for producing a flat insulated wire in which a uniform film is formed over the entire surface including the corner portion after baking without exposing the conductor surface without significant changes.
[0005]
[Means for Solving the Problems]
As a first aspect of the present invention, there is provided a method for producing a rectangular insulated wire, wherein an insulating paint is applied and baked a plurality of times on an outer periphery of a rectangular conductor to provide an insulating film having a predetermined film thickness to obtain a rectangular insulated wire,
Rolling a round conductor having a circular cross section into a flat conductor; and plasma treatment for improving wettability of the entire conductor surface or selectively on a conductor corner by plasma-treating the flat conductor; and the plasma An intermediate in which a thin insulating film is formed on the outside of the rectangular conductor (hereinafter referred to as an intermediate) during coating and baking of the insulating film having a predetermined film thickness by applying and baking an insulating coating several times on the outer periphery of the treated rectangular conductor A flat rectangular insulated wire with excellent insulating properties is manufactured by applying and irradiating ultraviolet rays to the entire intermediate surface or by selectively applying paint baking and ultraviolet irradiation treatment steps to improve the wettability of the intermediate corners. The present invention provides a method of manufacturing a flat insulated wire.
In the method for manufacturing a flat insulated wire according to the first aspect, the wettability of the flat conductor whole surface or selectively the flat conductor corner is improved by performing the plasma treatment step. It becomes large and film forming properties are imparted to the conductor corners. Next, in the paint coating baking / ultraviolet irradiation treatment step, the wettability of the intermediate body or selectively on the corners of the intermediate body is improved by subjecting the intermediate body to ultraviolet irradiation treatment without hitting the insulating film. As a result, an insulating film having excellent adhesion is uniformly formed over the entire surface including the corners, and the conductor surface is not exposed, and a flat insulated wire excellent in insulation can be manufactured.
[0006]
As a second aspect, the present invention resides in a method for producing a flat insulated wire in which the flat conductor is copper, aluminum, or copper clad aluminum.
In the manufacturing method of the second aspect, copper, aluminum, or copper clad aluminum can be preferably used as the flat conductor.
[0007]
As a third aspect, the present invention resides in a method for producing a flat insulated wire in which the wettability of the whole surface or corner of the plasma-treated flat conductor is 60 mN / m or more in terms of surface tension.
In the manufacturing method according to the third aspect, since the wettability of the whole or corner of the plasma-treated flat conductor is 60 mN / m or more in surface tension, the improvement of the wettability of the whole or corner of the flat conductor is further improved. In particular, the affinity between the conductor corner and the insulating paint can be increased, and film formation is sufficiently imparted to the conductor corner.
[0008]
According to a fourth aspect of the present invention, there is provided a method for manufacturing a flat insulated wire in which the lamp used for the ultraviolet irradiation treatment is a low-pressure ultraviolet lamp, and the wavelength emitted from the lamp peaks at 184.9 nm and 253.7 nm. is there.
In the method for producing a flat insulated wire according to the fourth aspect, a low-pressure ultraviolet lamp is preferable as the lamp used for the ultraviolet irradiation treatment, and the wavelength emitted from the lamp peaks at 184.9 nm and 253.7 nm. preferable.
[0009]
As a fifth aspect, the present invention resides in a method for producing a flat insulated wire in which the wettability of the entire surface or corner of the intermediate subjected to the ultraviolet irradiation treatment is 50 dyne / cm 2 or more in terms of solid surface tension.
In the method for producing a flat insulated wire according to the fifth aspect, the wettability of the entire surface or corner of the intermediate irradiated with ultraviolet rays is 50 dyne / cm 2 or more in terms of solid surface tension. The wettability can be further improved, and in particular, the affinity between the intermediate corner portion and the insulating coating can be increased, and the film forming property is sufficiently imparted to the intermediate corner portion.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the contents of the present invention will be described in more detail with reference to embodiments shown in the drawings. Note that the present invention is not limited thereby.
FIG. 1 is a chart showing an embodiment of a method for manufacturing a flat insulated wire of the present invention.
[0011]
-First Embodiment (Example 1)-
The manufacturing method of the flat insulated wire of Example 1 is demonstrated using the chart of FIG.
First, a round copper wire (φ0.70 mm) was rolled to produce a rectangular conductor having a conductor thickness of 0.30 mm and a conductor width of 1.30 mm. (Rolling process f1)
After the flat conductor was annealed, plasma treatment was performed on the entire flat conductor using a plasma irradiator ST-7000 (product name, manufactured by Keyence Corporation). (Plasma treatment process f2)
Next, in the process of applying and baking polyurethane insulating paint WD4307-30% (product name, manufactured by Hitachi Chemical Co., Ltd.) multiple times using an electric baking oven with a linear speed of 8m / min and a furnace temperature of 360 ° C, the film thickness on the rectangular conductor Using an ultraviolet surface modifier SSP-8 (product name manufactured by Sen Engineering Co., Ltd.) for the intermediate with a thickness of 0.004 mm, the corner of the intermediate is selectively irradiated with ultraviolet rays, and the film thickness is 0.012 mm. Thus, a rectangular insulation electric wire was manufactured by performing ultraviolet irradiation treatment and coating baking a plurality of times. (Paint application baking / ultraviolet irradiation treatment process f3)
When producing the flat insulated wire, a sample of a flat conductor subjected to plasma treatment was collected, and the wettability of the entire flat conductor and corners was measured. As a result, the surface tension was 60 mN / m or more. Further, a sample of the intermediate subjected to the ultraviolet irradiation treatment was collected, and the wettability of the entire surface and corners of the intermediate was measured. As a result, the solid surface tension was 50 dyne / cm 2 or more. The lamp used for the ultraviolet irradiation treatment is a low-pressure ultraviolet lamp, and the wavelength emitted from the lamp has a peak at 184.9 nm and 253.7 nm.
