Classifications

• • H—ELECTRICITY
  • H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
  • H02K—DYNAMO-ELECTRIC MACHINES
  • H02K3/00—Details of windings
  • H02K3/04—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors
  • H02K3/12—Windings characterised by the conductor shape, form or construction, e.g. with bar conductors arranged in slots
• • H—ELECTRICITY
  • H01—ELECTRIC ELEMENTS
  • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
  • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
  • H01B13/004—Apparatus or processes specially adapted for manufacturing conductors or cables for manufacturing rigid-tube cables

Definitions

• the present invention relates to an aggregated conductor formed by integrating a plurality of conductor wires and a method for manufacturing the same.
• Patent Document 1 a plurality of enamel wires having a circular cross section are arranged and twisted so as to form two horizontal rows, and the entire cross section becomes a rectangular flat twisted wire.
• the Litz wire is disclosed. According to this, it is stated that the space factor on the shoreline can be improved.
• Patent Document 2 an insulating layer and a self-bonding layer are sequentially formed on a conductor as a self-bonding assembly wire in which a self-bonding layer is provided outside a collecting wire in which a plurality of insulating wires are bundled.
• Patent Document 3 describes a self-bonding dislocation wire obtained by spirally winding an insulating tape around the outer periphery of a stranded wire obtained by assembling, dislocation, and twisting a plurality of self-bonding rectangular enamel wires.
• the self-bonding rectangular enameled wire is a self-lubricating / self-bonding rectangular enameled wire.
• the strands of the wires exhibit excellent mutual slipping properties, and when the coil is heat-sealed, the strands can be firmly heat-sealed. , And is described.
• Patent Document 1 Japanese Patent Laid-Open No. 2-242531
• Patent Document 2 JP-A-9-161547
• Patent Document 3 Japanese Patent Laid-Open No. 11-203948 Disclosure of the invention
• an induction motor induction motor
• a brushed DC motor a brushless DC motor, and the like are often used for driving an electric vehicle.
• the induction motor includes a stator core formed in a cylindrical shape, a coil attached to the stator core, and a rotor rotatably arranged with a certain gap on an inner peripheral wall of the stator core, The rotor is rotated by the induced magnetic field generated in the motor to obtain driving force.
• the stator core includes a plurality of concave portions (slots) and convex portions that are alternately formed in the circumferential direction on the inner peripheral wall or the outer peripheral wall thereof.
• a conductor wire such as an enamel wire constituting a coil is arranged.
• FIG. 45 is a cross-sectional view in which a plurality of conductor wires 103 having a circular cross section are arranged in the slots 130b between the ridges 130a.
• the conductor wire 103 includes a conductor wire 101 through which a current flows and a covering layer 102 covering the periphery thereof.
• the conductor wire 103 having a circular cross section is arranged in the slot 130b, a dead space is formed between the conductor wires 103, and the filling rate of the conductor wire 103 inside the slot 130b is increased. It is getting lower.
• motors for electric vehicles such as hybrid vehicles and hybrid vehicles are often driven by high-frequency alternating current generated by inverters.
• inverters For example, in the case of FIG.
• the current concentrates near the surface of the conductor wire 101 due to the skin effect, and the AC resistance increases.
• a coil is formed by winding a strip-shaped conductor of uniform width formed in a rectangular cross section a plurality of times so as to be fitted in the slot. That is, a laminated structure with the same conductor is formed in the slot.
• the slot 130b of the stator core 130 is generally formed to have a narrow width in accordance with the direction of the force from the bottom side to the opening, so the conductor 110 Dead spaces are formed on both sides of the laminated structure.
• the present invention has been made in view of the strong point, and an object of the present invention is to provide an assembly conductor capable of suppressing the generation of eddy current and improving the conductor space factor. I will stop doing it.
• the present invention integrates a plurality of conductor wires in a non-twisted state.
• the collective conductor according to the present invention is an collective conductor in which a plurality of conductor wires each having a partial cross-sectional shape obtained by dividing the overall cross-sectional shape are integrated in an untwisted state,
• Each conductor wire includes a conductor wire, an insulating coating layer provided so as to cover the conductor wire, and a binding layer provided so as to cover the coating layer. It is characterized by being bound to each other through layers!
• each conductor wire constituting the assembly conductor has a partial cross section of a partial shape obtained by dividing the entire cross section shape of the assembly conductor! Since the constituent conductor wires are insulated from each other by the covering layer, the conductor wires are tightly bound via the binding layer, so that the conductor space factor in the collective conductor is improved. In addition, since the conductor wires constituting the assembly conductor are integrated in an untwisted state! /, Local coils are not formed, and the generation of eddy currents is suppressed. Therefore, it is possible to suppress the generation of eddy currents and improve the conductor space factor in the integrated conductor.
• a cross section of the conductor wire may be formed in a rectangular shape!
• the cross section of the conductor wire constituting the conductor wire is rectangular,
• the cross section of the conductor wire is also rectangular. Therefore, by superimposing the side surfaces of the conductor wires, the conductor wires can be easily aligned in the width direction and the height direction, so that the conductor space factor in the collective conductor can be improved.
• each of the conductor wires may be formed in a rectangular shape.
• each conductor line is rectangular, the conductor lines are easily aligned in the width direction and the height direction by overlapping the side surfaces of each conductor line, It is possible to improve the conductor space factor in the conductor.
• the coating layer may be formed by electrodeposition coating, and the binding layer may be formed by dip coating.
• the coating layer is formed by electrodeposition coating, the coating layer is a uniform thin film and is reliably formed at the corners of the conductor wire. Therefore, the cross-sectional area of the covering layer is reduced, the conductor space factor in the conductor wire is improved, and the insulation between the conductor wires is improved. Furthermore, since the binder layer is formed by dip coating, the binder layer can be formed by a general method.
• the present invention is particularly effective for the coil of a motor driven by an inverter.
• the collective conductor according to the present invention is an collective conductor in which a plurality of conductor wires each having a partial cross-section obtained by dividing the overall cross-sectional shape are integrated in a non-twisted state.
