JP6846882B2 - Flat insulated wire and its manufacturing method - Google Patents

Description

The present invention relates to a flat insulated electric wire used for an electronic component such as a power transformer and a method for manufacturing the same. More specifically, the present invention can be flexible, have excellent coil linearity, increase the space factor, and reduce the size of the coil. The present invention relates to a flat insulated electric wire and a method for manufacturing the same.

For electronic components such as choke coils, transformers, and inductances, in order to increase the space factor, as shown in Patent Documents 1 and 2, a flat angle obtained by bundling a plurality of round lines having a circular cross section and then processing each round line into a rectangular cross section. Electric wires may be used.

In Patent Document 1, the coil winding property is good when winding an electric device coil, the coil space factor is large after coil winding, and a flat-angle litz wire capable of measuring miniaturization, high performance, and energy saving can be achieved. Has been proposed. This flat litz wire is formed by twisting a plurality of enamel wire strands to form a round litz wire having a circular cross section so that the cross section has a flat cross section, and an adhesive material or a thermoplastic material is applied to the outer periphery. It is manufactured so that the adhesive tape formed by coating is vertically aligned.

Further, Patent Document 2 proposes a flat-angle electric wire which is easy to use, can improve high-frequency characteristics, can shorten a manufacturing time, and can reduce a manufacturing cost. In this flat wire, a step of forming an oxide film on the outer periphery of a conductor having a round cross section, a step of aligning a plurality of the aligned conductors while twisting them, and a process of drawing (compressing) the aligned conductors into a flat shape. It is manufactured by a step of forming a flat-square twisted conductor portion and a step of extruding and forming an insulating layer around the flat-square twisted conductor portion.

Japanese Unexamined Patent Publication No. 2000-090747 JP-A-2009-245658

In the above-mentioned conventional flat wire, a wire having a round cross section (enamel wire or a conductor wire having an oxide film formed) is twisted to form a stranded wire having a round cross section, and the stranded wire has a flat cross section. It is formed into a shape (rolling or wire drawing), and then a vertical adhesive tape or an insulating layer is formed by extrusion coating on the outer circumference to make the cross section flat. .. In this way, when the cross section of the stranded wire obtained by twisting the conductor wires is molded into a flat shape, the cross section of each conductor wire is also flat and the conductor wires are not adhered to each other. , Each conductor wire is liable to come apart, and the cross-sectional shape (flat shape) of the entire stranded wire is liable to collapse in the subsequent step of applying an insulating coating.

In particular, in Patent Document 1, when an adhesive tape is vertically attached to the outer circumference of a flat-angle litz wire, the flat-angle shape is likely to collapse due to the tape tension during tape winding. Further, the adhesive-impregnated adhesive portion and the non-adhesive-impregnated adhesive portion are alternately provided along the longitudinal direction of the flat-angle litz wire, or heat-sealed along the longitudinal direction of a plurality of self-bonding enamel wires. When the portions and the non-thermally fused portions are provided so as to be alternately repeated, the conductor strands are bonded or fused to each other and do not move, so that the obtained flat-angle litz wire has poor flexibility, and particularly a small-diameter coil is manufactured. The winding property of the case is reduced.

Further, in Patent Document 2, when a plurality of conductor wires are twisted and aligned and then drawn to form a flat shape, the conductor wires are compressed and deformed, so that the conductor wires are flexible due to work hardening. The property is reduced, and the winding property is particularly reduced when a small-diameter coil is manufactured. In addition, a flat wire is manufactured by providing an insulating layer with extrusion coating on the outer circumference of the flat stranded wire, but every time there is a change in specifications such as wire diameter, a special size die must be changed, which makes the manufacturing process difficult. It gets complicated.

The present invention has been made to solve the above problems, and an object of the present invention is to be used for an electronic component such as a power transformer, to be flexible, to have excellent coil linearity, to increase the space factor, and to provide a coil. An object of the present invention is to provide a flat insulated electric wire that can be miniaturized and a method for manufacturing the same.

<1> The flat insulated wire according to the present invention for solving the above problems includes a stranded wire held in a flat or substantially flat cross-sectional shape and a stranded wire that covers the stranded wire and retains the cross-sectional shape of the stranded wire. It has one or more insulating tapes, and at least one of the two or more insulating tapes is provided with an adhesive layer, and the insulating tapes are bonded to each other by the adhesive layer. To do.

According to the present invention, since it is a flat insulated wire having a stranded wire having a flat or substantially flat cross-sectional shape, it is preferable as an insulated wire for a coil having a high space factor. Further, since two or more insulating tapes in which the insulating tapes are bonded to each other by an adhesive layer retain the cross-sectional shape of the stranded wire, the stranded wire and the insulating tape are not bonded to each other. As a result, the flat insulated wire is flexible and has excellent coil winding property. The cross section of the stranded wire is a flat or substantially flat cross section, but the conductor strands constituting the stranded wire have a round or substantially round cross section.

In the flat insulated electric wire according to the present invention, the adhesion is made at least at the overlapping portion of the insulating tapes among the two or more insulating tapes.

