JP5219619B2 - Magnetic flat braided wire and coil - Google Patents

Description

  The present invention relates to a magnetic flat braided wire and a coil, and more particularly to a magnetic flat braided wire and a coil that can reduce eddy current loss and copper loss due to proximity effects at high frequencies.

2. Description of the Related Art Conventionally, a spiral coil is known in which a long side of a flat wire is wound in a spiral shape (flat winding) with a long side facing in a radial direction (see, for example, Patent Document 2).
Also, an edgewise coil is known in which a plurality of round wires or foils are arranged in a direction perpendicular to the axial direction to form a plate-like wire rod group, and the wire rod group is edgewise wound (for example, patents) Reference 1).
On the other hand, an electronic component is known in which a braided wire obtained by knitting a plurality of insulation-coated copper wires into a rectangular cross section is wound around a bobbin (for example, see Patent Document 3).
JP-A-4-75303 JP-A-6-236996 (FIG. 1) JP 2002-141232 A

The conventional spiral coil described above has a problem that eddy current loss is large because a rectangular wire is used.
On the other hand, in the conventional edgewise coil and electronic component described above, an eddy current loss is caused by using an assembly wire in which a plurality of round wires or foils are assembled or a braided wire in which a plurality of insulation-coated copper wires are knitted into a rectangular cross section. Can be reduced.
However, since the magnetic field generated by the current flowing in one round wire, foil, or insulation-coated copper wire enters another round wire, foil, or insulation-coated copper wire, there is a problem that copper loss due to proximity effects increases at high frequencies. It was.
Therefore, an object of the present invention is to provide a magnetic flat braided wire and a coil that can reduce eddy current loss and copper loss due to proximity effects at high frequencies.

In the first aspect, the present invention is that a plurality of insulation coated magnetic material plated copper wires each having a magnetic plating layer formed on the surface of the copper wire and having an insulation coating formed on the surface of the magnetic plating layer are formed into a flat shape. A magnetic flat braided wire is provided.
In the magnetic flat braided wire electric wire according to the first aspect, since a braided wire obtained by braiding a plurality of insulation-coated magnetic material plated copper wires is used, eddy current loss can be reduced. In addition, the magnetic field generated by the current flowing in one insulation-coated magnetic material-plated copper wire is blocked by the magnetic-material plating layer, and it is difficult to enter the copper wire portion of the other insulation-coated magnetic material-plated copper wire (it is small even if it enters) Therefore, it is possible to suppress an increase in copper loss due to the proximity effect at high frequencies. Furthermore, since it was made into a flat shape, it can respond to a request for a low profile (miniaturization) and a thin shape of the coil shape.
Note that an adhesive layer may be formed on the outer periphery of the insulating coating to form a self-bonding line. Further, in order to increase the electric wire density, insulating coating magnetic material plated copper wires having different outer diameters may be mixed and used. Further, it may be knitted one by one, or may be knitted for a plurality of parallel bundles.

In a second aspect, the present invention provides an insulating coating magnetic material plated copper wire in which a magnetic plating layer is formed on the surface of the copper wire and an insulating coating is formed on the surface of the magnetic plating layer, and an insulating coating is formed on the surface of the copper wire. Provided is a magnetic flat braided wire characterized by braiding an insulation-coated copper wire into a flat shape.
In the magnetic flat braided wire electric wire according to the second aspect, since the braided wire obtained by braiding the insulation coated magnetic material plated copper wire and the insulation coated copper wire is used, the eddy current loss can be reduced. In addition, the magnetic field generated by the current flowing in one insulation-coated magnetic material-plated copper wire is interrupted by the magnetic-material plating layer, making it difficult to enter other insulation-coated magnetic material-plated copper wires or copper wire portions of insulation-coated copper wires ( In addition, the magnetic field generated by the current that flows in one insulation-coated copper wire is blocked by the magnetic material plating layer of the other insulation-coated magnetic material-plated copper wire, making it difficult to enter the copper wire portion. (Because it is small even if it enters), it is possible to suppress an increase in copper loss due to the proximity effect at high frequencies. Moreover, since it was made into a flat shape, it can respond to the request | requirement of the low profile (miniaturization) and thickness reduction of a coil shape. Furthermore, since the insulation-coated copper wire is mixed, the cost can be reduced.
Note that an adhesive layer may be formed on the outer periphery of the insulating coating to form a self-bonding line. Further, in order to increase the electric wire density, an insulating coated magnetic material plated copper wire and an insulating coated copper wire having different outer diameters may be mixed and used.

