JPS5952815A - Celluloseless transformer coil and method of producing same - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] The present invention relates to cellulose-free transformer coils.

In particular, it concerns multilayer resin insulation along the edges of the coil windings. Prior Art Although the concept of cellulose-free isolation transformers is known, efforts are currently being made to improve upon it. As part of the cellulose-free coil concept, a liquid resin is applied and cured on-site during coil winding. This concept was used to make the coil structure advantageous in the radial direction, by reducing the insulation in the radial direction, applying a thin resin film between the eyebrows, and repeating hardening of the thin resin film to create high and low spaces. A cellulose-free structure is obtained by forming a cellulose-free structure.

Structure of the Invention According to the invention ζζ, there is provided a tubular coil having a plurality of first layers of metal windings having an inner layer and an outer layer; a first coating of resin material between the first layers of the metal winding; a first coating of resin material on the outer seventh layer of the metal winding; and a plurality of coatings of the metal winding on the second layer of resin material. the first layer and each a-th layer of the metal winding
a 311 [coating] of a resin material between the layers, each coating of the resin material extending over both opposing edges of the metal winding and overlapping portions of the previously formed layers of the resin material, and having a high dielectric strength. A cellulose-free transformer coil is obtained having overlapping portions forming a multilayer coating.

Further, according to the present invention, the steps include: (IL) preparing a winding mandrel so as to be repeatedly rotated through the resin coating section and the resin hardening section; (b) applying at least one resin coating on the mandrel; (C) a step of spirally winding a large number of metal winding layers on the resin coating, (d) a step of applying a resin coating on each of the metal winding layers, and (e) a step of applying the resin coating in the above (el step). applying at least one resin coating on the outer layer of the metal winding, and (f) spirally extending a long conductor layer across and over the resin coating applied in step (e) above. a step of winding at least one layer; (gl above (fl
A cellulose-free transformer comprising the step of applying a resin coating on each turn of each layer of the long conductor applied in the process and flowing each resin coating on both opposing lines of the previously applied tree cover. An advantage of the transformer coil and method of manufacturing the same of the present invention is that the cellulose-free transformer coil structure does not cause insulation creep along the layer extension surface but dielectric breakdown during operation of the transformer coil. That's what you get. Multiple resin coatings on the edges of the coil layer have a higher dielectric strength than one applied in a single layer of the same thickness. Therefore, damage to the insulation in the event of an accident is minimized and less likely to occur.

EXAMPLE According to the present invention, a method for manufacturing a cellulose-free transformer coil consists of the following steps.

(al) A process of preparing a winding mandrel that can be rotated repeatedly through the resin application section and the resin hardening section.

(b) applying at least one resin coating on the mandrel; +C) winding multiple helical layers of metal windings on the mandrel.

(d) Applying a resin MI coating on each layer of the metal winding.

(e) Step of pouring multiple resin coatings onto the metal winding layer.

(f) winding at least one W4 spiral layer of the long conductor across and over the resin coating of step (e) above; (g) at least one additional resin coating on the outer layer of the long conductor; (h) flowing each resin coating over opposite edges of the layer of metal winding and the previously applied resin coating to form a multilayer coating on the edges of the coil structure.

In Figure 1, the transformer coil 3 is a tubular member formed by continuously applying a metal winding as a conductor and a resin coating on a mandrel s rotating around a center line 7. When the mandrel rotates in the direction indicated by the arrow (Fig. 1), the mandrel moves to the resin applicator //, the winding section /J for applying the winding conductor such as the wire 15 to the coil J, and the mandrel as shown by the arrow 9. of,? to' rotate through a working section that includes a resin curing section that cures the resin while rotating. The method of manufacturing the coil 3 described here can be changed as necessary.

As best shown in FIG. 7, the coil 3 comprises the following parts in the order in which they were applied. That is, coating/9 of resin material,
A plurality of layers of a metal conductor or winding (a plurality of first layers of a metal winding), 2/, a resin coating (first coating) between each layer 21, a plurality of resin coatings (a first coating), 2 left and 1 layer of metal conductor for winding (first layer of metal windings), 7, 29. J/
and 1st layer - 27, resin coating 33 between the bumps and 1st layer 9゜31
These are the resin coating aJ& (constituting the third coating together with the resin coating 33) in between, and the outer If411 resin coating 37. The transformer coil 3 further comprises several layers and laminated covers (multi-layer coatings) 39° on opposite edges of the coatings, which overlap when each resin coating is in place. It is.