• Each conductor wire has a conductor wire and a binding layer provided so as to cover the conductor wire, and is connected to each other through the above-described binding layer. To do.
• each conductor wire constituting the collective conductor has a partial cross section of a partial shape obtained by dividing the entire cross sectional shape of the collective conductor! Since the constituent conductor wires are tightly bound via the binding layer, the conductor space factor of the aggregate conductor is improved. Further, since the conductor wires constituting the assembly conductor are integrated in a non-twisted state, a local coil is not formed, and the generation of eddy current is suppressed. Therefore, it is possible to suppress the generation of eddy currents and improve the conductor space factor in the collective conductor become.
• a cross section of the conductor wire may be formed in a rectangular shape.
• the cross section of the conductor wire constituting the conductor wire is rectangular, the cross section of the conductor wire is also rectangular. Therefore, by superimposing the side surfaces of the conductor wires, the conductor wires can be easily aligned in the width direction and the height direction, so that the conductor space factor in the collective conductor can be improved.
• the binding layer may have an electric resistance value larger than that of the conductor wire.
• the present invention is particularly effective for the coil of a motor driven by an inverter.
• the method of manufacturing an aggregate conductor according to the present invention produces an aggregate conductor in which a plurality of conductor wires each having a partial cross-sectional shape obtained by dividing the overall cross-sectional shape are integrated in an untwisted state.
• a conductor wire bundle forming step of forming a conductor wire bundle by bundling the conductor wires having a binding layer formed on the surface thereof in an untwisted state, and pressing the conductor wire bundle from the side to And a monolithic process for integrating the wires through the binding layer.
• the conductor wire bundle forming step a plurality of conductor wires each having a partial cross-sectional shape obtained by dividing the entire cross-sectional shape of the collective conductor are bundled in an untwisted state.
• the conductor wires are integrated by pressing the conductor wire bundle from the side in the integration process, so that the conductor wires are tightly bound via the binding layer.
• the conductor space factor in the collective conductor is improved.
• the conductor wires constituting the assembly conductor are integrated in a non-twisted state, a local coil is not formed and the generation of eddy currents is suppressed.
• a cross section of the conductor wire bundle is formed in a rectangular shape, and in the integration step, two adjacent side faces of the conductor wire bundle may be pressed, respectively.
• the method includes a step of preparing a pair of straightening jigs each having a rectangular through-hole for penetrating the conductor wire bundle.
• the conductor wire bundle is passed through the one straightening jig. Pore force
• the conductor wires may be bonded to each other by advancing into the through hole of the other correction jig.
• the conductor wire bundle is bound between the pair of correction jigs. Therefore, the conductor wires are bound to each other while maintaining the alignment state of the conductor wires in the conductor wire bundle.
• two adjacent inner surfaces constituting the rectangular through hole of each correction jig may be brought into contact with two adjacent side surfaces of the conductor wire bundle.
• the two adjacent side surfaces of the conductor wire bundle are pressed.
• the radius of curvature of the corners of the rectangular through holes of each of the correction jigs may be smaller than the radius of curvature of the corners of the conductor wire bundle.
• the integration step may include a four-direction pressing step of pressing each side surface of the conductor wire bundle.
• Each conductor wire is provided so as to cover a conductor wire having a rectangular cross section, an insulating coating layer provided so as to cover the conductor wire, and the coating layer
• the binder layer may be provided.
• the cross section of the conductor wire constituting the conductor wire is rectangular, the cross section of the conductor wire is also rectangular. Therefore, the side of each conductor wire is overlapped.
• the conductor wires are easily aligned in the width direction and the height direction in a state where the conductor wires are insulated by the covering layer, the conductor space factor in the aggregate conductor can be improved.
• the present invention is particularly effective for the coil of a motor driven by an inverter.
• the collective conductor according to the present invention is an collective conductor in which a plurality of conductor wires each having a partial cross section obtained by dividing the entire cross section are integrated in an untwisted state.
• Each conductor wire has a conductor wire and a coating layer provided so as to cover the conductor wire, and is bonded to each other via the coating layer, and the coating layer is made of a tape material. It is characterized by being.
• each conductor wire constituting the assembly conductor has a partial cross-section of a partial shape obtained by dividing the entire cross-sectional shape of the assembly conductor! Since the constituent conductor wires are bundled through the covering layer, the conductor space factor in the collective conductor is improved. Further, since the conductor wires constituting the aggregated conductor are bundled in an untwisted state, the aggregated conductor itself does not form a local coil, and the generation of eddy current is suppressed. Therefore, it is possible to suppress the generation of eddy currents and improve the conductor space factor in the collective conductor.
• each conductor wire is covered with a coating layer made of a tape material, the conductor wires adjacent to each other in an integrated state are insulated by the tape material. It becomes possible.
• a cross section of the conductor wire may be formed in a rectangular shape!
• the cross section of the conductor wire constituting the conductor wire is rectangular, the cross section of the conductor wire is also rectangular. Therefore, by superimposing the side surfaces of the conductor wires, the conductor wires can be easily aligned in the width direction and the height direction, so that the conductor space factor in the collective conductor can be improved.
• the tape material may be made of greaves!
• the coating layer can be formed of a general and inexpensive material, and adjacent conductor wires can be insulated from each other.
• the present invention is particularly effective for the coil of a motor driven by an inverter.
• the collective conductor according to the present invention is an collective conductor in which a plurality of conductor wires each having a partial cross section obtained by dividing the entire cross section are integrated in an untwisted state.
• Each conductor wire includes a conductor wire and a coating layer made of a metal or metal compound provided on the outer periphery of the conductor wire and having an electric resistance value larger than the electric resistance value of the conductor wire. It is characterized by being.
• each conductor wire constituting the assembly conductor has a partial cross section of a partial shape obtained by dividing the entire cross section shape of the assembly conductor! Since the constituent conductor wires are bundled through the covering layer, the conductor space factor in the collective conductor is improved. Further, since the conductor wires constituting the aggregated conductor are bundled in an untwisted state, the aggregated conductor itself does not form a local coil, and the generation of eddy current is suppressed. Therefore, it is possible to suppress the generation of eddy currents and improve the conductor space factor in the collective conductor.