  Further, when the insulation-coated magnetic material-plated copper wire and the insulation-coated copper wire are mixed and twisted, the insulation-coated magnetic material-plated copper wire can be dispersedly arranged, so that the current bias can be reduced. In general, the loss is a square function, so even if the total current is the same, the loss can be reduced if the current bias is small.

In a third aspect, the present invention provides the magnetic flat braided wire according to the first or second aspect, wherein the flat shape is a flat tubular shape.
The magnetic flat braided wire according to the third aspect can be manufactured by braiding it into a tubular braided wire and then processing it into a flat shape, which is easier to manufacture than when it is braided into a rectangular cross section from the beginning.

In a fourth aspect, the present invention provides a coil comprising a coiled magnetic flat braided wire according to any one of the first to third aspects wound in a solenoid shape.
It is known that a coil using a core has a large leakage magnetic field from the core gap, so that the eddy current loss is rapidly increased by affecting the coil wire.
In the solenoid coil according to the fourth aspect, in addition to the low linear density due to the characteristics of the braid, the magnetic wire does not easily enter the copper wire because the copper wire is shielded by the magnetic material plating layer. Since the electrical resistance is large, the loss is reduced and the loss can be suppressed even if the leakage magnetic field is large.

In a fifth aspect, the present invention provides a coil comprising the coiled magnetic flat braided wire according to any one of the first to third aspects spirally wound.
The spiral coil according to the fifth aspect can be used as an IH heater driven at a high frequency, for example.

  According to the magnetic flat braided wire and coil of the present invention, loss at high frequencies can be reduced.

  Hereinafter, 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 cross-sectional view illustrating a magnetic flat braided wire 101 according to the first embodiment.
The magnetic flat braided wire 101 is obtained by braiding 168 insulation-coated magnetic material plated copper wires 10 into a tubular shape having a diameter of 4.5 mm at a single knitting pitch of 40 mm and then processing into a flat shape.
In addition, a figure is a schematic diagram (For example, the number of the insulation coating magnetic material plating copper wires 10 does not show a real number).

FIG. 2 is a cross-sectional view of the insulating coating magnetic material plated copper wire 10.
The insulation coating magnetic material plated copper wire 10 forms a magnetic material plating layer 2 having a two-layer structure of a 1.0 μm thick iron lower layer and a 0.5 μm thick nickel upper layer on the surface of a copper wire 1 having a diameter of 0.1 mm. The enamel insulating coating 3 corresponding to two types of insulating films is formed on the surface of the magnetic material plating layer 2.

FIG. 3 is a graph showing the change in the strength of the magnetic field generated by the current flowing through the insulating coating magnetic material plated copper wire 10 with respect to the radial distance from the center of the copper wire 1 of the insulating coating magnetic material plated copper wire 10.
It can be seen that the magnetic field is attenuated by the magnetic material plating layer 2.

  According to the magnetic flat braided wire 101 of the first embodiment, the eddy current loss can be reduced because a braided wire obtained by braiding a plurality of insulating coating magnetic material plated copper wires 10 is used. In addition, the magnetic field generated by the current flowing in one insulating coated magnetic material plated copper wire 10 is blocked by the magnetic material plated layer 2 and it is difficult to enter the copper wire 1 portion of the other insulating coated magnetic material plated copper wire 10 ( Therefore, an increase in copper loss due to the proximity effect at high frequencies can be suppressed. Furthermore, since it is a flat shape, it can respond to the low profile (miniaturization) and thickness reduction of a coil shape.