The resin coating 9 (FIG. 1) is applied by any suitable method, such as by spraying or using a resin applicator such as a paint roller. In practice, coating/9 consists of multiple layers applied repeatedly to cover any holes, cavities or undesirable contaminants that would weaken the dielectric strength of the coating. For this purpose, approximately o, osmmc approximately, □
nil ) thick coating! 30 sheets were applied. The coating is applied in a spiral manner by rotating the mandrel, and each coating is cured in a resin curing section 17. Preferably, the resin is a high temperature cross-linkable resin material. Is the resin, for example, acrylic epoxy dissolved in acrylate monomer that can be cured by UV irradiation? , acrylated epoxy novolak, acrylated hydantoin epoxy, and acrylated urethane. Each resin coating ranges from approximately Q, Q/-27 m1 to approximately 0.10 cmyp (approximately 0
．． 0001 in to o, oo4Io tn) thickness,
That is, approximately 0. It is possible to make 5 to 700 turns up to a thickness of /θ core am (g m11). The resin is applied in one or more thin layers and cured, depending on the dielectric strength required.

If the layers of the winding include pre-insulated surfaces, the coating 13. You can omit step 3.

The resin curing section/7 is equipped with a suitable radiation device such as infrared rays. For this purpose, an ultraviolet irradiation device or an electron beam device is satisfactory.

Ultraviolet irradiation appears to be practical.

Covering/? After applying , the conductor winding or layer 2/ is applied. The winding is a continuous metal strip of copper or aluminum. The layer 1 may have an insulating coating such as enamel on its outer surface, in which case continuous winding of the layer can be carried out without intervening fat coating. Generally, layer 21 will be the low voltage winding of transformer coil 3.

After the formation of the winding waste layer is completed, a plurality of turns of the coating tqO are coated, e.g., about 3 to 100 turns with a thickness of up to about 0,000 mils per turn. ) - Apply as in case.

After applying the required number of coatings 2S, the winding layer core is formed.

Perform 9.31. The winding is preferably a continuous conductor such as copper or aluminum, and preferably has an insulating coating such as enamel. As the mandrel turns, the winding layer 27 is applied by the wire /&. The wire 15 moves onto the outer surface of the insulating coating S and advances to the position /&a indicated by the broken line in FIG. When winding the winding layer core in a predetermined position, a roller for applying resin, that is, a resin applicator //
A resin coating 33 is applied to each winding by advancing the wire together with the wire. When the rotation continues in this manner, the first coating 33 passes through the resin hardening portion and hardens. When the next winding layer 27 is applied, it is also covered with the resin coating 33, and the previous coating 33 is also covered with the next resin coating. Finally, resin coating''
The number 33 is equal to the number of turns of the winding, forming a wedge-shaped insulator consisting of a plurality of separately cured resin coatings 3J.

Next, the winding layer 29 is applied by rotating the mandrel while advancing the wire/S in the opposite direction to the previous winding layer 27. Similarly, apply a separate resin coating 35 to each turn of one winding (advance the resin applicator from the broken line position /l in Fig. 2,
Each resin coating is cured and covered with multiple resin coatings until the wire/left reaches the left end of the coil shown in FIG. In this way, a wedge-shaped insulator consisting of a plurality of resin coatings 3S is completed.

Thereafter, the same process as in the case of the winding layer 27 is performed to form the winding layer 3/. If the winding layer 3/ is the last layer, an outer coating 37 is applied using a resin applicator //. First, after all the windings of the winding layer 31 are made, the mandrel is rotated and all the turns are coated with the resin coating 37 using a resin applicator/l.

As shown in FIG. 1, the resin coating 33, which is a wedge-shaped insulator, is tapered so that the thick end is on the left and the thin end is on the right. On the other hand, the thick end of the cover 33 is placed on the right and the thin end is placed on the left. Winding layer: 17, 29, 3/ are the highest winding wires, so the wedge-shaped resin plate is 1%, ? ,y
, ,? s is desirable. However, the structure and method of the present invention is such that the intermediate winding layers such as the first winding layer, 27, etc. are not inclined as shown in FIG.
, 3/ in parallel.

