JP6346843B2 - Manufacturing method of flat insulated wire for edgewise coil - Google Patents

Description

According to the present invention, when a flat rectangular insulated wire for an edgewise coil is wound, the thickness of the insulating coating on the outer peripheral side portion is not thinner than the thickness of the insulating coating on the inner peripheral side portion, and good insulation can be maintained. It is related with the manufacturing method about a flat insulated wire.

As shown in FIG. 6, the flat insulated wire 60 is provided with an insulating coating 64 on the surface of a conductive wire 63 having a quadrilateral cross section surrounded by a long side 61 and a short side 62. The edgewise coil 65 is a coil wound with the short side 62 of the flat insulated wire 60 as the rotation fulcrum side. Since the edgewise coil 65 has a quadrangular cross section of the rectangular insulated wire 60, the space between the wires in the wound state is smaller than that of a coil in which a round wire having a circular cross section is wound, and the space factor of the cross sectional area of the wire is reduced. Is widely used for motors for automobiles. Patent Document 1 (Japanese Patent Laid-Open No. 10-284335) describes an edgewise coil formed by winding a rectangular electric wire into a cylindrical shape.

A conventional edgewise coil wound in a cylindrical shape is shown in FIG. The XY cross section of FIG. 7 is shown in FIG. As shown in the figure, when the flat insulated wire 60 is wound, the outer peripheral portion 60A is extended by tensile stress, and the inner peripheral portion 60B is compressed by compressive stress. For this reason, when a flat rectangular insulated wire 60 having a uniform thickness on the outer peripheral side portion 60A and the inner peripheral side portion 60B is used as in the conventional edgewise coil 60 shown in FIG. 6, as shown in FIG. The thickness of the outer peripheral portion 60A of the flat rectangular insulated wire 60 is thinner than the thickness of the inner peripheral portion 60B, and a gap 61 is likely to occur between the laminated insulated wires 60 in the outer peripheral portion of the coil. The space factor of the wire cross-sectional area of the coil outer peripheral side portion is reduced. On the other hand, since the thickness of the inner peripheral side portion 60B of the flat insulated wire 60 is thicker than the thickness of the outer peripheral side portion 60A, the length C of the coil inner peripheral side portion in the stacking direction is increased, and the coil storage container is large. There is a problem such as.

Patent Document 2 (Japanese Patent Application Laid-Open No. 2007-36056) discloses an edgewise coil in which the length C in the stacking direction of the coil inner peripheral side portion is suppressed by processing the cross section of the electric wire into a flat shape or an irregular shape. Is described. Specifically, as shown in FIG. 9, in the rectangular electric wire 70 having a quadrilateral cross section surrounded by the long sides 71 and 72 and the short sides 73 and 74, the long sides 71 and 72 face the short side 73 on one side. In other words, an edgewise coil is described in which a rectangular electric wire 70 having wedge-shaped cross sections approaching each other is used and wound with the short side 73 having a small thickness on the rotation fulcrum side.

The edgewise coil of Patent Document 2 is wound because the outer peripheral side of the short side 74 with a large thickness is stretched by winding, while the inner peripheral side of the short side 73 with a small thickness is compressed. After that, the thickness of the short sides on both sides becomes substantially uniform, and the length C in the stacking direction of the coil inner peripheral side portion is prevented from increasing.

Japanese Patent Laid-Open No. 10-284335 JP 2007-36056 A

The edgewise coil of Patent Document 2 is described as being the same even when the thickness of the insulation coating is taken into account, but as shown in FIG. 9, the coating thickness of the insulation coating 75 covering the surface of the rectangular electric wire 70 is shown. Is uniformly formed on the winding outer peripheral side and the winding inner peripheral side, the insulating coating 75 on the winding outer peripheral side is extended, while the insulating coating 75 on the winding inner peripheral side is compressed. Therefore, the coating thickness on the outer periphery side of the winding becomes thinner than the coating thickness on the inner periphery side of the winding, and there is a concern that the insulating property on the outer periphery side of the winding is lowered.

The present invention solves the above-mentioned conventional problems with respect to a flat insulated wire for an edgewise coil, and when wound, the thickness of the insulation coating on the outer peripheral portion is larger than the thickness of the insulation coating on the inner peripheral portion. so as not thin, eliminating the concern that insulation of the outer peripheral portion is reduced, to provide a method for manufacturing a rectangular insulated wire that can be maintained good insulation.