• the conductor strands of these conductor wires are covered by a covering layer made of a metal having a larger electric resistance value than the conductor wires. It is possible to ensure necessary and sufficient insulation between the two.
• a binder layer may be provided on the outermost periphery of the conductor wire. As a result, the conductor wires can be securely bonded to each other.
• the conductor wire has a rectangular cross section! You can do it.
• the conductor wire since the cross section of the conductor wire constituting the conductor wire is rectangular, the cross section of the conductor wire is also rectangular. Therefore, by superimposing the side surfaces of the conductor wires, the conductor wires can be easily aligned in the width direction and the height direction, so that the conductor space factor in the collective conductor can be improved.
• the conductor wire may be formed of copper or a copper alloy, and the coating layer may be formed of nickel or a nickel alloy.
• the conductor wire may be formed of copper or a copper alloy, and the covering layer may be formed of tin or a tin alloy. Also
• the conductor element wire may be formed of a metal, and the covering layer may be formed of an oxide of the conductor element wire.
• the coating layer can be configured with a general and inexpensive material.
• the present invention is particularly effective for the coil of a motor driven by an inverter.
• a plurality of conductor wires each having a binding material partially provided on the outermost periphery are bonded to each other via the binding material in an untwisted state. It is characterized by.
• Each of the plurality of conductor wires may have a coating layer on the surface.
• the plurality of conductor wires may have a rectangular cross-sectional shape.
• the plurality of conductor wires have m rows Xn columns (m ⁇ 1, n ⁇ 2, m and n are integers) in the cross section.
• Each of the plurality of conductor wires may be provided such that the outermost binder is in non-contact with the binder of the adjacent conductor wire.
• the plurality of conductor wires are brought into close contact with each other via the binding material partially provided on the outermost periphery of each of the conductor wires. Compared to the collective conductor
• the generation of eddy currents is suppressed, and a collective conductor suitable for use as a coil can be obtained.
• adjacent conductor wires can be separated by the thickness of the binder, and no current flows between the conductor wires. Can be reduced, thereby improving the space factor.
• the space factor is high! ⁇ m rows X n columns (for example,
• M ⁇ l, n ⁇ 2, m and n are integers
• the collective conductor according to the present invention is an aggregate configured in a strip shape in which a plurality of conductor wires each having a partial cross section obtained by dividing the entire cross section are integrated in an untwisted state.
• the conductor is characterized in that it is formed so that its width gradually increases from one end to the other end.
• One end force The thickness may gradually decrease toward the other end.
• the overall cross-sectional shape may be a trapezoid having hypotenuses on both sides in the width direction! /.
• the method for manufacturing an aggregate conductor according to the present invention is configured in a band shape in which a plurality of conductor wires each having a partial cross-sectional shape obtained by dividing the overall cross-sectional shape are integrated in an untwisted state. And a step of forming a strip having a uniform width obtained by integrating a plurality of conductor wires in a non-twisted state, and gradually increasing the width of the strip toward the other end. And a step of forming so as to be wide.
• the slot is formed to have a width narrower from the bottom toward the opening.
• a laminated structure of an aggregate conductor having a wide width at the bottom side of the slot and a narrow width at the opening side is formed, and therefore formed on both sides of the laminated structure of the aggregate conductor. The dead space that is generated can be reduced.
• the collective conductor according to the present invention is a strip-shaped collective conductor in which a plurality of conductor wires are integrated, and is formed so that the width at one end gradually increases toward the other end. It is characterized by.
• the one end force may also be directed toward the other end so that the thickness is gradually reduced.
• the overall cross-sectional shape may be trapezoidal! /.
• the method for manufacturing an aggregate conductor according to the present invention is a method for manufacturing a strip-shaped aggregate conductor in which a plurality of conductor wires are integrated, and the conductor wires are integrated to have a uniform width in the length direction.
• the conductor wire may have a circular cross-sectional shape! /.
• the one end force is an aggregate conductor formed so that the width gradually increases toward the other end
• the slot is formed to have a narrow width from the bottom toward the opening.
• a laminated structure of an aggregate conductor having a wide width at the bottom side of the slot and a narrow width at the opening side is formed. The dead space formed on both sides of the laminated structure is reduced.
• FIG. 1 is a perspective view of a collective conductor 10 according to Embodiment 1.
• FIG. 1 is a perspective view of a collective conductor 10 according to Embodiment 1.
• FIG. 2 is a schematic cross-sectional view showing an example of the conductor wire 3 constituting the assembly conductor 10.
• FIG. 3 is a cross-sectional view showing a state in which the assembly conductor 10 is disposed inside the slot 30b of the stator core 30.
• FIG. 4 is a top view of an assembly conductor manufacturing apparatus 50 that manufactures the assembly conductor 10.
• FIG. 5 is a side view of an assembly conductor manufacturing apparatus 50 that manufactures the assembly conductor 10.
• FIG. 6 is a cross-sectional view of first die 22a taken along line VI—VI in FIG.
• FIG. 7 is a cross-sectional view showing an example of a rectangular shape that is a cross-sectional shape of the conductor wire 1.
• FIG. 8 is a cross-sectional view of a first collective conductor according to Embodiment 2.
• FIG. 9 is a cross-sectional view of a second collective conductor according to the second embodiment.
• FIG. 10 is a perspective view of the collective conductor 10 according to the third embodiment.
• FIG. 11 is a cross-sectional view of the first die 22a corresponding to FIG.
• FIG. 12 is a cross-sectional view of a first collective conductor according to Embodiment 4.
• FIG. 13 is a cross-sectional view of a second collective conductor according to the fourth embodiment.
• FIG. 14 is a top view of the assembly conductor manufacturing apparatus 50a according to the fifth embodiment.
• FIG. 15 is a side view of the assembly conductor manufacturing apparatus 50a.