In the flat insulating electric wire according to the present invention, the two insulating tapes that are adhered to each other are wound in opposite directions, or are wound in the same direction but with different winding pitches.

In the flat insulated wire according to the present invention, (1) the two insulating tapes to be adhered directly cover the stranded wire, or (2) the insulating tape is not adhered by the adhesive layer. The non-adhesive insulating tape directly covers the stranded wire, and the two adhesive insulating tapes cover the non-adhesive insulating tape.

<2> The method for manufacturing a flat insulated electric wire according to the present invention includes a step of preparing a stranded wire and two or more insulating tapes provided with an adhesive material on at least one insulating tape, and the stranded wire is described. The step of covering with two or more insulating tapes, the step of processing the stranded wire after covering with the two or more insulating tapes to obtain a flat or substantially flat cross-sectional shape, and the step of maintaining the cross-sectional shape. It is characterized by having a step of solidifying the adhesive material in a state and holding the cross-sectional shape.

According to the present invention, it is possible to manufacture an insulated wire for a coil that is flexible, has excellent coil linearity, and has a high space factor.

In the method for manufacturing a flat insulated electric wire according to the present invention, two or more of the insulating tapes are used in the step of covering with the insulating tape, and the adhesive material is applied to at least the overlapping portion of the insulating tapes among the two or more insulating tapes. Cover so that it is placed.

In this case, the two insulating tapes are wound in opposite directions, or in the same direction but with different winding pitches. In such a case, (1) the two insulating tapes may be provided directly on the stranded wire, or (2) the insulating tape having no adhesive material among the insulating tapes may be provided on the stranded wire. Insulation tape having the adhesive material may be provided directly on the surface and via the insulating tape.

In the method for manufacturing a flat insulated electric wire according to the present invention, in the step of processing into the cross-sectional shape, the processing is performed by roll rolling or die processing.

In the method for manufacturing a flat insulated electric wire according to the present invention, in the step of maintaining the cross-sectional shape, the adhesive material is solidified during or immediately after the processing.

According to the present invention, there is provided a flat insulated electric wire used for electronic components such as a power transformer, which is flexible, has excellent coil linearity, has an increased space factor, and can be miniaturized, and a method for manufacturing the same. be able to.

It is a schematic explanatory view which shows an example of the flat insulation electric wire which concerns on this invention, (A) is a sectional view, (B) is a perspective view. It is explanatory drawing of each process of the manufacturing method of a flat insulation electric wire. It is a schematic explanatory drawing which shows an example of a flat insulating electric wire wound with two insulating tapes, (A) is an example which an adhesive layer was provided on the first insulating tape, and (B) is two. This is an example in which an adhesive layer is provided on the insulating tape of the eyes. It is an example of winding with two insulating tapes, (A) is an example of being wound in opposite directions, and (B) is an example of being wound in the same direction but with different winding pitches. .. This is an example in which a non-adhesive insulating tape that is not adhered by an adhesive layer among the insulating tapes directly covers the stranded wire, and two adhesive insulating tapes cover the non-adhesive insulating tape. This is an example in which an insulating layer (resin coating layer or extruded resin layer) is further provided on the outer periphery of two or more insulating tapes.

Hereinafter, the heater wire and the heater for the seat according to the present invention will be described with reference to the drawings. The present invention is not limited to the illustrated embodiment.

[Flat insulated wire]
As shown in FIG. 1, the flat insulated wire 10 according to the present invention has a stranded wire 1 held in a flat or substantially flat cross-sectional shape and a stranded wire 1 covering the stranded wire 1 to maintain the cross-sectional shape of the stranded wire 2. It has one or more insulating tapes 2. An adhesive layer 6 is provided on at least one of the two or more insulating tapes 2, and the insulating tapes are adhered to each other by the adhesive layer 6.

Since the flat insulated wire 10 is a flat insulated wire having a stranded wire 1 having a flat or substantially flat cross section, it is preferable as an insulated wire for a coil having a high space factor. Further, since the two or more insulating tapes 2 in which the insulating tapes are bonded to each other by the adhesive layer 6 hold the cross-sectional shape of the stranded wire 1, the stranded wire 1 and the insulating tape 2 are not bonded to each other. As a result, the flat insulated wire 10 is advantageous in that it is flexible and has excellent coil linearity. In each figure, the adhesive material 6'and the adhesive layer 6 are described together, but the adhesive material 6'is the one before solidification and the adhesive layer 6 is the one after solidification. It is used properly when explaining the present invention.

Hereinafter, the components of the flat insulated electric wire will be described in detail.

(Twisted wire)
The stranded wire 1 is an aggregated wire rod in which a plurality of conductor strands 1a are twisted together, and is held flat or substantially flat as an entire cross section. The degree of flatness or substantially flatness is about 1.5: 1 in the ratio of the major axis to the minor axis of the cross-sectional shape, and for example, the flatness [(maximum diameter-minimum diameter) / maximum diameter] is 33% or more. It can be said that the degree of flatness of is a preferable degree. With this degree of flatness, it is possible to obtain a flat insulated wire 10 capable of coil winding having a high space factor, which is preferable. On the other hand, the smaller the flatness, the smaller the space factor of the coil. For example, if it is less than 15%, it cannot be said that the insulated wire enables coil winding with a high space factor.

