JPS62188209A - Manufacture of wound core - Google Patents

Abstract

PURPOSE:To contrive the simplification of a manufacturing process and the reduction of a manufacturing cost by rewinding a required length tape like magnetic core material to a product shape after the insulating treatment of the material in a required shape winding. CONSTITUTION:A tape like magnetic core material 1 of such as an amorphous magnetic alloy thin plate is wound is a circular shape within only a required length. The tape like magnetic core material 1 is put in a dipping bath 4 filled with a liquid insulating material 3, the insulating material 3 is infiltrated in the whole of the tape like magnetic core material 1 and especially, between the layers and an insulating layer 5 is formed in these regions. In this case, there are closely adhered regions and minute gap regions of mutual contact adjacent layers between the layers due to the recession and the projection of outer surface unevenness based on the structure of the amorphous alloy thin plate itself and the rewinding process for a product is carried out.

Description

DETAILED DESCRIPTION OF THE INVENTION [Technical Field of the Invention] The present invention relates to a method for manufacturing a wound core, and particularly to a method for manufacturing a wound core in which an interlayer insulation treatment process is improved.

[Technical background of the invention and its problems] Conventionally, tape-shaped magnetic core materials (for example, amorphous alloy thin plates, etc.) have been made into circular, elliptical, or rectangular shapes as wound cores used in transformers and various coil devices. It is known that it is made by winding around.

In this J: eel-wound core, when interlayer insulation is required, the manufacturing method involves winding a long tape-shaped magnetic core material onto a reel 21 in advance as shown in FIG. A tape-shaped magnetic core material is fed into a dipping tank 23 filled with an insulating material 22, and an insulating material 2 is applied to the outer peripheral surface of the tape-shaped magnetic core material.
After performing the immersion treatment in which the tape-shaped magnetic core material f+ 2 is repeatedly immersed, the tape-shaped magnetic core material f+ 2 is placed on another reel 24 while being heated by the heater 25.
There is a known method in which a wire is wound up, treated for burning, then cut to a required length and wound into a product shape.

However, such a method requires many manufacturing steps and has a slow processing speed, resulting in poor efficiency and high manufacturing costs.

There is also a method in which the tape-shaped magnetic core material is coated with an insulating material and then wound into a product shape, but this method is basically the same as the case of performing the dipping treatment described above. I have a similar problem.

Generally speaking, there is also a method in which a tape-shaped magnetic core material is first wound into a product shape, and then the insulating material is immersed in a dipping bath or oxidized to provide interlayer insulation in the wound portion of the tape-shaped magnetic core material. be.

This method is the most efficient method if complete interlayer insulation is possible, but in this case, it is difficult for the insulating material to soak between each layer of the wound part, or oxidation occurs between each layer. There is a problem in that the interlayer insulation becomes insufficient and effective interlayer insulation cannot be achieved. In particular, problems occur in the parts that are originally in contact during winding. To explain this in more detail, as shown in FIG. 10, an interlayer insulating film 22a is formed in the part where there is a gap between the thin plates (part b), but in the part where the thin plates are in contact with each other (part a). (a) The interlayer insulating film 22a is not formed because the d liquid does not enter and the air does not come into contact with it. In other words, the objective of preventing the thin plates from coming into contact with each other cannot be achieved.

[Purpose of the Invention] The present invention has been made in view of the above circumstances, and involves insulating a tape-shaped magnetic core material of a required length while being wound into a predetermined shape, and then converting it into a product shape. Wrapped iron core'tA simplifies the manufacturing process, reduces manufacturing costs, and provides effective living room insulation by rewinding.
The purpose is to provide a method for manufacturing.

[Summary of the Invention] The outline of the present invention for achieving the above object is as follows: a first step of applying insulation treatment to a tape-shaped magnetic core material that is cut to a required length and wound into a predetermined shape; This method is characterized by including a second step of rewinding the tape-shaped magnetic core material after the insulation treatment obtained in the first step into a predetermined product shape.

[Embodiments of the invention] The present invention will be explained in detail below.

First, as shown in FIG. 1, a tape-shaped magnetic core material 1 such as an amorphous magnetic alloy thin plate is wound into a circular shape by a required length.

More preferably, the effect is enhanced by applying a weak tension during winding and winding loosely. Then, as shown in FIG. 2, this tape-shaped magnetic core material 1 is placed in a dipping tank 4 filled with a liquid insulating material 3, and the entire tape-shaped magnetic core material 1 is
In particular, an insulating material 3 is immersed in each interlayer portion to form an insulating layer 5 in these portions as shown in an enlarged view in FIG.

As a method to penetrate the insulation material more completely between each layer,
In the dipping step shown in FIG. 2, vacuum impregnation can be carried out to make it more complete.

At this time, especially between each layer, due to unevenness due to unevenness on the outer surface due to the @ structure of the amorphous alloy thin plate itself,
Since there are parts where adjacent layers that are in contact with each other are in close contact with each other and parts where minute gaps are formed, the insulating layer 5 is not formed in the parts where they are in close contact with each other. That is, in this insulation treatment step, portions without the insulating layer 5 are randomly scattered on the outer surface of the wound tape-shaped magnetic core material 1 depending on the unevenness thereof.

After the wound tape-shaped magnetic core material 1 which has been subjected to the insulation treatment process in this manner is taken out from the dipping tank 4 and dried, a rewinding process for a product is performed.