According to the invention, each time a resin coating is applied, the overlap extending beyond the ends of the winding layer flows onto the ends of the previously applied core component. For example, if the winding layer 2/ is applied close to the resin coating /9, the overlapping portion of the opposite end of the first winding layer is applied to the opposite winding layer 1 and the resin coating /9
A resin coating 23 is applied so as to flow upward. The next winding layer 2/ is similarly covered with another resin coating layer 3,
The overlapping portion also flows over the overlapping portion of the resin coating 23 previously applied on the opposite end of the winding layer 1.

Similarly, each time each resin coating 2j is applied, the overlapping part is rolled up on the opposite side of the winding layer and the previously applied resin coating 2j is applied.
3 and cover them.

As each resin coating 33 is applied, the overlapping portion is the resin coating applied earlier on the previously applied winding layer 27, as shown by the lamination force Bark/2J, , 2! Extends downwardly over the overlapping portion of ; Similarly, as each resin coating 33 is applied, the overlapping portion extends downwardly over the end of the coil 3 to completely cover the overlapping portion of the previously applied resin coating 23°S. Finally, the resin cover 37 is a laminated cover, ? ? , lI/
It has overlapping parts extending downward on both sides as part of the .

Effects of the Invention The cellulose-free transformer coil of the present invention provides a multilayer resin coating at the edges of the coil, where greater dielectric strength is required than would be obtained with the same thickness of resin formed in a single layer. . The advantage of this multilayer resin coating is that it minimizes or virtually eliminates the possibility of dielectric breakdown in the event of an accident. Also, because the resin coating is multilayered, breakdown voltage occurs during operation of the transformer rather than insulation creep along the plane in which the layers extend.

[Brief explanation of the drawing]

FIG. 1 is a partial cross-sectional view showing a winding layer and a resin coating thereon. FIG. 1 is a schematic perspective view showing one method of forming the coil structure of FIG. 1. 3 - coil, 1 - multiple first layers of metal windings (winding layers), 3 - first coating (resin coating) 1.2S - second coating (resin coating). Koku, Kot, 3/- Plural second layers of metal windings (containing winding waste J3.J!; - Third coating (resin coating).

Claims (1)

Claims: (1) A tubular coil having a plurality of m first m of metal windings having an inner layer and an outer layer. a first coating of a resin material between the first layers of the metal winding; a second coating of resin material on the outer first layer of metal windings; and a plurality of second layers of metal windings on the first layer of resin material. and a third coating of a resin material between each a-th layer of the metal winding. Each coating of resin material has an overlapping portion extending over opposing edges of the metal winding and overlapping portions of the previously formed layers of resin material to form a high dielectric strength multilayer coating. Transformer coil without cellulose. (,2) A patent in which the resin material is a mixture of acrylated epoxy, acrylated epoxy-novolak, acrylated hydantoin ψ epoxy, and acrylated urethane dissolved in an acrylate monomer that is UV cured. A cellulose-free transformer coil according to claim 1. (3) The third layer of the resin material is wedge-shaped, being thin at one edge of the adjacent paired second layer of the metal winding and thick at the other edge of the paired second layer. Cellulose-free transformer coils listed in Range @1. (4'l ta) preparing a winding mandrel for repeated rotation through the resin application section and the resin hardening section; (b) spirally winding multiple layers of metal windings on the mandrel; (cl) A step of applying a large number of 'fli@ coatings on the layer of metal winding applied in step (1) above. (d) spirally wrapping at least one long layer of conductor across and over the resin coating; (e) applying at least one additional resin coating on the outer layer of the elongated conductor; (f) flowing each resin coating over opposite edges of the layer of metal winding and the previously applied resin coating to form a multilayer coating on the edge of the carp/L/spear structure; Method for manufacturing a cellulose-free transformer coil ◎ (&) Claim 9, wherein at least one resin coating is applied on the mandrel before the (tel step).
A method for manufacturing a cellulose-free transformer coil as described in .