• FIG. 16 is a cross-sectional view of first die 22a taken along line XVI—XVI in FIG.
• FIG. 17 is an enlarged sectional view of a corner (corner) C in FIG.
• FIG. 18 is a top view of an aggregate conductor manufacturing apparatus 50b according to Embodiment 6.
• FIG. 19 is a side view of the assembly conductor manufacturing apparatus 50b.
• FIG. 20 is a cross-sectional view partially showing a four-way roller die 22c constituting the assembly conductor manufacturing apparatus 50b.
• FIG. 21 is a perspective view showing an assembly conductor 10 according to the seventh embodiment.
• FIG. 22: 1 FIG. 22 is a perspective view showing an assembly conductor according to the eighth embodiment.
• FIG. 23 is an enlarged cross-sectional view of a rectangular cross section of a conductor wire.
• FIG. 24 is an enlarged cross-sectional view of a rectangular cross section of a conductor wire.
• FIG. 25 is an enlarged cross-sectional view of a rectangular cross section of a conductor wire.
• FIG. 26 is an enlarged cross-sectional view of a rectangular cross section of a conductor wire.
• FIG. 27 is an enlarged cross-sectional view of a rectangular cross section of a conductor wire.
• FIG. 28 is an enlarged sectional view showing a sectional structure of the coating layer.
• FIG. 29 is an enlarged sectional view showing a sectional structure of the coating layer.
• FIG. 30 is an enlarged cross-sectional view showing the cross-sectional structure of the coating layer.
• FIG. 31 is an enlarged cross-sectional view showing a rectangular cross section of the conductor wire according to the ninth embodiment.
• FIG. 32 is an enlarged cross-sectional view of a rectangular cross section of a conductor wire.
• FIG. 33 is an enlarged cross-sectional view of a rectangular cross section of a conductor wire.
• FIG. 34 is an enlarged cross-sectional view of a rectangular cross section of a conductor wire.
• FIG. 35 is an enlarged cross-sectional view of a rectangular cross section of a conductor wire.
• FIG. 36 is a perspective view of the assembly conductor according to the tenth embodiment.
• FIG. 37 is an explanatory view showing a method of attaching a binder to a conductor wire using a roller.
• FIG. 38 shows the surface of the roller.
• FIG. 38 is an explanatory view showing a method of attaching a binder to a conductor wire using a spray nozzle.
• FIG. 40 is a perspective view of the assembly conductor of the eleventh embodiment.
• FIG. 41 is a perspective view of an assembly conductor according to Embodiment 12.
• FIG. 41 is a perspective view of an assembly conductor according to Embodiment 12.
• FIG. 42 is a cross-sectional view showing a state in which the assembly conductor according to Embodiment 12 is provided in the slot.
• FIG. 43 is an explanatory view showing a forming process from a strip to an aggregate conductor.
• FIG. 44 is a perspective view of the collective conductor according to Embodiment 14.
• FIG. 44 is a perspective view of the collective conductor according to Embodiment 14.
• FIG. 45 is a guide with a circular cross section inside the slot 130b of the stator core 130.
• FIG. 6 is a cross-sectional view showing a state where a body wire 103 is arranged.
• FIG. 46 is a cross-sectional view showing a state in which a conventional conductor is provided in the slot.
• Embodiment 1 of the Invention 1 to 7 show Embodiment 1 of the collective conductor according to the present invention.
• FIG. 1 is a perspective view of the collective conductor 10 according to the present embodiment.
• this collective conductor 10 has a plurality of conductors integrated so as to be aligned in the width direction (lateral direction in the figure) and the height direction (vertical direction in the figure) in an untwisted state.
• Each of the conductor wires 3 is bound to each other by a binding layer 4 formed on the surface thereof.
• the term “integrated layer” means that there is no contact interface between the binding layers 4 of the adjacent conductor wires 3.
• the conductor wire 3 includes a linear conductor element wire 1 having a rectangular cross section, an insulating covering layer 2 provided so as to cover the conductor element wire 1, and the covering layer 2 And a binding layer 4 provided to cover.
• the rectangular cross-sectional shape of the conductor wire 3 (conductor wire 1) is a partial shape obtained by dividing the rectangular overall cross-sectional shape of the integrated conductor 10.
• FIG. 7 (a) to FIG. 7 the rectangular shape that is the cross-sectional shape of the conductor wire 1 (and the conductor wire 3) is shown in FIG. 7 (a) to FIG.
• the shape is as shown in (e). That is, the rectangular shape has a square cross section with a right corner as shown in FIG. 7 (a), a rectangular cross section with a right angle as shown in FIG. 7 (b), and FIG. ) As shown in FIG. 7 (d), and a cross-sectional rectangle as shown in FIG. 7 (d). Examples include shapes that are parallel and arc-shaped on the other side (cross-sectional track shape).
• Each of the shapes shown in FIGS. 7 (a) to 7 (e) can be formed by forming a conductor bus as a wire drawn by a die, or by a processing molding apparatus such as roller rolling.
• the track-shaped one shown in Fig. 7 (e) may be formed by subjecting a round bus to one-way force rolling and machining.
• the cross-sectional shape of the conductor wire 1 is preferably the above-mentioned rectangular shape from the viewpoint of space factor and productivity, and may be a polygon such as a triangle or a hexagon.
• the conductor wire 1 having a rectangular cross section is a rectangular wire having a relatively small surface area, the area occupied by the covering layer 2 can be reduced, and can be adapted to the collective conductors 10 of various sizes. Can do.
• the length of the long side is set to 1 to 1.5 times (preferably 1 to 1.2 times) of the short side, so that m When aligned in rows and n columns (m and n are natural numbers, for example, 3 rows and 6 columns as shown in Fig. 1), the conductor space factor is improved and an insulating conductor with a large surface area is obtained. Motors used in electric vehicles (high frequency (Including conductor wires through which alternating current flows) can be reduced in size and weight.
• cross-sectional shapes of the conductor wires 1 constituting the assembly conductor 10 may not all be the same.