Since the stranded wire 1 is only held flat or substantially flat as a whole, each conductor wire 1a itself is not deformed, and even if it has a round cross section or is slightly deformed. It is very small and can be said to have a substantially round cross section. In this way, since the conductor strands 1a constituting the stranded wire 1 are not deformed into a rectangular shape (flat shape), the rectangular conductor strands 1a are in close contact with each other, resulting in reduced flexibility or a coil. The winding property does not decrease.

The number of conductor strands 1a is not particularly limited, and is arbitrarily set according to the required product specifications and coil specifications. Usually, it is about 8 to 300. The twisting form of the conductor wire 1a may include collective twisting, concentric twisting, and the like, and the twisting pitch is arbitrarily set and is not particularly limited, but is usually preferably in the range of 5 mm to 100 mm. The diameter of the conductor wire 1a is not particularly limited, but may be, for example, 0.03 mm or more and 0.5 mm or less.

The conductor wire 1a may be any conductive material, but is preferably a conductive conductor that can be soldered. For example, it may be a composite material such as copper or a copper alloy, an aluminum or an aluminum alloy, a copper clad aluminum, or a metal plated with another metal having good solderability. When the conductor itself cannot be soldered, it is preferable to provide a metal having good solderability by plating or the like. Examples of the metal having good solderability include tin, solder, nickel, gold, silver, copper, palladium, and one or more alloys thereof.

A lubricant or an antioxidant may be applied to the conductor wire 1a. Since the lubricant improves the slipperiness of the conductor wire 1a, the stranded wire 1 is made easier, and the individual conductor wire 1a slips when the coil is wound with the finally obtained flat insulated wire. It can be improved and the winding property can be made easier. The antioxidant has an effect of preventing the oxidation of the conductor wire 1a, and can prevent possible oxidation at the time of twisting or winding the tape.

An insulating film may be provided on the conductor wire 1a, if necessary. Examples of the insulating film include various types of enamel films, and preferred examples include urethane-based and polyester-based enamel films that do not interfere with soldering. In particular, when it is desired to reduce the high frequency loss due to the skin effect, it is preferable to use the conductor wire 1a provided with the insulating film.

(Insulating tape)
The insulating tape 2 covers the stranded wire 1 and maintains a flat or substantially flat cross-sectional shape. As the insulating tape 2, two or more insulating tapes (2a, 2b, 2c, ...) Are used. An adhesive layer 6 is provided on at least one of the two or more insulating tapes 2, and the insulating tapes are adhered to each other by the adhesive layer 6.

The flat or substantially flat cross-sectional shape of the stranded wire 1 is held by the insulating tape 2 bonded by the adhesive layer 6. The shape is maintained by the insulating tape 2 by the rigidity of the solidified adhesive layer 6 and the rigidity of the insulating tape 2 bonded by the adhesive layer 6. To maintain such a shape, as will be described in FIG. 2 and the description column of the manufacturing method described later, the cross-sectional shape of the stranded wire 1 is deformed to be flat or substantially flat in a state where the adhesive layer 6 is not solidified, and at the same time as the deformation. Alternatively, the adhesive material 6'is solidified immediately after deformation while maintaining flatness or substantially flatness. By such a method, the flat or substantially flat cross-sectional shape of the stranded wire 1 can be maintained. The cross-sectional shape is preferably deformed by rolling or die processing, but it is deformed to the same shape as the cross-sectional shape at the time of deformation by rolling or die processing, or even if it is not the same, it returns slightly. It has been transformed into.

Two or more insulating tapes 2 are used. Of the two or more insulating tapes, at least the overlapping portion of the insulating tapes is adhered by the adhesive layer 6. FIG. 3 is a schematic explanatory view showing an example of a flat insulated wire 10 wound with two insulating tapes 2a and 2b. FIG. 3A is an example in which the adhesive layer 6 is provided on the first insulating tape 2a, and FIG. 3B is an example in which the adhesive layer 6 is provided on the second insulating tape 2b. After bonding, it may not be known which insulating tape the adhesive layer 6 is provided with, but in the manufacturing process, it becomes as shown in FIG. 3 (B).

In the example of FIG. 3A, first, the first insulating tape 2a provided with the adhesive material 6'and the second insulating tape 2b not provided with the adhesive material 6'are prepared. Next, the first insulating tape 2a is wound around the stranded wire 1 with the surface provided with the adhesive material 6'facing the side opposite to the stranded wire 1 side. The winding form (winding pitch, etc.; the same applies hereinafter) at this time is not particularly limited, but for example, it is preferable to superimpose a part of the insulating tape 2a and wind it in a spiral shape. Next, a second insulating tape 2b on which the adhesive material 6'is not provided is wrapped around the tape. The winding form at this time is not particularly limited, but for example, it is preferable to superimpose a part of the insulating tape 2b and wind it spirally in the direction opposite to that of the insulating tape 2a.