  Note that an adhesive layer may be formed on the outer periphery of the insulating coating 3 to form a self-bonding wire. In addition, in order to increase the electric wire density, insulating coating magnetic material plated copper wires 10 having different outer diameters may be mixed and used.

FIG. 4 is a cross-sectional view illustrating the composite wire 102 according to the second embodiment.
The magnetic flat braided wire 102 is formed by mixing the insulation-coated magnetic material-plated copper wire 10 and the insulation-coated copper wire 20 into a tubular shape and then processing it into a flat shape.
The insulating coating magnetic material plated copper wire 10 and the insulating coating copper wire 20 are arranged side by side so that the insulating coating copper wires 20 are not adjacent to each other as much as possible.

FIG. 5 is a cross-sectional view of the insulation-coated copper wire 20.
The insulating coating copper wire 20 is obtained by forming the insulating coating 3 on the surface of the copper wire 1.

  According to the magnetic flat braided wire 102 of Example 2, since the braided wire obtained by braiding the insulation-coated magnetic material plated copper wire 10 and the insulation-coated copper wire 20 is used, eddy current loss can be reduced. Further, the magnetic field generated by the current flowing in one insulation coated magnetic material plated copper wire 10 or the insulation coated electric wire 20 is blocked by the magnetic material plating layer 2 of the insulation coated magnetic material plated copper wire 10, and another insulation coated magnetic material Since it becomes difficult to enter the copper wire 1 portion of the plated copper wire 10 or the insulation-coated copper wire 20 (because it becomes small even if it enters), an increase in copper loss due to the proximity effect at high frequencies can be suppressed. Furthermore, since it is a flat shape, it can respond to the low profile (miniaturization) and thickness reduction of a coil shape.

  In addition, since the insulating coating magnetic material plated copper wire 10 and the insulating coating copper wire 20 are arranged so that the insulating coating copper wires 20 are not adjacent to each other as much as possible, the resistance against eddy currents is averaged, and the current bias is reduced. Loss can be reduced.

  Note that an adhesive layer may be formed on the outer periphery of the insulating coating 3 to form a self-bonding wire. Further, in order to increase the electric wire density, the insulating coated magnetic material plated copper wire 10 and the insulating coated copper wire 20 having different outer diameters may be mixed and used.

FIG. 6 is a plan view illustrating the solenoid coil 201 according to the third embodiment. 7 is a cross-sectional view taken along line AA ′ of FIG.
The solenoid coil 201 is obtained by edgewise winding the magnetic flat braided wire 101 of the first embodiment. The inner diameter is 15 mm, the outer diameter is 22 mm, the coil length is 10.5 mm, and the number of turns is 12.5.

FIG. 8 is a frequency characteristic diagram showing the AC loss increase coefficient Rs / R0 of the solenoid coil 201 and the comparative example (Rs: AC series equivalent resistance, R0: DC resistance).
The comparative example is a solenoid coil manufactured in the same manner as in Example 3 except that an insulation-coated copper wire having an enamel insulation coating formed on the surface of a copper wire 1 having a diameter of 0.1 mm is used.
FIG. 9 is a frequency characteristic diagram showing a coefficient ratio obtained by dividing the AC loss increase coefficient Rs / R0 of the solenoid coil 201 by the AC loss increase coefficient Rs / R0 of the comparative example.
It can be seen that at a high frequency of 600 kHz or higher, the embodiment can reduce the loss by half compared to the comparative example.