The present invention relates to a method for manufacturing a rectangular insulated wire for an edgewise coil that has solved the conventional problems with the following configuration.
[1] An electrodeposition solution containing a strip-shaped rectangular conductive wire in which the thickness of the conductive wire on the outer periphery of the winding is thicker than the thickness of the conductive wire on the inner periphery of the winding. the feed to the electrodeposition bath containing the electrode disposed on the side of the thicker the outer peripheral portion of the thickness of the flat angle conductive wires, thin the inner peripheral portion of the wall thickness by away Succoth from the electrode, Energizing the rectangular conductive wire, electrodepositing the insulating coating component on the surface of the rectangular conductive wire, so that the insulating coating component of the outer peripheral portion is thicker than the insulating coating component of the inner peripheral portion , The insulating coating component that has been electrodeposited is baked to produce a rectangular insulated wire in which the insulating coating is formed thicker than the insulating coating on the inner peripheral portion on the outer peripheral portion where the thickness of the conductive wire is thick. A method for manufacturing a flat insulated wire.

The manufacturing method of the present invention includes the following aspects.
[2] The method for producing a rectangular insulated wire according to the above [1], wherein the thickness of the insulating coating on the outer peripheral portion is 1.5 times or more the thickness of the insulating coating on the inner peripheral portion.
[3] The thickness including the conductive wire and insulating coating on the outer peripheral portion is 1.2 to 1.7 times the thickness including the conductive wire and insulating coating on the inner peripheral portion. The method for producing a rectangular insulated wire according to [1] or [2] above .

[Specific description]
The flat insulated wire according to the manufacturing method of the present invention (hereinafter referred to as the flat insulated wire of the present invention) is a flat insulated wire for an edgewise coil, and the thickness of the conductive wire on the winding outer peripheral side is within the winding. It is characterized in that it is thicker than the thickness of the conductive wire of the peripheral side portion, and the thickness of the insulating coating of the winding outer peripheral portion is thicker than the thickness of the insulating coating of the winding inner peripheral portion. This is a flat insulated wire for edgewise coils.
The rectangular insulated wire of the present invention is a strip-shaped rectangular conductive wire formed by making the thickness of the conductive wire on the winding outer peripheral portion thicker than the thickness of the conductive wire on the winding inner peripheral portion. The electrode is placed on the side of the thick outer peripheral portion of the rectangular conductive wire, and the thin inner peripheral portion is removed from the electrode. By separating, by energizing the rectangular conductive wire, the insulating coating component on the surface of the rectangular conductive wire, so that the insulating coating component of the outer peripheral portion is thicker than the insulating coating component of the inner peripheral portion, It is possible to manufacture by electrodepositing, baking the electrodeposited insulating coating component, and forming the insulating coating thicker than the insulating coating on the inner peripheral portion on the outer peripheral portion where the thickness of the conductive wire is thick. it can.

The rectangular insulated wire of the present invention is a strip-like elongated insulated wire for an edgewise coil, has a quadrilateral cross section, and has a wall thickness including a conductive wire and an insulation coating on the outer peripheral side portion of the winding. The thickness is larger than the thickness including the conductive wire and the insulating coating on the inner peripheral side portion of the winding.

The rectangular insulated wire of the present invention is specifically a rectangular insulated wire in which an insulating coating is provided on the surface of a strip-shaped elongated conductive wire having a quadrilateral cross section surrounded by a long side and a short side, A pair of long sides of the cross section forms a wedge-shaped quadrilateral cross section that approaches each other toward the short side of one side, and the thickness of one short side is made thinner than the thickness of the other short side Has been. Edgewise winding is performed with the short side of the thin wall as a rotation fulcrum. The short-side portion having a small thickness is referred to as an inner peripheral portion, and the short-side portion having a large thickness is referred to as an outer peripheral portion.

The flat insulated wire of the present invention is a flat insulated wire in which an insulating coating is provided on the surface of a strip-like elongated conductive wire having a wedge-shaped cross section surrounded by two long sides and at least one short side. May be. Also in this case, the thickness of the intersection side of two long sides which are one of the wedge-shaped cross sections is formed thinner than the thickness of the short side which is the other. Edgewise winding is performed using the thin side as a rotation fulcrum. The portion with the thinner thickness is called the inner peripheral portion, and the portion with the thicker thickness is called the outer peripheral portion.

Furthermore, the flat insulated wire of the present invention is formed such that the thickness of the insulating coating on the outer peripheral side portion of the winding is larger than the thickness of the insulating coating on the inner peripheral side portion of the winding. The thickness of the insulating coating on the outer peripheral portion is preferably 1.5 times or more the thickness of the insulating coating on the inner peripheral portion. Each side may be a straight line, or may have a shape partially including a curved line such as an arc at the end of the side as long as the effects of the invention are achieved.

