KR20110106914A - Insulated wire and coil - Google Patents

Abstract

Provides insulated wire with excellent high frequency and insulation characteristics.
Seven enameled wires 4 having a non-circular cross section are gathered in parallel and insulated on the outer periphery of the aggregate line 11 as if the aggregated line 11 and the aggregate line 11 are bound together. The 1st insulating coating 1 which winds a tape is provided.
Compared with disconnection having the same conductor cross section, high frequency loss can be reduced. The outer diameter can be made smaller than a Ritz line having the same conductor cross-sectional area. In addition, by winding the insulating tape, it is easy to maintain the binding force of the assembly line without any meticulousness, so that the appearance drift can be reduced and the insulation characteristics are also excellent.

Description

Insulated wire and coil

The present invention relates to an insulated wire and a coil, and more particularly, to an insulated wire and a coil excellent in high frequency characteristics and insulation characteristics.

DESCRIPTION OF RELATED ART Conventionally, the Ritz line | wire is characterized by providing a self-fusion layer on the outer periphery of what twisted the twisted line comprised by the some enameled wire from the outer side to the round, and the enamelled wire was alternately closely contacted. (See, eg, Patent Document 1.).

Publication No. 06-119825

The conventional Ritz line is excellent in high frequency characteristics.

In manufacture, however, a twisted line composed of a plurality of enamelled wires is passed through a circular die and compressed into a circular shape from the outside. At this time, an enamel layer corresponding to the outer circumferential surface is damaged by friction with the circular die, and the insulating property of the outer circumferential surface is degraded. do. That is, the conventional Ritz line has a problem in insulation characteristics. For this reason, when it winds around a coil, it is easy to produce a short, ie, a short-shot between windings, and there exists a problem in reliability. In addition, a self-sealing layer is provided on the outer circumferential surface, but this does not guarantee insulation characteristics.

Then, the objective of this invention is providing the insulated wire and coil excellent in the high frequency characteristic and the insulation characteristic.

According to a first aspect, the present invention is an assembly line in which a plurality of enamel lines having a non-circular cross-sectional outline are gathered to form a circular cross-sectional outline as a whole, and the insulation tape is wound around the outer periphery of the assembly line as if the collective lines are bundled. The insulated wire provided with the 1st insulating coating is provided.

In the insulated wire which concerns on said 1st viewpoint, an insulating tape is wound up and it is set as a 1st insulating coating, as a plurality of enameled wires of which a non-circular cross-sectional outline is gathered, and the collective line of which the whole cross-sectional outline is circular are tied. When a plurality of enamel wires are compressed circularly from the outside through a circular die to produce an aggregate line, an enamel layer corresponding to the outer peripheral surface of the aggregate line is damaged by friction with the circular die, and the insulation characteristics of the outer peripheral surface of the aggregate line are degraded. However, since at least one insulating coating is provided on the outer periphery of the assembly line, sufficient insulating characteristics can be obtained. In addition, since the disturbance of the assembly line can be prevented by winding the tape, a uniform finish outer diameter can be obtained even when the coil is wound. In addition, it is possible to reduce high frequency copper loss compared to disconnection, so it is excellent in high frequency characteristics.

It is preferable that the total number of the enameled wires which comprise an assembly line shall be four or more from a viewpoint of a high frequency characteristic improvement. Moreover, when compressing using circular dice for manufacture of aggregate lines, it is preferable to set it as 11 or less from a compressibility viewpoint.

In a 2nd viewpoint, this invention is the insulated wire which concerns on the said 1st viewpoint, and provides the insulated wire which bundle | stacked the said some enamel wire in parallel, without twisting.

In the insulated wire which concerns on said 2nd viewpoint, since a some enamel wire is bundled in parallel without twisting, the finishing appearance can be made smaller than when twisted. In addition, the line length can be shortened. In addition, the DC resistance can be reduced. In the case of twisting a plurality of enameled wires, the twisting process has a lower processing line speed compared with the compression process or the tape winding process, which leads to poor productivity and an increase in manufacturing cost, but the twisting process does not require the twisting process. Therefore, productivity can be improved and manufacturing cost can be reduced.

In a 3rd viewpoint, this invention is an insulated wire by the said 1st or 2nd viewpoint, Comprising: The soft magnetic layer was formed in the outer periphery of all or some copper wires of the some enameled wire. It provides an insulated wire characterized by the above-mentioned.