On the other hand, in the example of FIG. 3B, first, the first insulating tape 2a not provided with the adhesive material 6'and the second insulating tape 2b provided with the adhesive material 6'are prepared. .. Next, the first insulating tape 2a on which the adhesive material 6'is not provided is wound around the stranded wire 1. The winding form at this time is not particularly limited, but for example, it is preferable to superimpose a part of the insulating tape 2a and wind it in a spiral shape. Next, the second insulating tape 2b is wound on the surface with the surface provided with the adhesive material 6'facing the first insulating tape 2a side. The winding form at this time is not particularly limited, but for example, it is preferable to superimpose a part of the insulating tape 2b and wind it spirally in the direction opposite to that of the insulating tape 2a.

In the winding form shown in FIGS. 3A and 3B, both the first insulating tape 2a and the second insulating tape 2b may have the adhesive material 6'. In that case, the insulating tapes 2a and 2b are wound around the insulating tapes 2a and 2b so that the adhesive material 6'is facing the opposite insulating tapes.

By wrapping in such a form, the adhesive material 6'is not exposed on the outermost surface, so that the outer circumference is not sticky. As a result, the adhesive material 6'does not adhere to the rolling roll or die during the deformation process with the rolling roll or die, and the deformation process can be performed stably. Further, since the adhesive layer 6 is not adhered to the stranded wire 1, the degree of freedom of the stranded wire 1 is secured, the stranded wire 1 is flexible, and the coil winding property is excellent.

FIG. 4 shows an example (A) in which two insulating tapes 2a and 2b are wound in opposite directions, and an example (B) in which they are wound in the same direction but with different winding pitches. Is shown. In either case, if the adhesive material 6'is solidified immediately after or at the same time as the stranded wire 1 is deformed to be flat or substantially flat while maintaining the flatness or substantially flatness, the stranded wire 1 is flattened or substantially flat. Can retain the cross-sectional shape of. When winding in the same direction, it is more preferable to wind them so that the pitches are different as shown in FIG. 4B, but they may be wound at the same pitch.

In FIG. 5, of the insulating tapes, the non-adhesive insulating tape 2d that is not adhered by the adhesive layer directly covers the stranded wire 1, and the two adhesive insulating tapes 2b and 2c cover the non-adhesive insulating tape 2d. This is an example. Even in this case, the insulating tapes 2b and 2c cover the stranded wire 1 and maintain a flat or substantially flat cross-sectional shape. Further, since the adhesive layer is not adhered to the stranded wire 1, the degree of freedom of the stranded wire 1 is secured, the stranded wire 1 is flexible, and the coil winding property is excellent. Further, since the adhesive material 6'is not exposed on the outermost surface, the outer circumference is not sticky, and the adhesive material 6'does not adhere to the rolling roll or die during deformation processing with a rolling roll or die, and blocking or the like does not occur. ..

The material of the insulating tape 2 is not particularly limited, but is polyethylene terephthalate (PEN), polyimide (PI), polyphenylene sulfide (PPS), ethylene-ethylene tetrafluoride copolymer (ETFE), ethylene tetrafluoride-6. Examples thereof include fluorinated propylene copolymer (FEP), fluorinated resin copolymer (perfluoroalkoxy alkane resin: PFA), polyether ether ketone (PEEK), polyethylene terephthalate (PET), polyamide (PA) and the like.

The thickness of the insulating tape 2 is not particularly limited, but is usually preferably in the range of 4 μm or more and 25 μm or less. The width of the insulating tape 2 is also not particularly limited, but is usually preferably in the range of 2 mm or more and 20 mm or less. The thickness and width of each insulating tape in the two or more insulating tapes may be the same or different.

In particular, the flat insulated wire 10 insulated with three or more insulating tapes realizes high insulation properties and is certified as an insulated wire that meets safety standards such as IEC60950, and is a wire rod for coils such as an insulating transformer and an IH heater. Can be used as. When the flat insulated wire 10 is used as a coil for a transformer, the primary side and the secondary side can be reliably insulated.

(Adhesive layer)
The adhesive layer 6 is provided on at least one of two or more insulating tapes 2. As described above, the adhesive layer 6 adheres the insulating tapes to each other. Examples of the constituent material of the adhesive layer 6 include an adhesive material that is solidified by heat, ionizing radiation, or the like. The adhesive material that is bonded and solidified by heat is a heat-sealing material, and examples thereof include heat-sealing adhesive materials such as polyester-based, acrylic-based, and epoxy-based. Examples of the adhesive material that is adhered and solidified by ionizing radiation (for example, ultraviolet rays) include an ionizing radiation adhesive material such as an acrylic type or an epoxy type.

The adhesive material 6'constituting the adhesive layer 6 is relatively flexible until it is solidified, and the insulating tape 2 is wrapped around the outer circumference of the stranded wire 1 to hinder deformation during deformation processing by a rolling roll or a die. It is desirable that there is no such thing. On the other hand, it is preferable that the adhesive layer 6 after the adhesive material 6'is solidified by heat or ionizing radiation can solidify the insulating tape to suppress the flexibility of the insulating tape and suppress the deformation of the stranded wire 1. The adhesive material 6'preferably has such properties, and particularly preferably is a material that instantly solidifies immediately after being deformed by a rolling roll, a die, or the like. As such an adhesive material 6', it is particularly preferable that the adhesive material is a polyester-based, acrylic-based, epoxy-based, olefin-based, polyurethane-based or the like that is solidified by heat.