In the flat braided wire of the comparative example, the flat front and back two surfaces approach each other, so the loss increases due to the proximity effect. However, in the magnetic flat braided wire of the present invention, the loss increases due to the magnetic material plating layer 2. Is small.
Furthermore, in the flat braided wire of the comparative example, the proximity effect changes depending on the crossing angle (or the braid pitch) of the clockwise line group and the counterclockwise line group of the line set when making the braid, and a change in high-frequency loss is recognized, In the magnetic flat braided wire of the present invention, since the influence of the proximity effect is small, the change in high-frequency loss is small.
That is, in the magnetic flat braided wire of the present invention, even if the braided wire expands and contracts due to changes in winding tension, etc., the high-frequency loss changes even if the crossing angle (or braided pitch) between the clockwise line group and the counterclockwise line group changes. The stability that there is little is improved.

  The magnetic flat braided wire 101 of Example 1 may be wound in a solenoid shape with the short side in the radial direction.

FIG. 10 is a plan view illustrating the spiral coil 202 according to the fifth embodiment. 11 is a cross-sectional view taken along line AA ′ of FIG.
The spiral coil 202 is obtained by winding the magnetic flat braided wire 101 of Example 1 in a spiral shape with the long side in the radial direction.

FIG. 12 is a plan view illustrating the spiral coil 203 according to the sixth embodiment. 13 is a cross-sectional view taken along line AA ′ of FIG.
The spiral coil 203 is obtained by winding the magnetic flat braided wire 101 of Example 1 in a spiral shape with the short side in the radial direction.

  In Examples 3 to 6, a gap, a tape, a spacer, or the like may be interposed between the turns.

  In Examples 3 to 7, the magnetic flat braided wire 102 of Example 2 may be used.

  The magnetic flat braided wire and coil of the present invention can be suitably used in a high frequency circuit. As a specific example, it can be used for an air core or magnetic core coil or transformer, an inductor, a TV deflection yoke, an IH heater coil, a motor or the like in an electric power transmission electric circuit or a power supply circuit.

2 is a cross-sectional view showing a magnetic flat braided wire according to Example 1. FIG. 1 is a cross-sectional view showing an insulation coating magnetic material plated copper wire according to Example 1. FIG. It is a graph which shows the change of the strength of the magnetic field which insulation coating magnetic material plating copper wire makes. It is sectional drawing which shows the magnetic flat braided wire which concerns on Example 2. FIG. 6 is a cross-sectional view showing an insulation-coated copper wire according to Example 2. FIG. 6 is a cross-sectional view showing a solenoid coil according to Embodiment 3. FIG. It is A-A 'sectional drawing of FIG. It is a frequency characteristic figure which shows the alternating current loss increase coefficient of Example 3 and a comparative example. It is a frequency characteristic figure which shows the coefficient ratio which divided the alternating current loss increase coefficient of Example 3 by the alternating current loss increase coefficient of the comparative example. 6 is a cross-sectional view showing a spiral coil according to Embodiment 5. FIG. It is A-A 'sectional drawing of FIG. 6 is a cross-sectional view showing a spiral coil according to Example 6. FIG. It is A-A 'sectional drawing of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Copper wire 2 Magnetic material plating layer 3 Insulation coating 10 Insulation coating magnetic material plating copper wire 20 Insulation coating copper wire 30 Magnetic material plating copper wire 101, 102 Magnetic flat braided wire 201 Solenoid coil 202, 203 Spiral coil

Claims (5)

A magnetic flat braided wire comprising a plurality of insulation coated magnetic material plated copper wires formed by forming a magnetic plating layer on a surface of a copper wire and having an insulating coating formed on the surface of the magnetic plating layer to form a flat shape. An insulating coated magnetic material plated copper wire having a magnetic plated layer formed on the surface of the copper wire and an insulating coating formed on the surface of the magnetic plated layer, and an insulating coated copper wire having an insulating coating formed on the surface of the copper wire are braided and flattened. Magnetic flat braided wire characterized by its shape. 3. The magnetic flat braided wire according to claim 1 or 2, wherein the flat shape is a flat tubular shape.
A coil obtained by winding the magnetic flat braided wire according to claim 1 in a solenoid shape. A coil formed by winding the magnetic flat braided wire according to any one of claims 1 to 3 in a spiral shape.

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