In the insulated wire according to the third aspect, since the copper wire is covered by the soft magnetic layer, the magnetic flux that causes eddy current damage is more likely to pass through the magnetic layer on the surface than the copper wire portion. Since the magnetic layer has higher resistivity than copper, eddy current damage can be reduced. Therefore, the high frequency copper loss can be further reduced, so that the high frequency characteristics can be further improved.

In a fourth aspect, the present invention is a configuration in which a plurality of enamel lines and bare copper wires having a non-circular cross-sectional outline are gathered so that the entire cross-sectional contour is circular, and the bare copper wires are not adjacent to each other. The insulated wire provided with the 1st insulating coating which wound the insulation tape in the outer periphery of the said assembly line like the assembly line which tied this assembly line is provided.

In the insulated wire according to the fourth aspect, a plurality of enameled wires having a non-circular cross section and a plurality of bare copper wires are gathered so that the entire cross-sectional contour is circular, and the aggregated wire is formed of an arrangement in which the bare copper wires are not adjacent to each other. As a bundle, the insulation tape is wound to be the first insulation coating. When a plurality of enameled wires and bare copper wires are compressed from the outside into a circular shape through a circular die, the aggregated line is manufactured, the enamel layer corresponding to the outer circumferential surface of the aggregated line is damaged by friction with the circular die, so that the insulating characteristics of the outer peripheral surface of the aggregated line are reduced. Degrades. However, since at least one insulating coating is provided on the outer periphery of the assembly line, sufficient insulating characteristics can be obtained. In addition, since the disturbance of the assembly line can be prevented by winding the tape, a uniform finish outer diameter can be obtained even when the coil is wound. In addition, the high frequency dynamic loss can be reduced as compared with the disconnection, so the high frequency characteristics are excellent. In addition, since bare copper wire is used for some parts, the solderability can be improved and the cost can be reduced, rather than all being enameled wire.

It is preferable that the total number of the enameled wire and bare copper wire which comprise an aggregate line shall be four or more from a viewpoint of a high frequency characteristic improvement. Moreover, when compressing using circular dice for manufacture of aggregate lines, it is preferable to set it as 11 or less from a compressibility viewpoint.

In a fifth aspect, the present invention provides an insulated wire according to the fourth aspect, wherein the plurality of enameled wires and bare copper wires are bundled in parallel without being twisted.

In the insulated wire according to the fifth aspect, the plurality of enameled wires and bare copper wires are bundled in parallel without twisting, so that the finished appearance can be made smaller than in the case of braiding. In addition, the line length can be shortened and the DC resistance can be reduced. In the case of braiding a plurality of enameled wires and bare copper wires, the twisting process is slower than the compression process or the tape winding process, so that the productivity is worsened and the manufacturing cost is increased, but the twisting process is performed. Since it is not necessary, productivity can be improved and manufacturing cost can be reduced.

In a sixth aspect, the present invention is an insulated wire according to the fourth or fifth aspect, wherein the soft magnetic layer is formed on at least one outer periphery of all or part of copper wires and bare copper wires of all or part of the plurality of enameled wires. It provides an insulated wire, characterized in that formed.

In the insulated wire according to the sixth aspect, since the copper wire is covered by the soft magnetic layer, the magnetic flux causing eddy current damage is more likely to pass through the magnetic layer on the surface than the copper wire portion. Since the magnetic layer has higher resistivity than copper, eddy current damage can be reduced. Therefore, the high frequency copper loss can be further reduced, and the high frequency characteristics can be further improved.

In a seventh aspect, the present invention is an insulated wire according to any one of the fourth to sixth aspects, wherein a tin-plated layer is formed on the outermost periphery of all or part of the bare copper wire. to provide.

In the insulated wire by the said 7th viewpoint, since a tin plating layer is exposed to a part of assembly line, solderability can be improved.

In an eighth aspect, the present invention is an insulated wire according to any one of the first to seventh aspects, wherein an insulating tape is wound around the outer circumference of the first insulating coating to form a second insulating coating, and the second An insulated wire is provided, wherein an insulating tape is wound around the outer periphery of the insulating coating to form a third insulating coating.

In the insulated wire according to the eighth aspect, the insulation tape is wound three or more layers, so when used as a high-frequency transformer used as a switching power supply, which is regarded as a reinforced insulated wire defined by the safety standard, the insulating partition wall is formed between the primary and secondary. It is possible to contribute to the miniaturization of the high-frequency transformer, such as no need to provide a.