The adhesive layer 6 is provided on one side of the insulating tape with a predetermined thickness depending on the type of the adhesive material 6'constituting, and the insulating tapes are bonded and solidified to each other. The thickness is not particularly limited as long as it is formed to have a minimum thickness sufficient for adhering and solidifying the two insulating tapes, but is provided in the range of 1 μm or more and 10 μm or less, for example.

The adhesive layer 6 is usually provided on the entire surface of the insulating tape to be formed. If cost is not taken into consideration, it can be provided on a part of the insulating tape.

(Other)
The insulating layer 7 is not an essential configuration, but is arbitrarily provided on the outer periphery of the insulating tape 2 as shown in FIG. Examples of the insulating layer 7 include an insulating layer provided by the coating means and an insulating layer provided by the extrusion means. Examples of the constituent material of the insulating layer 7 include polyurethane resin, polyester resin, and fluorine-based resin. In addition, ethylene-ethylene tetrafluorinated copolymer (ETFE), ethylene tetrafluorinated-propylene hexafluorinated copolymer (FEP), fluorinated resin copolymer (perfluoroalkoxy alkane resin: PFA), polyetheretherketone (PEEK), polyethylene terephthalate (PET), polyamide (PA) may be used.

The insulating layer 7 may be a single layer or a laminated layer. When the insulating layer 7 is in a laminated form, the same or different resin layers described above can be provided. The thickness of the insulating layer 7 is not particularly limited regardless of whether it is a single layer or a laminated layer, but it is usually preferably 10 μm or more.

The flat insulated wire 10 according to the present invention has been described above. Since the flat insulated wire 10 has a stranded wire 1 held in a flat or substantially flat cross section, the space factor is increased and the coil is miniaturized. It is preferably used as an insulated wire for a coil. In the flat insulated wire 10, the insulating tapes 2 covering the stranded wires 1 are adhered to each other by the adhesive layer 6, but the stranded wires 1 and the insulating tape 2 are not adhered to each other. As a result, the flat insulated wire 10 is flexible and has excellent coil linearity. In particular, it is preferably used for a small coil that requires a high dielectric strength.

[Manufacturing method of flat insulated wire]
In the method for manufacturing a flat insulated wire 10 according to the present invention, as shown in FIG. 2, a stranded wire 1 and two or more insulating tapes 2 in which an adhesive material 6'is provided on at least one insulating tape are prepared. (Preparation step), the step of covering the stranded wire 1 with the two or more insulating tapes 2 (insulating tape coating step), and processing the stranded wire 1 after covering the stranded wire 1 with the two or more insulating tapes 2. A step of forming a flat or substantially flat cross-sectional shape (deformation processing step) and a step of solidifying the adhesive material 6'while maintaining the cross-sectional shape to maintain the flat or substantially flat cross-sectional shape ( It has a shape retention process). The flat or substantially flat insulated wire 10 manufactured by this method is an insulated wire for a coil that is flexible, has excellent coil linearity, has an increased space factor, and can reduce the size of the coil.

(Preparation process)
The preparatory step is a step of preparing the stranded wire 1 and two or more insulating tapes 2 in which the adhesive material 6'is provided on at least one insulating tape 2. Since the stranded wire 1, the insulating tape 2, and the adhesive material 6'have already been described, the description thereof will be omitted here.

(Insulating tape coating process)
The insulating tape coating step is a step of covering the stranded wire 1 with two or more insulating tapes 2, and uses two or more insulating tapes 2 to adhere to at least the overlapping portion of the two or more insulating tapes 2. Cover so that material 6'is placed. In this case, it is preferable to wind the two insulating tapes 2 in opposite directions, or to wind them in the same direction but with different winding pitches. When wound in this way, two insulating tapes 2 may be provided directly on the stranded wire 1, or an insulating tape having no adhesive material 6'of the insulating tape 2 may be provided directly on the stranded wire 1. An insulating tape having the adhesive material 6'may be provided via the insulating tape. The method of covering with the insulating tape has also been described in detail in the explanation column of the insulating tape, and thus the description thereof will be omitted here.

(Deformation processing process)
The deformation processing step is a step of processing the stranded wire 1 after covering with two or more insulating tapes 2 to form a flat or substantially flat cross-sectional shape. This deformation processing is performed by roll rolling processing or die processing. The cross-sectional shape is formed by flattening the conductor strands 1a of the twisted stranded wires 1 with a pressure rolling roll or a die so as not to deform them. As a result, there is no partial adhesion as in Patent Document 1 and work hardening as in Patent Document 2.

(Shape retention process)
In the shape holding step, the adhesive material 6'is solidified and the cross-sectional shape is held in a state where the cross-sectional shape of the stranded wire 1 after being covered with two or more insulating tapes 2 is maintained flat or substantially flat. It is a process. In this step, the adhesive material 6'is solidified during or immediately after the deformation processing.