• the size of the conductor wire 1 is, for example, 0.05mn on one side! ⁇ A 2 mm (preferably 0. 05mn! ⁇ Lmm), 0. 03mm ⁇ 2.
• the transverse cross-sectional area Yogu if size corresponding to the round wire of Omm phi, and 0. 0007mm 2 ⁇ 4mm 2 become.
• the conductor wire 1 is made of a conductive material such as copper, aluminum, silver, iron, gold, or an alloy thereof.
• the material of the coating layer 2 is formed by dip coating, such as polyamide imide, polyester imide, polyester, urethane, acrylic, epoxy, polyimide, polybul formal, etc.
• the resin formed by electrodeposition coating include acrylic, polyester, polyimide, epoxy, and urethane resins.
• polyimide resins, polyamideimide resins, and the like are preferable.
• urethane-based resins that are easily thermally decomposed are preferable.
• an acrylic resin is preferable.
• the coating layer 2 may be an acid film in which the surface of the conductor wire 1 is acidified.
• the film thickness of the coating layer 2 is 1 ⁇ m to 5 m (preferably 1 ⁇ m to 3 m) in the case of electrodeposition coating, and 1 ⁇ m to 10 m in the case of dip coating.
• the coating layer 2 can be reliably formed at the corners of the conductor wire 1.
• the thickness force of the covering layer 2 at the end portion in the width direction of the conductor wire 1 is formed to be the same as the thickness of the covering layer 2 in the center portion in the width direction of the conductor wire 1. It is possible to improve the insulation between the conductor wires 1 in the assembly conductor 10 without reducing the conductor space factor. Further, as shown in FIG. 2, the thickness d2 of the covering layer 2 at the end portion (corner portion) in the width direction of the conductor wire 1 is formed larger than the thickness dl of the covering layer 2 in the center portion in the width direction. May be. In this case, the thicknesses dl and d2 are 5 m to 10 m.
• the covering layer 2 at the corners of the conductor wire 1 is reinforced, the insulation between the conductor wires 1 in the aggregate conductor 10 can be improved. If high pressure resistance is not required, the coating layer 2 may not be formed uniformly on the surface of the conductor wire 1.
• binder layer 4 as a fusing material, polyvinyl butyral-based, polyamide-based, epoxy-based, polyester-based heat-resisting resin, polyamide-soluble modified with alcohol, etc.
• adhesive EVA, acryl, urethane, epoxy, black-prene, cyanoacrylate, silicone, nitrile, PVC, Examples thereof include vinyl acetate resins. Since the binding layer 4 is made of the above-described resin, the insulation property between the conductor wires 1 in the assembly conductor 10 can be improved.
• the film thickness of the binding layer 4 is 0.5 m to 3 ⁇ m.
• the binding layer 4 may not be uniformly formed on the surface of the conductor wire 3 as long as each conductor wire 3 can be fixed to the assembly conductor 10.
• a tape having insulating properties such as polyimide, aramid, polyester, and nylon is provided on the surface of the collective conductor 10.
• dip coating similar to coating layer 2 may be applied.
• the assembly conductor 10 having the above configuration is arranged in a plurality of layers (for example, four layers) inside each slot 30b of the stator core 30 constituting the motor. According to this, it is possible to suppress the formation of a dead space inside the slot as in the case where a plurality of conductor wires 103 having a circular cross section are arranged (see FIG. 45).
• the stator core 30 is formed in a cylindrical shape, and includes a plurality of ridge portions 30a and ridge portions (slots 30b) alternately formed in the circumferential direction on the inner peripheral wall or the outer peripheral wall thereof.
• the force slot 30b shown by replacing the curved stator core 30 with a flat surface has, for example, a bottom portion with a width force of about mm and an opening portion with a width of about 6 mm. The length is about 30mm.
• the collective conductor 10 is manufactured using the collective conductor manufacturing apparatus 50 shown in the top view of FIG. 4 and the side view of FIG.
• this collective conductor manufacturing apparatus 50 a plurality of unwinding rolls 20, a first guide roll 21, a first die 22a, a binding treatment chamber 23, a second die 22b, and a second guide roll 24 And the take-up roll 25 and the force S—in a row.
• the first guide roll 21 guides the conductor wire 3 unwound from each unwinding roll 20 to the first dice 22a.
• the first die 22a has a plurality of conductor wires 3 formed on the surface with the binding layer 4 supplied from the first guide roll 21 aligned in the width direction and the height direction. This is a straightening jig for straightening.
• FIG. 6 is a cross-sectional view of the first die 22a taken along line VI-VI in FIG.
• the binding treatment chamber 23 is for binding the aligned conductor wires 3 together.
• the binding processing chamber 23 in the case of using a heat-fusible bonding material as the bonding layer 4 includes a heater for heating the aligned conductor wires 3.
• the binding processing chamber 23 in the case of using a fusion material having alcohol fusion properties as the binding layer 4 is provided with a coater for applying alcohol to the aligned conductor wires 3.
• the binding processing chamber 23 coats the plurality of aligned conductor wires 3 with an adhesive, and dries (cures) the applied adhesive. Equipped with a heater!
• the second die 22b is a correction jig for correcting the plurality of conductor wires 3 to be aligned in the width direction and the height direction.
• the second guide roll 24 guides the collective conductor 10 supplied from the second die 22b to the take-up roll 25.
• the surface of the conductor wire 1 having a rectangular cross section is electrodeposited with an epoxy-modified acrylic resin-based water-dispersed varnish, and then dried and baked to form a coating layer on the surface.
• a conductor wire 3 with 2 is formed.
• each unwinding roll 20 is set in the collective conductor manufacturing apparatus 50, and the conductor wire 3 is unwound from each unwinding roll 20 and passed through the first guide roll 21, as shown in FIG.
• a plurality of conductor wires 3 are arranged in alignment inside the first die 22a and the second die 22b.
• the binding chamber 23 is operated to heat the conductor wires 3 arranged in an aligned state. At this time, the adjacent conductor wires 3 are fused and integrated with each other, and the aggregate conductor 10 is obtained.