In a ninth aspect, the present invention is an insulated wire according to any one of the first to seventh aspects, wherein the resin is extruded to an outer circumference of the first insulation coating to form a second insulation coating, and the second insulation An insulated wire is provided by resin extrusion on the outer periphery of the coating to form a third insulating coating.

In an insulated wire according to the ninth aspect, the winding property can be improved. In addition, sufficient insulating characteristics can be obtained. Therefore, it can be used for coils of high frequency transformers, such as a switching power supply, for example, and it can contribute to miniaturization of a high frequency transformer etc. by not having to provide an insulation partition between primary and secondary.

In a tenth aspect, the present invention is an insulated wire according to any one of the first to ninth aspects, and provides an insulated wire provided with a self-sealing layer at its outermost circumference.

In the insulated wire according to the tenth aspect, the shape retention of the coil can be obtained. In addition, when the inner layer of the self fusion layer is a resin extrusion layer, the formation of the self fusion layer is facilitated.

In a 11th aspect, this invention provides the coil which wound the insulated wire by any one of said 1st-10th viewpoint.

In the coil according to the eleventh aspect, an insulated wire having excellent high frequency characteristics and insulation characteristics is used, and thus a coil having excellent high frequency characteristics and insulation characteristics is obtained. In addition, it is easy to downsize. For example, it can be used for coils of high frequency transformers, such as a switching power supply, and in this case, it can contribute to miniaturization of a high frequency transformer, for example, eliminating the need for providing an insulating partition between primary and secondary.

According to the insulated wire of this invention, a high frequency characteristic and an insulation characteristic can be improved. Moreover, the finishing outer diameter can be made small.

According to the coil of the present invention, high frequency characteristics and insulation characteristics can be improved. In addition, it is easy to downsize.

1 is a side view showing an insulated wire according to the first embodiment.
FIG. 2 is a cross-sectional view taken along the line AA 'of FIG. 1. FIG.
3 is a cross-sectional view showing an insulated wire according to the second embodiment.
4 is a cross-sectional view showing an insulated wire according to the third embodiment.
5 is a cross-sectional view showing an insulated wire according to the fourth embodiment.
6 is a cross-sectional view showing an insulated wire according to the fifth embodiment.
7 is a side view showing an insulated wire according to the sixth embodiment.

EMBODIMENT OF THE INVENTION Hereinafter, this invention is demonstrated further in detail by embodiment shown to drawing. In addition, this invention is not limited by this.

Example 1

FIG. 1: is a side view which shows the insulated wire 101 which concerns on Example 1. FIG. FIG. 2 is a cross-sectional view taken along the line AA 'of FIG. 1.

The insulated wire 101 is assembled in such a way that seven enameled wires 4 having a non-circular cross-sectional outline are gathered in parallel so that the aggregated line 11 and the aggregated line 11 whose entire cross-sectional contour is circular are bundled together. The first insulating coating 1 to wind the insulating tape on the outer circumference of the wire 11, the second insulating coating 2 to wind the insulating tape on the first insulating coating 1, and the second insulating coating ( It is provided with the 3rd insulating coating 3 which wound the insulating tape in 2).

The enamel wire 4 coats the enamel layer 4b on the outer periphery of the copper wire 4a.

As a specific example, the outer diameter of the insulated wire 101 is 0.69 mm, the conductor cross section is 0.191 square mm, and the insulating tape is a polyester film.

The insulated wire 101 is, for example, assembled in parallel with seven enameled wires having a cross-sectional profile of 0.21 mm in outer diameter and a heat-resistant urethane resin coated with a thickness of 1.5 μm in a circular copper wire, and compressed through a circular die having a diameter of 0.51 mm. The assembly line 11 is manufactured (compression step), and the tape winding is performed in three stages (tape winding process) on the outer periphery of the assembly line 11, and it can manufacture continuously.

According to the insulated wire 101 of Example 1, the following effects can be acquired.

(1) The high frequency loss can be reduced compared to the disconnection having the same conductor cross-sectional area.

(2) It has three insulation coatings 1, 2, and 3, and is excellent in insulation characteristics.

(3) Winding the insulating tape can prevent the compressed aggregate line 11 from being disturbed.

(4) Since the enamel wire 4 is bundled in parallel without twisting, the appearance can be made smaller than in the case of braiding. Moreover, the line length can be shortened. In addition, the DC resistance can be reduced.

(5) In the case of twisting a plurality of enameled wires 4, the twisting processing step is slower than the compression step or the tape winding step, so that the productivity is worsened and the manufacturing cost is increased, but the twisting Since no machining step is required, productivity can be improved and manufacturing cost can be reduced.