The means of solidification differs depending on the type of the adhesive material 6'. For example, in the case of a heat-bondable adhesive material that is solidified by heat, the adhesive material can be solidified by a heating means such as a heating furnace, a hot roll, or hot air. .. Further, in the case of an adhesive material that is solidified by ionizing radiation (ultraviolet rays or the like), the adhesive material can be solidified by irradiation means such as ultraviolet rays or electron beams.

The timing of application of the deformation processing step and the shape holding step may be arbitrarily changed depending on the solidification time of the adhesive material 6'used. For example, when a heat-bondable adhesive material is used, heat is applied before the deformation process to start solidifying the adhesive material, and during the solidification process, the adhesive material is deformed by a rolling roll, a die, or the like. Sometimes it cools and solidifies to retain its shape. On the other hand, when an adhesive material that is cured by ionizing radiation such as ultraviolet rays is used, the adhesive material may be instantly solidified by irradiation with ionizing radiation. In such a case, ionizing radiation is applied during or immediately after the deformation process. By irradiating, it solidifies and retains its shape.

As yet another step, a step of providing an insulating layer (resin coating layer or extruded resin layer) 7 on the outer periphery of two or more insulating tapes 2 can be mentioned. The insulating layer 7 and the method for forming the insulating layer 7 have also been described in detail in the explanation column of the insulating layer 7, and the description thereof will be omitted here.

Hereinafter, the present invention will be described in more detail with reference to Examples. It should be noted that this does not limit the present invention.

[Example 1]
38 annealed copper wires having a diameter of 0.08 mm were used as the conductor strands 1a, and the conductor strands 1a were twisted at a twist pitch of 18 mm to prepare a stranded wire 1 having an outer diameter of 0.57 mm. Prepare a PPS tape having an adhesive material 6'on one side as the first layer insulating tape 2a, prepare a PPS tape having an adhesive material 6'on one side as the second layer insulating tape 2b, and prepare a third layer insulating tape. As 2c, a PPS tape having an adhesive material 6'on one side was prepared.

First, the first layer of insulating tape 2a was spirally wound around the stranded wire 1. At this time, a part of the insulating tape 2a was overlapped and wound so that the adhesive material 6'was on the outside. Next, the second layer insulating tape 2b was spirally wound around the first layer insulating tape 2a. At this time, a part of the insulating tape 2b was overlapped and wound so that the adhesive material 6'was on the inside. Next, the third layer insulating tape 2c was spirally wound around the second layer insulating tape 2b. At this time, a part of the insulating tape 2c was overlapped and wound so that the adhesive material 6'was on the inside. The outer diameter of the three-layer wound insulated wire around which the three insulating tapes 2a, 2b, and 2c were wound was 0.74 mm. The adhesive material 6'possessed by each of the insulating tapes 2a, 2b, and 2c has a heat-meltable polyester-based adhesive having a thickness of 2 μm and is provided on the surface of each insulating tape.

Next, the three-layer wound insulated wire was run in a heating furnace at 160 ° C. for 15 seconds to heat it, and immediately after leaving the heating furnace, it was run between two metal rolling rolls to roll. The distance between the two metal rolling rolls can be set arbitrarily, and the thickness of the three-layer wound insulated wire is set to 0.6 mm before rolling. By the rolling, the width of the three-layer wound insulated wire became about 0.95 mm. By heating here, the adhesive material 6'possessed by each insulating tape is thermally melted by heating to increase the fluidity, and the insulating tapes are bonded to each other during the rolling immediately after, but at this stage, they are cooled and begin to solidify. However, it is not completely solidified.

Next, the three-layer wound insulated wire was cooled by the air cooling device at the outlet of the metal rolling roll, and the heat-sealing adhesive material 6'was fixed to form the adhesive layer 6, and each insulating tape was bonded and flattened. The cross-sectional shape of the stranded wire 1 is maintained. In this way, a flat insulated wire 10 having a thickness of 0.6 mm and a width of 0.95 mm was produced.

The fracture voltage of the obtained flat insulated wire 10 measured with a withstand voltage tester (manufactured by Kikusui Denshi Kogyo Co., Ltd.) based on JIS C 3216 (winding test method) was 11.5 kV, and the tensile tester (stock). The elongation measured by the company Orientec, model number: STA-1225) was 20%. By using the flat insulated wire 10 having this cross-sectional shape, the outer diameter of the coil could be reduced by 10%. The flat insulated wire 10 was flexible and had excellent linearity around a core having a diameter of 8 mm.

[Example 2]
In Example 1, two insulating tapes 2a and 2b were wound around the stranded wire 1 without using the third layer insulating tape 2c. A flat insulated wire 10 having a thickness of 0.55 mm and a width of 0.90 mm was produced in the same manner as in Example 1 except for the above.

The breaking voltage of the obtained flat insulated wire was 11.0 kV, and the elongation was 20%. The flat insulated wire was flexible and had excellent linearity around a core having a diameter of 8 mm. The flat insulated wire 10 had a breaking voltage smaller than that of the first embodiment, but had good linearity and the like.