In the flat insulated wire of the present invention, the ratio between the thickness L1 including the conductive wire and the insulating coating on the outer peripheral portion of the winding and the thickness L2 including the conductive wire and the insulating coating on the inner peripheral portion of the winding. L1 / L2 is preferably about 1.2 to 1.7 times. If this ratio is less than 1.2, the effect is small. On the other hand, if this ratio exceeds 1.7 times, the thickness L1 of the outer peripheral side portion is larger than the thickness L2 of the inner end portion when edgewise winding is performed. It is not preferable because it remains easily.

Thus, in the flat insulated wire of the present invention, the thickness including the conductive wire and the insulating coating on the outer peripheral portion of the winding is greater than the thickness including the conductive wire and the insulating coating on the inner peripheral portion of the winding. Since the outer peripheral portion is outwardly wound with edgewise winding, the thick outer peripheral portion is stretched to reduce the thickness including the insulating coating and the conductive wire, Since the thin inner peripheral side portion is compressed, the thickness including the insulating coating and the conductive wire increases, and as a result, the outer peripheral portion including the insulating coating and the conductive wire and the inner peripheral side portion are increased. The thickness including the insulation coating and the conductive wire becomes substantially uniform. For this reason, it is difficult for a gap to be formed between the insulated wires in the outer peripheral portion of the edgewise coil, and the thickness of the insulating coating on the outer peripheral portion is not thinner than the thickness of the insulating coating on the inner peripheral portion. There is no concern that the insulation of the part will be lowered.

The rectangular conductive wire used for the rectangular insulated wire of the present invention can be manufactured by using a pressure roller having a wedge-shaped cross-section gap, and pulling out while pressing the conductive wire such as a copper wire into the wedge-shaped cross-section gap. it can. The gap between the wedge-shaped cross sections of the pressure roller is, for example, a pressure roller whose roll surface is inclined from one end to the other end, and facing so that the inclination of the roller surfaces approaches each other. By installing a pressure roller, a wedge-shaped cross-sectional gap can be formed between the roll surfaces.

The insulating coating can be formed by an electrodeposition method. Specifically, the rectangular conductive wire is fed into an electrodeposition tank containing an electrodeposition liquid containing an insulating coating component, and the rectangular conductive wire is passed through the electrodeposition tank while energizing the flat conductive wire. A rectangular insulated wire can be produced by electrodepositing an insulating coating component on the surface and baking the electrodeposited insulating coating component.

In the above electrodeposition method, an electrode is disposed on the side of the thick outer peripheral portion of the rectangular conductive wire, and the thin inner peripheral portion of the flat conductive wire is placed away from the electrode. By passing through the electrodeposition tank while energizing the rectangular conductive wire, the current density of the outer peripheral portion becomes higher than the current density of the inner peripheral portion, so that the insulation coating on the outer peripheral portion is A flat rectangular insulated wire formed thicker than the insulating coating on the inner peripheral side portion can be manufactured. Except for the arrangement of the electrodes, electrodeposition may be performed according to electrodeposition conditions for producing a normal insulated wire.

In the manufacturing method of the flat insulated wire of the present invention, the ratio L1 of the wall thickness L1 including the conductive wire and insulating coating on the outer peripheral side portion and the wall thickness L2 including the conductive wire and insulating coating on the inner peripheral side portion. The thickness of the insulating coating on the outer peripheral portion depends on the ratio of the long side to the short side of the wedge-shaped cross section of the rectangular conductive wire so that / L2 is 1.2 to 1.7 times. The insulating film may be formed so as to be 1.5 times or more the thickness of the insulating coating.

The flat insulated wire of the present invention is formed such that the thickness including the conductive wire and insulating coating on the outer peripheral side portion of the winding is thicker than the thickness including the conductive wire and insulating coating on the inner peripheral side portion of the winding. Therefore, when edgewise winding is performed with the outer peripheral side facing outward, the thickness of the outer peripheral side and the inner peripheral side is substantially uniform, and there is a gap between the insulated wires on the coil outer peripheral part. Not likely to occur.

Furthermore, since the thickness of the insulation coating on the outer peripheral side portion is thicker than the thickness of the insulation coating on the inner peripheral side portion, the flat insulated wire of the present invention has an edge with the outer peripheral portion as the outside. When wise winding is performed, the thickness of the insulating coating on the outer peripheral portion does not become thinner than the thickness of the insulating coating on the inner peripheral portion. Therefore, there is no concern that the insulation of the coil outer peripheral portion will be lowered.