• the assembly conductor 10 is wound around the winding roll 25 via the second guide roll 24.
• the collective conductor 10 can be manufactured as described above.
• each conductor wire 3 constituting the collective conductor 10 is a partial shape obtained by dividing the rectangular overall cross-sectional shape of the collective conductor 10.
• each conductor has a rectangular cross section, and the conductor wires 1 constituting each conductor wire 3 are insulated from each other by the covering layer 2 and the side surfaces of the conductor wires 3 are overlapped. Since the wires 3 are tightly bound by the binding layer 4, the conductor space factor in the aggregate conductor 10 can be improved. Further, since the conductor wires 3 constituting the assembly conductor 10 are integrated and twisted in a non-twisted state, a local coil is not formed, and the generation of eddy current can be suppressed. Therefore, the generation of eddy current can be suppressed and the conductor space factor in the collective conductor 10 can be improved.
• the collective conductor 10 of the present embodiment is formed by integrating a plurality of conductor wires 3, the skin current is divided and the eddy current is canceled between adjacent conductor wires 3. Therefore, the AC resistance can be lowered and the current loss can be reduced.
• the coating layer 2 can be thinly formed by electrodeposition coating, so the conductor space factor in the collective conductor 10 and each conductor wire 3 is improved, and the motor Efficiency can be increased.
• each conductor wire 3 is fixed by the binding layer 4, each conductor wire 3 can be held in an aligned state even when deformed by bending or the like. it can. Since the assembly conductor 10 is easier to form than to form a plurality of single conductor wires by bundling them, it can be applied to coils having various shapes. [0123] Furthermore, in the collective conductor 10 of the present embodiment, each conductor wire 3 is bound by the binding layer 4 made of resin, so that the binding can be released by solvent treatment or heating. Is possible.
• the collective conductor 10 of the present embodiment is a rectangular wire having a rectangular cross section, handling is easy.
• FIGS. 8 and 9 are perspective views of the collective conductor according to the present embodiment.
• the same parts as those in FIGS. 1 to 7 are denoted by the same reference numerals, detailed description thereof will be omitted, and differences will be mainly described.
• the collective conductor 10 in which the conductor wire 3 (conductor element wire 1) has a rectangular cross-sectional shape has been described.
• Conductor wire 3 (conductor wire 1) has a circular cross-sectional shape and a conductor row 3 arranged vertically and horizontally, an m-row n-column type collective conductor, and each conductor wire 3 ( The present invention can also be applied to a close-packed type collective conductor in which the cross-sectional shape of the conductor wire 1) is circular and the conductor wires 3 are arranged in a close-packed manner.
• FIG. 10 is a perspective view of the collective conductor 10 according to the present embodiment.
• the collective conductor 10 has a plurality of conductors integrated so as to be aligned in the width direction (lateral direction in the figure) and the height direction (vertical direction in the figure) in an untwisted state.
• Each of the conductor wires 3 is bound by a binding layer 4 formed on the surface.
• the term “integration” means that there is no contact interface between the binding layers 4 of the adjacent conductor wires 3.
• the conductor wire 3 includes a linear conductor wire 1 having a rectangular cross section and a binding layer 4 provided so as to cover the conductor wire 1.
• the rectangular cross-sectional shape of the conductor wire 1 is a partial shape obtained by dividing the rectangular overall cross-sectional shape of the collective conductor 10.
• the binding layer 4 may not be uniformly formed on the surface of the conductor element wire 1 as long as each conductor element wire 1 can be fixed in the assembly conductor 10.
• the binding layer 4 may be partially formed in the form of dots or stripes on the surface of the conductor wire 1.
• the conductor wires 1 are insulated from each other in a space formed between the conductor wires 1.
• each conductor element constituting the collective conductor 10 Since the same potential is supplied to the wires 1 and current does not easily flow between the conductor elements 1, depending on the usage of the integrated conductor 10, the insulation between the conductor wires 1 may be low.
• the first guide roll 21 guides the conductor wire 1 unwound from each unwinding roll 20 to the first die 22a.
• the first die 22a aligns a plurality of conductor strands 1 having a binding layer 4 supplied from the first guide roll 21 on the surface in the width direction and the height direction. It is a correction jig for correcting the condition.
• FIG. 11 is a cross-sectional view of the first die 22a corresponding to FIG.
• the binding treatment chamber 23 is for binding the aligned conductor wires 1 to each other.
• the binding processing chamber 23 in the case of using a heat-fusible sealing material as the binding layer 4 is provided with a heater for heating the aligned conductor wires 1.
• the binding treatment chamber 23 in the case of using a fusion material having an alcohol fusion property as the binding layer 4 is provided with a coater for applying alcohol to a plurality of aligned conductor wires 1.
• the binding processing chamber 23 includes a coater for applying the adhesive to the aligned conductor wires 1 and a heater for drying (curing) the applied adhesive. And prepare.
• the second die 22b is a correction jig for correcting the plurality of conductor strands 1 to be aligned in the width direction and the height direction.
• an epoxy varnish is dip-coated on the surface of the conductor wire 1 having a rectangular cross section to form the binding layer 4 on the surface.
• the conductor wire 1 on which the binding layer 4 is formed is wound around a plurality of unwinding rolls 20.
• each unwinding roll 20 is set in the assembly conductor manufacturing apparatus 50, and the conductor wire 1 is unwound from each unwinding roll 20, and the first guide roll 21 is passed through to FIG. As shown In addition, the plurality of conductor wires 1 are arranged in an aligned state inside the first die 22a and the second die 22b.
• the binding processing chamber 23 is operated to heat the conductor wires 1 arranged in an aligned state. At this time, the adjacent conductor wires 1 are fused and integrated with each other, and the aggregate conductor 10 is obtained.
• the assembly conductor 10 is wound around the winding roll 25 through the second guide roll 24.
• the collective conductor 10 can be manufactured as described above.