[Example 3]
In Example 1, an insulating tape 2d having no adhesive material was used instead of the first layer insulating tape 2a. Further, unlike the first embodiment, the second layer of the insulating tape 2b wound around the insulating tape 2d is wound so that the adhesive material 6'is on the outside, and the third layer of the insulating tape 2c is the same as in the first embodiment. The adhesive material 6'was wound so that it was on the inside. A flat insulated wire 10 having a thickness of 0.59 mm and a width of 0.94 mm was produced in the same manner as in Example 1 except for the above.

The breaking voltage of the obtained flat insulated wire was 11.5 kV, and the elongation was 30%. The flat insulated wire was flexible and had excellent linearity around a core having a diameter of 8 mm.

[Comparative Example 1]
In Example 1, when the three insulating tapes 2a, 2b, and 2c were wound around the stranded wire 1, all the adhesive materials 6'that each insulating tape had were wound inside. A flat insulated wire of Comparative Example 1 was produced in the same manner as in Example 1 except for the above.

The breaking voltage of the obtained flat insulated wire was 11.5 kV, and the elongation was 20%. In the flat insulated wire, the adhesive layer of the first insulating tape 2a was adhered to the stranded wire 1, and the wire was not very soft, and the winding property to the core having a diameter of 8 mm was not good.

[Example 4]
In this example, a flat insulated wire with a reduced number of conductors was produced. As the conductor wire 1a, 19 annealed copper wires having a diameter of 0.08 mm were used, and the conductor wire 1a was twisted at a twist pitch of 12 mm to prepare a stranded wire 1 having an outer diameter of 0.40 mm. Prepare a PPS tape having an adhesive material 6'on one side as the first layer insulating tape 2a, prepare a PPS tape having an adhesive material 6'on one side as the second layer insulating tape 2b, and prepare a third layer insulating tape. As 2c, a PPS tape having an adhesive material 6'on one side was prepared.

First, the first layer of insulating tape 2a was spirally wound around the stranded wire 1. At this time, a part of the insulating tape 2a was overlapped and wound so that the adhesive material 6'was on the outside. Next, the second layer insulating tape 2b was spirally wound around the first layer insulating tape 2a. At this time, a part of the insulating tape 2b was overlapped and wound so that the adhesive material 6'was on the inside. Next, the third layer insulating tape 2c was spirally wound around the second layer insulating tape 2b. At this time, a part of the insulating tape 2c was overlapped and wound so that the adhesive material 6'was on the inside. The outer diameter of the three-layer wound insulated wire around which the three insulating tapes 2a, 2b, and 2c were wound was 0.61 mm. The adhesive material 6'possessed by each of the insulating tapes 2a, 2b, and 2c has a heat-meltable polyester-based adhesive having a thickness of 2 μm and is provided on the surface of each insulating tape.

Next, the three-layer wound insulated wire was run in a heating furnace at 160 ° C. for 15 seconds to heat it, and immediately after leaving the heating furnace, it was run between two metal rolling rolls to roll. The distance between the two metal rolling rolls can be set arbitrarily, and the thickness of the three-layer wound insulated wire is set to 0.53 mm before rolling. By the rolling, the width of the three-layer wound insulated wire became about 0.72 mm. By heating here, the adhesive material 6'possessed by each insulating tape is thermally melted by heating to increase the fluidity, and the insulating tapes are bonded to each other during the rolling immediately after, but at this stage, they are cooled and begin to solidify. However, it is not completely solidified.

Next, the three-layer wound insulated wire was cooled by the air cooling device at the outlet of the metal rolling roll, and the heat-sealing adhesive material 6'was fixed to form the adhesive layer 6, and each insulating tape was bonded and flattened. The cross-sectional shape of the stranded wire 1 is maintained. In this way, a flat insulated wire 10 having a thickness of 0.53 mm and a width of 0.72 mm was produced.

The breaking voltage of the obtained flat insulated wire was 13.9 kV, and the elongation was 30%. The flat insulated wire was flexible and had excellent linearity around a core having a diameter of 6 mm.

[Example 5]
In this example, a large size flat insulated wire was produced. 133 annealed copper wires having a diameter of 0.1 mm are used as the conductor strands 1a, and 19 conductor strands 1a are first twisted at a pitch of 35 mm to form a child-twisted conductor, and seven of the child-twisted conductors are twisted at a pitch of 45 mm. A stranded conductor 1 having an outer diameter of 1.73 mm was prepared by twisting (parent twisting). A PET tape having no adhesive material is prepared as the first layer insulating tape 2a, a PET tape having an adhesive material 6'on one side is prepared as the second layer insulating tape 2b, and the third layer insulating tape 2c is prepared. As a result, a PET tape having an adhesive material 6'on one side was prepared.