[0012]
-Comparative Example 1-
Using a flat conductor with a conductor thickness of 0.30 mm and conductor width of 1.30 mm rolled from round copper wire (φ0.70 mm), plasma treatment and UV irradiation treatment are not performed after annealing, and the other conditions are the same as in Example 1 except that coating is applied. Baking was performed to produce a flat insulated wire.
[0013]
-Characteristic test-
About the flat insulated wire obtained by the said Example 1 and the comparative example 1, the pinhole test and the dielectric breakdown voltage test (metal cylinder method) were done according to the JIS C3003 enameled copper wire and enameled aluminum wire test method. The results are shown in Table 1 below.
[0014]
[Table 1]
As is clear from Table 1 above, the flat insulated wire obtained by the method for producing a flat insulated wire of the present invention is a pinhole, although the insulating film thickness is thin, compared to the flat insulated wire of the comparative example. It can be seen that the breakdown voltage value is very excellent.
[0016]
【The invention's effect】
According to the method for producing a rectangular insulated wire of the present invention, the wettability of the entire rectangular conductor or selectively the rectangular conductor corner is improved by performing plasma treatment after rolling the round conductor into a rectangular conductor. The affinity between the conductor corner and the paint is increased, and film formation is imparted to the conductor corner. Further, in the coating and baking process, the wettability of the entire surface of the intermediate body or selectively at the corners is improved without damaging the insulating film by irradiating the intermediate body with ultraviolet rays. As a result, an insulating film having excellent adhesion is uniformly formed over the entire surface including the corner portion, and the conductor surface is not exposed, and a flat insulated wire excellent in insulation can be obtained. For this reason, the reliability of a coil or the like wound by using the flat insulated wire obtained by the present invention has been greatly improved. Therefore, the present invention has an extremely large effect contributing to the industry.
[Brief description of the drawings]
FIG. 1 is a chart showing an embodiment of a method for producing a rectangular insulated wire of the present invention.
Claims (5)
断面円形の丸導体を圧延して平角導体とする圧延工程；と、前記平角導体にプラズマ処理することにより導体全面または選択的に導体角部の濡れ性を向上させるプラズマ処理工程；と、前記プラズマ処理した平角導体の外周に絶縁塗料を複数回塗布焼付して所定皮膜厚さの絶縁皮膜を設ける塗料塗布焼付け中、平角導体の外側に薄絶縁皮膜が形成された中間体に紫外線を照射処理することにより、中間体全面または選択的に中間体角部の濡れ性を向上させる塗料塗布焼付け・紫外線照射処理工程；とにより絶縁性に優れた平角絶縁電線を製造することを特徴とする平角絶縁電線の製造方法。A method for producing a rectangular insulated wire, in which an insulating paint is applied and baked a plurality of times on the outer circumference of a rectangular conductor to provide an insulating film having a predetermined film thickness, thereby forming a rectangular insulated wire,
Rolling a round conductor having a circular cross section into a flat conductor; and plasma treatment for improving wettability of the entire conductor surface or selectively on a conductor corner by plasma-treating the flat conductor; and the plasma Insulating paint is applied and baked multiple times on the outer periphery of the treated rectangular conductor to provide an insulating film with a predetermined film thickness. During coating application baking, the intermediate with the thin insulating film formed on the outside of the rectangular conductor is irradiated with ultraviolet rays. A flat insulated wire having excellent insulation properties is manufactured by coating and baking / ultraviolet irradiation treatment process for improving the wettability of the entire intermediate body or selectively the corner of the intermediate body. Manufacturing method.
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| JP2002135440A JP4079312B2 (en) | 2002-05-10 | 2002-05-10 | Manufacturing method of flat insulated wire |
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| JP2002135440A JP4079312B2 (en) | 2002-05-10 | 2002-05-10 | Manufacturing method of flat insulated wire |
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| JP4079312B2 true JP4079312B2 (en) | 2008-04-23 |
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| MD4092C1 (en) * | 2009-09-24 | 2011-08-31 | Технический университет Молдовы | Microwire casting installation |
| MD4100C1 (en) * | 2009-09-24 | 2011-09-30 | Технический университет Молдовы | Method for manufacturing a resistor from a conductor |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
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| JP5737273B2 (en) | 2012-11-15 | 2015-06-17 | 株式会社デンソー | Stator winding and method for manufacturing stator winding |
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2002
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Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| MD4092C1 (en) * | 2009-09-24 | 2011-08-31 | Технический университет Молдовы | Microwire casting installation |
| MD4100C1 (en) * | 2009-09-24 | 2011-09-30 | Технический университет Молдовы | Method for manufacturing a resistor from a conductor |
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| JP2003331672A (en) | 2003-11-21 |
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