-Example 2-

3 is a cross-sectional view showing an insulated wire 102 according to the second embodiment.

The insulated wire 102 is formed by grouping the assembly line 12 and the assembly line 12 in which seven enameled magnetic lines 5 having a non-circular cross-sectional outline are gathered in parallel and the entire cross-sectional outline is circular. The first insulating coating 1 to wind the insulating tape around the outer periphery of the assembly line 12, the second insulating coating 2 to wind the insulating tape around the first insulating coating 1, and the second insulating coating. It is provided with (3) the 3rd insulating coating 3 which wound the insulating tape.

The enamel magnetic wire 5 forms the soft magnetic layer 5a on the outer periphery of the copper wire 4a, and coats the enamel layer 4b on the outer periphery.

To give a specific example, the soft magnetic layer 5a is nickel or a nickel alloy which is easy to be subjected to compressive deformation or elongation deformation in the compression step. The thickness of the soft magnetic layer 5a is 1.5 μm, for example.

According to the insulated wire 102 of Example 2, in addition to the effect of the insulated wire 101 of Example 1, a high frequency loss can be further reduced by the magnetic shield effect of the soft magnetic layer 5a.

-Example 3-

4 is a cross-sectional view showing an insulated wire 103 according to the third embodiment.

This insulated wire 103 gathers six enameled wires 4 having a noncircular cross section in parallel around one bare copper wire 6 having a noncircular cross section so that the entire cross-sectional contour is circular. Insulating tape is wound around the first insulation coating 1 and the first insulation coating 1, which are wound around the outer periphery of the assembly line 13 in such a manner as to enclose the assembly line 13 and the assembly line 13. It is provided with the 2nd insulating coating 2 which becomes a 2nd, and the 3rd insulating coating 3 which winds an insulating tape in the 2nd insulating coating 2.

According to the insulated wire 103 of Example 3, since the bare copper wire 6 is used in addition to the effect of the insulated wire 101 of Example 1, cost is reduced rather than making all the enameled wires 4 can do.

-Example 4-

5 is a cross-sectional view showing an insulated wire 104 according to the fourth embodiment.

This insulated wire 104 includes three enameled magnetic wires 5 having a noncircular cross section and three tin plating having a noncircular cross section around one enamel magnetic line 5 having a noncircular cross section. The aggregate lines 14 are arranged in parallel so that the entire cross-sectional contour is circular, and the aggregate lines 14 are arranged in such a manner that the tinned copper lines 7 are not adjacent to each other and the aggregate lines 14 are bundled together. The first insulating coating 1 to wind the insulating tape around the outer periphery of (14), the second insulating coating 2 to wind the insulating tape on the first insulating coating 1, and the second insulating coating 2 ) Is provided with a third insulating coating (3) wound around the insulating tape.

According to the insulated wire 104 of Example 4, in addition to the effect of the insulated wire 103 of Example 3, since tin-plated copper wire 7 is used, solderability can be improved.

-Example 5-

6 is a side view showing an insulated wire 105 according to the fifth embodiment.

The insulated wire 105 is assembled in such a way that seven enameled wires 4 having a non-circular cross-sectional outline are gathered in parallel so that the aggregated line 11 and the aggregated line 11 whose entire cross-sectional contour is circular are bundled together. A first insulating coating (1) formed by winding an insulating tape on the outer circumference of the wire (11), a second insulating coating (2 ') formed by coating the outer circumference of the first insulating coating (1) by resin extrusion, It is provided with the 3rd insulating coating (3 ') formed by coating the outer periphery of 2 insulation coating (2') by resin extrusion.

According to the insulated wire 105 of Example 5, in addition to the effect of the insulated wire 103 of Example 3, a coil property can be improved.

Example 6

FIG. 7: is sectional drawing which shows the insulated wire 106 which concerns on Example 6. FIG.

This insulated wire 106 forms the self-fusion layer 9 in the outermost periphery of the insulated wire 105 of the fifth embodiment.

According to the insulated wire 106 of Example 6, in addition to the effect of the insulated wire 105 of Example 5, shape maintainability at the time of coiling can be improved.

Example 7

You may provide each element of Example 1-Example 6 suitably. For example, the self-fusion layer 9 may be provided on the outer circumference of the third insulating coating 3 of the first embodiment. Note that a tin-plated copper wire may be used instead of the bare copper wire 6 of the third embodiment.