The schematic cross section which shows the cross section of the flat insulated wire of this invention. External view of edgewise coil. XY sectional drawing of the coil of FIG. The conceptual diagram which shows arrangement | positioning of the pressure roller which forms a wedge-shaped clearance gap. The conceptual diagram which shows the manufacture example of the insulated wire by an electrodeposition method. Cross section of conventional flat insulated wire External view of conventional edgewise coil XY sectional view of the edgewise coil of FIG. Sectional view of flat insulated wire of Patent Document 2

An example of the flat insulated wire 10 of the present invention is shown in FIG. An example of the edgewise coil 20 using the flat insulated wire 10 is shown in FIG. The edgewise coil of FIG. 2 is an example of a field track shape in which both ends of a pair of linear portions are connected by a semicircular portion in plan view. The shape of the edgewise coil 20 using the flat insulated wire 10 of the present invention is not limited to the shape of FIG. In plan view, it is used for edgewise coils of various winding shapes such as a rectangular shape in which corners of four corners are wound in an arc shape or a circular shape.

As shown in FIG. 1, the thickness L1 of one side of the flat insulated wire 10 of the present invention is formed to be thicker than the thickness L2 of the other side, and as shown in FIG. The insulated wire 10 is edgewise wound with the thick side as the outer peripheral side 10A of the winding and the thin side as the inner peripheral side 10B of the winding.

The rectangular insulated wire 10 shown in FIG. 1 has a strip-like shape in which an insulating coating 16 is provided on the surface of a strip-like elongated conductive wire 15 having a quadrilateral cross section surrounded by long sides 11 and 12 and short sides 13 and 14. It is an elongated insulated wire. The pair of long sides 11 and 12 of the quadrilateral cross section of the conductive wire 15 forms a wedge-shaped quadrilateral cross section that approaches each other toward the short side 13 on one side, and the length T2 of one short side 13 is the other. The short side 14 is formed shorter than the length T1.

Further, the flat insulated wire 10 of the present invention is formed such that the thickness S1 of the insulation coating 16 on the short side 14 side is thicker than the thickness S2 of the insulation coating 16 on the short side 13 side. The thickness L1 and L2 of the insulated wire including the coating 16 is formed such that the thickness L1 on the short side 14 side is larger than the thickness L2 on the short side 13 side (L1> L2). The short side 14 side of the flat insulated wire 10 is the outer peripheral side 10A of the winding, and the short side 13 side is the inner peripheral side 10B of the winding.

Since the generally used rectangular electric wire for the edgewise coil has a lateral width, that is, the length of the long sides 11 and 12 is generally 0.1 to 10 mm, the thickness S1 and the short side of the insulating coating 16 on the short side 14 side The ratio S1 / S2 of the thickness S2 of the insulating coating 16 on the 13th side is preferably 1.5 times or more, and the ratio (L1 / L2) between the thickness L1 and the thickness L2 including the conductive wire 15 and the insulating coating 16 is approximately 1.2 to 1.7 times is preferable.

When the thickness ratio S1 / S2 of the insulation coating is less than 1.5 times, the insulation coating 16 on the short side 14 side is extended when edgewise winding is performed, and S1 may be smaller than S2. This is not preferable. In addition, when the ratio L1> L2 of the thickness including the conductive wire and the insulation coating is less than 1.2, the effect is small. On the other hand, when the ratio exceeds 1.7 times, the thickness L1 is obtained when edgewise winding is performed. Is not preferable because it tends to remain in a state larger than the wall thickness L2.

FIG. 3 shows a coil cross section along the line XY in FIG. As shown in the figure, the edgewise coil 20 using the flat insulated wire 10 of the present invention has the outer peripheral side portion 20A and the inner peripheral side portion 20B having substantially uniform wall thicknesses L1 and L2 by winding. It is difficult for a gap to be formed between the insulated wires 10. Further, the thickness of the insulating coating 16 on the outer peripheral portion 20A is substantially equal to the thickness of the insulating coating 16 on the inner peripheral portion 20B. Therefore, the insulating property of the outer peripheral portion 20A stretched by winding is good. Is maintained.

An example of a method for manufacturing the flat insulated wire 10 of the present invention is shown in FIGS. The rectangular conductive wire 15 having a wedge-shaped quadrilateral cross section used for the flat insulated wire 10 uses a pressure roller in which a wedge-shaped cross section gap is formed, and the conductive wire 15 such as a copper wire is passed through the wedge-shaped cross section gap. It can be manufactured by pulling out while applying pressure.

As shown in FIG. 4, for example, the gap between the wedge-shaped cross sections uses the pressure roller 30 in which the roll surface 31 is inclined from one end portion toward the other end portion, and the inclination of the loam surface 31 approaches each other. By placing the pressure roller 30 so as to face each other, a gap having a wedge-shaped cross section is formed between the roll surfaces 31 and 31.