• each conductor wire 1 constituting the collective conductor 10 is a partial shape obtained by dividing the rectangular overall cross-sectional shape of the collective conductor 10, In other words, since the conductor strands 1 are tightly bound by the binding layer 4 while having a rectangular cross section, the conductor space factor in the aggregate conductor 10 can be improved. Further, since the conductor wires 1 constituting the assembly conductor 10 are integrated in a non-twisted state, a local coil is not formed, and the generation of eddy current can be suppressed. Therefore, the generation of eddy current can be suppressed and the conductor space factor in the collective conductor 10 can be improved. Thereby, motor efficiency can be made high.
• the binding layer 4 that binds the conductor wires 1 since the binding layer 4 that binds the conductor wires 1 has insulation properties, the side surfaces of the conductor wires 1 are overlapped. The conductor wires 1 are bonded together in a state where they are insulated by the bonding layer 4. Therefore, it is possible to improve the insulation between the conductor wires 1 in the assembly conductor 10 without reducing the conductor space factor in the assembly conductor 10.
• the collective conductor 10 of the present embodiment is formed by integrating a plurality of conductor strands 1, so that the skin current is divided and an eddy current is generated between the adjacent conductor strands 1.
• the AC resistance can be lowered and the current loss can be reduced because of the cancellation.
• each conductor element wire 1 is fixed by the binding layer 4, each conductor element wire 1 is held in an aligned state even when deformed by bending or the like. be able to.
• the assembly conductor 10 of the present embodiment is easier to form than forming a plurality of single conductor wires by bundling them, and thus can be applied to coils having various shapes.
• each conductor element wire 1 is bound by the binding layer 4 made of resin, so that the binding is released by solvent treatment or heating. be able to.
• the collective conductor 10 of the present embodiment is a rectangular wire having a rectangular cross section, so that handling is easy.
• each conductor wire 1 has a circular cross-sectional shape and its conductor elements.
• the present invention can also be applied to a close-packed type aggregate conductor in which line 1 is arranged in a close-packed manner.
• this assembly conductor manufacturing apparatus 50a as shown in Figs. 14 and 15, a plurality of unwinding rolls 20, a sheep 26, a first guide roll 21, and a first die 22a are bonded.
• the processing chamber 23, the second die 22b, the second guide roll 24, and the take-up roll 25 are arranged so as to be connected in a row.
• Each unwinding roll 20 is configured such that an equivalent back tension can be added to the unwound conductor wire 3.
• tension is applied to the conductor wire 3 supplied from the unwinding rolls 20 to the first dice 22a through the sheep 26 and the first guide rolls 21, so that the inside of the first dice 22a Conductor wire 3 can be placed in an aligned state.
• the sheep 26 is a pulley with a groove for removing twists and bends of the conductor wire 3.
• the first guide roll 21 connects the conductor wire 3 unwound from each unwinding roll 20 to the first die. This is a guide to 22a.
• the first die 22a and the second die 22b are formed by connecting a plurality of conductor wires 3 having a binding layer 4 supplied from the first guide roll 21 on the surface thereof in the width direction and the height direction. It is a pair of straightening jigs for straightening the conductor wire bundle 5 aligned in the vertical direction.
• FIG. 16 is a cross-sectional view of the first die 22a taken along line XVI-XVI in FIG.
• first die 22a and the second die 22b have a through hole H having a rectangular cross section for allowing the conductor wire bundle 5 to pass therethrough. Furthermore, the clearance (for example, 0.1 mm) between the inner side surface of the through hole H of the second die 22b and the side surface of the conductor wire bundle 5 is the same as the inner surface of the through hole H of the first die 22a and the side surface of the conductor wire bundle 5. The clearance is smaller than (for example, 0.5 mm).
• the central axis Ad of the first die 22a and the second die 22b is in the left-right direction (the width direction of the conductor wire bundle 5) with respect to the central axis A1 of the production line. It is slightly shifted in the vertical direction (height direction of the conductor wire bundle 5).
• the production line speed is 1. OmZ seconds and the distance between the first die 22a and the second die 22b is 1.
• the central axis Ad of the first die 22a and the second die 22b is The vertical axis and the horizontal direction are offset by about 0.5 cm from the center axis A1 of the production line.
• the two adjacent inner side surfaces constituting the through holes H of the first die 22a and the second die 22b are in contact with the two adjacent side surfaces of the conductor wire bundle 5, and the conductor wire bundle 5 is connected to each through hole.
• H can be moved to one side in the width direction and the height direction at H, and as shown in FIG. 16, two adjacent inner surfaces in the through holes H of the first die 22a and the second die 22b Two adjacent sides can be pressed by pressing force F.
• the radius of curvature R2 (for example, 0.01 mm) of the corner C of each through-hole H of the first die 22a and the second die 22b is, as shown in FIG.
• the curvature radius of corner C in 3) is smaller than R1 (for example, 0.05 mm). According to this, the floating of the corner portion C of the conductor wire bundle 5 at the corner portion C of each through hole H of the first die 22a and the second die 22b can be suppressed, and the conductor wire 3 in the conductor wire bundle 5 can be suppressed. The alignment state can be maintained.
• the binding processing chamber 23 is for binding the conductor wires 3 constituting the conductor wire bundle 5 together.
• a binding treatment chamber 23 in the case of using a heat-fusible adhesive as the binding layer 4 23 Includes a heater for heating the conductor wire bundle 5.
• the binding processing chamber 23 in the case of using an alcohol-bonding adhesive as the binding layer 4 is provided with a coater for applying alcohol to the conductor wire bundle 5.
• the binder processing chamber 23 heats the conductor wire bundle 5 with a coater for applying the adhesive to the conductor wire bundle 5, and dries (hardens) the applied adhesive. ) Equipped with a heater!
• the second guide roll 24 guides the collective conductor 10 supplied from the second die 22b to the take-up roll 25.
• a method for manufacturing the aggregate conductor 10 when the aggregate conductor manufacturing apparatus 50a having the above-described configuration is prepared and a fusion-bonding material having heat-fusibility is used as the binding layer 4 will be described below.