Example 8

The insulated wire 101 (conductor cross-sectional area 0.191 square mm, outer diameter 0.69 mm) which concerns on Example 1 was wound, and the air core coil of 52 turns, coil length 5 mm, and coil inner diameter 20 mm was produced.

The number of coil layers of the hollow core coil was 7 layers, the coil outer diameter was 30 mm, the coil direct current resistance was 0.360 Ω, the effective resistance at 100 kHz was 0.82 Ω, and the effective resistance at 200 kHz was 2.17 Ω.

Comparative Example 1

The single wire (conductor cross-sectional area 0.196 square mm, outer diameter 0.68 mm) which produced the tape winding in three steps on the copper wire outer periphery with a circular cross section of 0.5 mm in diameter was produced. This disconnection was wound and the air core coil of 52 turns, a coil length of 5 mm, and a coil inner diameter of 20 mm was produced.

The number of coil layers of the hollow core coil was 7 layers, the coil outer diameter was 30 mm, the coil direct current resistance was 0.355 Ω, the effective resistance was 2.76 Ω at 100 kHz, and the effective resistance was 5.70 Ω at 200 kHz.

The coil of Example 8 was excellent in high frequency characteristics, while having the same outer diameter dimension as the coil of Comparative Example 1.

-Comparative example 2-

In the copper wire with a cross section of 0.2 mm in outer diameter, seven enameled wires were made by braiding a heat-resistant urethane resin with a thickness of 1.5 μm (twisting process), and tape winding was carried out in three stages on the outer periphery of the aggregated wire. A Ritz line (conductor cross section 0.220 square mm, outer diameter 0.84 mm) was produced. The Ritz wire was wound up to produce an air core coil of 52 turns, a coil length of 5 mm and a coil inner diameter of 2 mm.

The number of coil layers of the hollow core coil was 9 layers, the coil outer diameter was 35 mm, the coil direct current resistance was 0.341 Ω, the effective resistance at 100 kHz was 0.78 Ω, and the effective resistance at 200 kHz was 2.02 Ω.

The coil of Example 8 was excellent in miniaturization while being substantially equal to the high frequency loss of the coil of Comparative Example 2.

The insulated wire and coil of this invention can be used for the transformer of a switching power supply, the coil of a non-contact power supply device, a motor, etc.

1: 1st insulating coating 2, 2 ＇: 2nd insulating coating
3, 3 ': 3rd insulating coating 4: enameled wire
4a: copper wire 4b: enamel layer
5: enameled magnetic line 5a: soft magnetic layer
6: bare copper wire 7: tinned copper wire
7a: tin plating layer 9: self-sealing layer
11 ~ 14: assembly line 101 ~ 106: insulated wire

Claims (11)

A plurality of enameled wires having a non-circular cross-sectional outline and a plurality of enameled wires having a circular cross-sectional outline, and a first insulating coating wound around the periphery of the aggregated line as if the aggregated lines are bundled. Insulated wire. The method according to claim 1,
An insulated wire, characterized in that the plurality of enameled wires are bundled in parallel without twisting. The method according to claim 1 or 2,
An insulated wire formed with a soft magnetic layer on the outer periphery of all or part of said plurality of enameled wires. A plurality of enamel lines and bare copper wires having a non-circular cross section are gathered to form a circular cross-section of the entire cross-section. An insulated wire provided with a 1st insulating coating which winds up a tape. The method of claim 4, wherein
Insulated wire, characterized in that the plurality of enameled wire and the bare copper wire is bundled in parallel without twisting. The method according to claim 4 or 5,
An insulated wire formed with a soft magnetic layer on at least one outer periphery of all or part of the plurality of enameled wires and all or part of bare copper wires. The method according to any one of claims 4 to 6,
An insulated wire, wherein a tin plating layer is formed on the outermost circumference of all or part of the bare copper wire. The method according to any one of claims 1 to 7,
An insulated wire, wherein the insulating tape is wound around the outer circumference of the first insulating coating to form a second insulating coating, and the insulating tape is wound around the outer circumference of the second insulating coating to form a third insulating coating. The method according to any one of claims 1 to 7,
An insulated wire formed by resin extrusion on an outer circumference of the first insulation coating to form a second insulation coating, and resin extrusion on the outer circumference of the second insulation coating to form a third insulation coating. The method according to any one of claims 1 to 9,
The insulated wire provided with the self-fusion layer in the outermost periphery of the said insulated wire. The method according to any one of claims 1 to 10,
The coil wound around the said insulated wire.

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