The rectangular conductive wire 15 having a wedge-shaped conductive wire cross section in which the long sides 11 and 12 approach each other toward the short side 13 by feeding the conductive wire 15 into the gap of the wedge-shaped cross section and pulling it out while applying pressure. Is formed.

As shown in FIG. 5, the rectangular conductive wire 15 having a wedge-shaped cross section is fed into the electrodeposition tank 40. The electrodeposition tank 40 contains an electrodeposition liquid 41 in which the components of the insulating coating 16 are dissolved. By energizing the rectangular conductive wire 15 and allowing the electrodeposition liquid 41 to pass through, the components of the insulating coating 16 are electrodeposited on the surface of the rectangular conductive wire 15, and the components of the electrodeposited insulating coating 16 are baked. The insulating coating 16 is formed by processing.

In the electrodeposition method, as shown in FIG. 5, the electrode 42 is disposed close to the thick short side 14 side of the flat conductive wire 15, and the thin short side 13 side extends from the electrode 42. The flat conductive wire 15 and the electrode 42 are energized away from the power source 43. Since the current density on the short side 14 approaching the electrode 42 is denser than that on the short side 13 on the opposite side, the film formation of the insulation coating component proceeds, and the insulation coating on the short side 14 approaching the electrode 42 is on the opposite side. It is formed thicker than the insulation coating on the short side 13 side. Except for the arrangement of the electrodes, electrodeposition may be performed according to electrodeposition conditions for producing a normal insulated wire.

In the manufacturing method of the flat insulated wire of the present invention, the ratio L1 of the wall thickness L1 including the conductive wire and insulating coating on the outer peripheral side portion and the wall thickness L2 including the conductive wire and insulating coating on the inner peripheral side portion. / L2 is 1.2 to 1.7 times larger, and the thickness of the insulating coating on the outer peripheral portion depends on the ratio of the longer side to the shorter side of the wedge-shaped cross section of the rectangular conductive wire. The insulating film may be formed so as to be 1.5 times or more the thickness of the portion of the insulating coating.

In the case of an immersion method in which a rectangular conductive wire 15 having a wedge-shaped cross section is immersed in a paint containing an insulating coating component to form an insulating coating, the short side 13 side is up and the short side 14 side is down. By dipping and drying, the rectangular insulating coated electric wire 10 of the present invention can be manufactured.

10-flat insulated wire, 10A-outer peripheral part, 10B-inner peripheral part, 11, 12-long side, 13, 14-short side, 15-conductive wire, 16-insulation coating, S1, S2-short side Length, thickness of T1, T2-conductive wire 15, L1, L2-thickness including conductive wire 15 and insulation coating 16, 20-edgewise coil, 20A-outer peripheral side, 20B-inner peripheral side Part, 30-pressure roller, 31-roll surface, 40-electrodeposition tank, 41-electrodeposition liquid, 42-electrode, 43-power source, 60-flat rectangular insulated wire, 61-long side, 62-short side, 63 -Conductive wire, 64-insulation coating, 70-flat insulated wire, 71,72-long side, 73,74-short side, 75-insulation coating.

Claims (3)

A strip-shaped rectangular conductive wire in which the thickness of the conductive wire on the outer periphery of the winding is thicker than the thickness of the conductive wire on the inner periphery of the winding is filled with an electrodeposition liquid containing an insulating coating component. electrodeposition tank infeed, an electrode is arranged on the side of the thicker the outer peripheral portion of the thickness of the flat angle conductive wires, a thin the inner peripheral portion of the wall thickness away Succoth from the electrode, the flat angle conductivity The conductive wire was energized, and the insulation coating component was electrodeposited on the surface of the rectangular conductive wire so that the insulation coating component on the outer peripheral portion was thicker than the insulation coating component on the inner peripheral portion . A rectangular insulation electric wire characterized in that the insulation coating component is baked to produce a rectangular insulated wire in which the insulation coating is formed thicker than the insulation coating on the inner peripheral portion on the outer peripheral portion where the thickness of the conductive wire is thick. Electric wire manufacturing method. The method for manufacturing a rectangular insulated wire according to claim 1 , wherein the thickness of the insulating coating on the outer peripheral portion is formed to be 1.5 times or more the thickness of the insulating coating on the inner peripheral portion. The wall thickness containing a conductive wire and an insulating coating of the outer peripheral portion, with respect to the thickness including the conductive wire and the insulating coating of the inner peripheral portion, claim to form a 1.2 to 1.7-fold The manufacturing method of the flat insulated wire of Claim 1 or Claim 2 .

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