In this rewinding step, as shown in FIG. 4, the tape-shaped magnetic core material 1 that has undergone the insulation treatment step is unwound from its outer end and wound around a wound core jig 6 formed into a rectangular shape, for example. The wound core 10 has a rectangular shape as shown in FIG. The winding direction of the tape-shaped magnetic material 11 in this wound core 10 may be opposite to the original winding direction of the tape-shaped magnetic core material 1 as shown in FIG. 4, or it may not be shown in the figure. may be in the same direction as the initial winding direction.

In the thus obtained wound core 10, as shown in an enlarged view in FIG. 6, the contact state between each layer of the tape-shaped magnetic core material 1 is different from the contact state at the end of the insulation treatment process.
There is a low probability that the non-insulated parts without the insulating layer 5 between each layer will come into contact with each other, and even if there is a place where the non-insulated parts come into contact with each other, the area ratio of that place to the whole interlayer contact part is small. Therefore, when this wound core 10 is used, there is no effect to the extent that the interlayer insulation is destroyed, and as a result, a wound core without any practical problems can be obtained. At this time, preferably, if the diameter used in the insulation treatment process and the diameter of the product shape are different, the probability that the parts that were in contact in the insulation treatment process will come into contact in the product process can be reduced.

The method for manufacturing the wound core 10 described above also includes a step of insulating the tape-shaped magnetic material 1 wound into a circular shape, and a step of rewinding the tape-shaped magnetic core material 1 after the insulation treatment into a product shape. Therefore, compared to the conventional method shown in Fig. 10, in which a long tape-shaped magnetic core material is fed at a constant processing speed and insulated, then cut and wrapped around the product shape. Since the method of this embodiment can insulate the container by one immersion treatment, the manufacturing process can be simplified and the manufacturing cost can be reduced.

In addition, as another example of the above-mentioned insulation treatment process, the seventh heating,
Another example is a high-temperature oxidation method in which an insulating layer of an oxide film is formed on each part of the tape-shaped magnetic core material 1 in an air atmosphere. An insulating layer similar to that described above can also be formed using a manufacturing process including such an insulating treatment process.

Examples of the present invention will be briefly described. Product shape is outer diameter 31#
, it had a toroidal shape with an inner diameter of 19mm and a width of 8mm.

Sample 1 (comparative example) An amorphous alloy thin plate (composition Fe5tS i 1782) was coated with Mgo powder dissolved in alcohol, baked at 200°C, dried, and then rolled into a product shape 440'. C- Heat treatment was performed in an N2 gas atmosphere for 1 hour.

Heat treated in air.

Sample 3 (present invention) The same thin plate was wound around a metal reel having an inner diameter of 10 cm and an outer diameter of 20 cm, and was oxidized in air at 350° C. for 1 hour. After the oxidation treatment, it was wound into a product shape and heat treated in air at 440°C for 1 hour.

The current rate (μe)-frequency (f) characteristic of each sample is
As shown in the figure. From this, it can be seen that the present invention has characteristics 1q that are almost the same as Sample 1, which was completely subjected to interlayer insulation.

The present invention is not limited to the embodiments described above, and various modifications can be made within the scope of the invention.

For example, in the above-mentioned rewinding process, the rectangular wound core 10
Although we have explained the case of manufacturing circular shapes,
By using an elliptical jig, it is possible to manufacture wound cores having various shapes corresponding to each shape.

Furthermore, in the above-mentioned embodiments, an amorphous alloy thin plate was used as the tape-shaped magnetic core material, but in addition to this,
The present invention can be similarly applied to the case where a wound core is manufactured using a magnetic core material whose surface is relatively rough.

[Effects of the Invention] According to the present invention described in detail above, it is possible to provide a method for manufacturing a wound core that can simplify the manufacturing process, reduce manufacturing costs, and obtain an effective interlayer insulation state. .

[Brief explanation of drawings]

Fig. 1 is a perspective view showing a tape-shaped magnetic core material used in an embodiment of the method of the present invention, Fig. 2 is a schematic sectional view showing the first step in an embodiment of the method of the present invention, and Fig. 3 is the same as above. FIG. 4 is a schematic perspective view showing the second step of the same, and FIG. 5 is an embodiment of the present invention. FIG. 6 is an enlarged cross-sectional view showing the interlayer state of the tape-shaped core material obtained by the method described above, and FIG. 7 is a schematic diagram showing the other side of the first step of the method described in this book. The cross-sectional view, FIG.
A graph showing a comparison of magnetic permeability characteristics, FIG. 9 is a schematic sectional view showing a conventional example of the interlayer insulation method, and FIG. 10 is an enlarged sectional view showing the state of the interlayers manufactured by the conventional method. 1... Tape-shaped magnetic core material, 3... Insulating material, 5...
Insulating layer, 10... winding core. Figure 1 Figure 2 Figure 3

Claims (4)

[Claims] (1) A first step of insulating the tape-shaped magnetic core material that has been cut to the required length and wound into a predetermined shape, and the tape-shaped magnetic core material after the insulation treatment obtained in the first step. and a second step of rewinding the core into a predetermined product shape. (2) The method for manufacturing a wound core according to claim 1, wherein the tape-shaped core material is an amorphous alloy thin plate. (3) The method for manufacturing a wound core according to claim 1 or 2, wherein the first step is to immerse the tape-shaped magnetic core material in a liquid insulating material. (4) The method for manufacturing a wound core according to claim 1 or 2, wherein the first step is to perform an oxidation treatment on the tape-shaped magnetic core material.