First, a part of the first layer of insulating tape 2a was overlapped around the stranded wire 1 and wound spirally. Next, the second layer insulating tape 2b was spirally wound around the first layer insulating tape 2a. At this time, a part of the insulating tape 2b was overlapped and wound so that the adhesive material 6'was on the inside. Next, the third layer insulating tape 2c was spirally wound around the second layer insulating tape 2b. At this time, a part of the insulating tape 2c was overlapped and wound so that the adhesive material 6'was on the inside. The outer diameter of the three-layer wound insulated wire around which the three insulating tapes 2a, 2b, and 2c were wound was 1.88 mm. The adhesive material 6'possessed by each of the insulating tapes 2a, 2b, and 2c has a heat-meltable polyester-based adhesive having a thickness of 2 μm and is provided on the surface of each insulating tape.

Next, the three-layer wound insulated wire was run in a heating furnace at 160 ° C. for 15 seconds to heat it, and immediately after leaving the heating furnace, it was run between two metal rolling rolls to roll. The distance between the two metal rolling rolls can be set arbitrarily, and the thickness of the three-layer wound insulated wire is set to 1.41 mm before rolling. By the rolling, the width of the three-layer wound insulated wire became about 1.72 mm. By heating here, the adhesive material 6'possessed by the insulating tapes of the second and third layers is thermally melted by heating to increase the fluidity, and the insulating tapes are bonded to each other during the rolling immediately after that. It has cooled and started to solidify, but it has not completely solidified.

Next, the three-layer wound insulated wire was cooled by the air cooling device at the outlet of the metal rolling roll, and the heat-sealing adhesive material 6'was fixed to form the adhesive layer 6, and each insulating tape was bonded and flattened. The cross-sectional shape of the stranded wire 1 is maintained. In this way, a flat insulated wire 10 having a thickness of 1.41 mm and a width of 1.72 mm was produced.

The breaking voltage of the obtained flat insulated wire was 8.0 kV, and the elongation was 20%. The flat insulated wire was flexible and had excellent linearity around a core having a diameter of 10 mm.

1 Twisted wire 1a Conductor wire 2 Insulation tape 2a 1st insulation tape 2b 2nd insulation tape 2c 3rd insulation tape 2d Non-adhesive insulation tape 6 Adhesive layer 6'Adhesive material 7 Insulation layer 10 Flat insulated wire

Claims (11)

It has a stranded wire held in a flat or substantially flat cross-sectional shape, and two or more insulating tapes that directly cover the stranded wire and hold the cross-sectional shape of the stranded wire.
Each conductor wire itself constituting the stranded wire is not deformed in order to hold the stranded wire flat or substantially flat, and remains in a round cross section.
An adhesive layer is provided on at least one of the two or more insulating tapes, and at least two of the two or more insulating tapes are adhered to each other by the adhesive layer. The adhesive layer is a flat insulated electric wire that is not adhered to the stranded wire and is not exposed on the outermost surface. The flat insulating electric wire according to claim 1, wherein the two or more insulating tapes are such that the insulating tapes are adhered to each other at an overlapping portion of the insulating tapes. The flatness according to claim 1 or 2, wherein the insulating tapes bonded by the adhesive layer are wound in opposite directions, or are wound in the same direction but with different winding pitches. Insulated wire. The flat insulated electric wire according to any one of claims 1 to 3, wherein the two insulating tapes that are adhered directly cover the stranded wire. The insulating tape has three or more insulating tapes, and at least one of the three or more insulating tapes is provided with an adhesive layer.
At least two of the three or more insulating tapes are adhered to each other by the adhesive layer, and at least one of the three or more insulating tapes is not adhered by the adhesive layer. ,
The insulating tapes of the insulating tapes that are not adhered by the adhesive layer directly cover the stranded wires, and the two adhesive tapes that are adhered do not directly cover the stranded wires. The flat insulated electric wire according to any one of 3. A process of preparing a stranded wire and two or more insulating tapes in which an adhesive material is provided on at least one insulating tape.
The step of covering the stranded wire with the two or more insulating tapes and
A step of processing the stranded wire after covering it with the two or more insulating tapes to obtain a flat or substantially flat cross-sectional shape.
A method for manufacturing a flat insulated electric wire, which comprises a step of solidifying the adhesive material and holding the cross-sectional shape while maintaining the cross-sectional shape. The sixth aspect of claim 6, wherein in the step of covering with the insulating tape, two or more of the insulating tapes are used, and the adhesive material is arranged so as to be arranged at least in the overlapping portion of the insulating tapes among the two or more insulating tapes. How to manufacture flat insulated wires. The method for manufacturing a flat insulated electric wire according to claim 7, wherein the two insulating tapes are wound in opposite directions, or in the same direction but with different winding pitches. The two insulating tapes are provided directly on the stranded wire, or
The flat insulating electric wire according to claim 7 or 8, wherein an insulating tape having no adhesive material among the insulating tapes is provided directly on the stranded wire, and an insulating tape having the adhesive material is provided via the insulating tape. Manufacturing method. The method for manufacturing a flat insulated electric wire according to any one of claims 6 to 9, wherein in the step of processing into the cross-sectional shape, the processing is performed by roll rolling or die processing. The method for manufacturing a flat insulated electric wire according to any one of claims 6 to 10, wherein in the step of maintaining the cross-sectional shape, the adhesive material is solidified during or immediately after the processing.

Images