• the surface of the conductor wire 1 having a rectangular cross section is electrodeposited with an epoxy-modified acrylic resin-based water-dispersed varnish, and then dried and baked to form a coating layer on the surface.
• a conductor wire 3 with 2 is formed.
• an epoxy varnish is dip-coated on the surface of the conductor wire 3 to form a binding layer 4 on the surface.
• the conductor wire 3 on which the binding layer 4 is formed is wound up by 20 winding rolls.
• each unwinding roll 20 is set in the collective conductor manufacturing apparatus 50a, and the conductor wire 3 is unwound from each unwinding roll 20, and is passed through the sheep 26 and the first guide roll 21 to obtain FIG.
• a plurality of conductor wires 3 are arranged in the first die 22a in an aligned state to form a conductor wire bundle 5, and the tip of the conductor wire bundle 5 is sent into the second die 22b (lead). Body bundle forming process).
• the binding processing chamber 23 is operated, and the conductor wire bundle 5 is heated.
• the conductor wires 3 adjacent to each other in the conductor wire bundle 5 are fused and integrated with each other to obtain the aggregate conductor 10 (integration process).
• the conductor wire bundle 5 is connected to the first die 22a and the second die. Since the wires 22b are integrally formed, the conductor wires 3 constituting the conductor wire bundle 5 can be bonded to each other while maintaining the aligned state of the conductor wires 3 in the conductor wire bundle 5.
• the aggregated conductor 10 is wound around the winding roll 25 via the second guide roll 24.
• each conductor wire 3 constituting the collective conductor 10 has a rectangular shape of the collective conductor 10 during the conductor wire bundle forming process.
• the conductor wire 1 constituting each conductor wire 3 is insulated from each other by the covering layer 2 as well as having a partial shape obtained by dividing the overall cross-sectional shape of the conductor, that is, a rectangular cross section.
• the conductor wire bundle 5 is formed by superimposing the side surfaces of the conductor wires 3, and then the conductor wire bundle 5 is also pressed by the first die 22a and the second die 22b in the integral die process to cause each conductor wire 3 to be pressed.
• the conductor wires 3 are tightly bound through the binding layer 4 and the conductor space factor in the aggregate conductor 10 can be improved.
• the conductor wires 3 constituting the assembly conductor 10 are integrated in a non-twisted state, a local coil is not formed, and the generation of eddy current can be suppressed. Therefore, it is possible to manufacture the collective conductor 10 that can suppress the generation of eddy currents and improve the conductor space factor.
• the collective conductor 10 of the present embodiment is configured by bundling a plurality of conductor wires 3, the skin current is divided and the eddy current is canceled between the adjacent conductor wires 3. Therefore, the AC resistance can be lowered and the current loss can be reduced.
• the coating layer 2 can be formed thin by electrodeposition coating, so that the conductor space factor in the collective conductor 10 and each conductor wire 3 is improved, and the motor Efficiency can be increased.
• each conductor wire 3 since each conductor wire 3 is fixed by the binding layer 4, each conductor wire 3 can be held in an aligned state even when deformed by bending or the like. it can. Since the assembly conductor 10 is easier to form than to form a plurality of single conductor wires by bundling them, it can be applied to coils having various shapes.
• each conductor wire 3 is bound by the binding layer 4 made of grease, so that the binding can be released by solvent treatment or heating. Is possible.
• the collective conductor 10 of the present embodiment is a rectangular wire having a rectangular cross section, so that handling is easy.
• the present invention is, for example, a precursor of 3 rows and 1 column. 6 pieces, that is, It is possible to manufacture 6 columns, and then stack the 6 precursors and bind them into 3 rows and 6 columns to produce the assembly 10.
• the collective conductor described in the first embodiment is the same as in the fifth embodiment.
• a method for manufacturing 10 will be described using the assembly conductor manufacturing apparatus 50b shown in the top view of FIG. 18 and the side view of FIG. FIG. 20 shows the assembly conductor manufacturing apparatus 50b.
• FIG. 4 is a cross-sectional view partially showing a four-way roller die 22c.
• a four-way roller die 22c is provided between the first die 22a and the binding processing chamber 23.
• the configuration other than the four-way roller die 22c is the same as that of the collective conductor manufacturing apparatus 50a described in the first embodiment.
• the four-way roller die 22c includes a first roller die 22ca that contacts the upper surface of the conductor wire bundle 5, a second roller die 22cb that contacts the lower surface of the conductor wire bundle 5, and a conductor.
• a third roller die 22cc that comes into contact with the left side surface of the wire bundle 5 and a fourth roller die 22cd that comes into contact with the right side surface of the conductor wire bundle 5 are provided.
• the first roller die 22ca and the second roller die 22cb are formed in a rotatable cylindrical shape.
• the peripheral wall is configured to be pressed by the pressing force F against the upper side surface and the lower side surface of the conductor wire bundle 5.
• the third roller die 22cc and the fourth roller die 22cd are formed in a rotatable disk shape having a peripheral wall, and the peripheral wall is pressed against the left side surface and the right side surface of the conductor wire bundle 5 by a pressing force F. It is configured to press.
• the conductor wire bundle 5 is the first in the integral winding process in the method of manufacturing the assembly conductor 10 described in the fifth embodiment. It is only necessary to press each side surface of the conductor wire bundle 5 while the die 22a and the second die 22b are integrated together (four-way pressing step).
• each side surface of the conductor wire bundle 5 is pressed in the four-direction pressing step of the integration step, so that the entire cross section of the assembly conductor 10 is Variations in shape (finished dimensions) can be suppressed, and variations in binding force that binds the conductor wires 3 to each other can be suppressed.
• a four-way roller die between the binding processing chamber 23 and the second die 22b. 22c may be placed.
• the conductor wire bundle 5 is integrated by pressing the conductor wire bundle 5 from the side by the first die 22a, the second die 22b, and the four-direction roller die 22c. a and / or the second die 22b may be omitted.
• the assembly conductor 10 in which the cross-sectional shape of the conductor wire 1 is a rectangular shape has been described, but the present invention, for example, as shown in FIGS. 8 and 12, As shown in FIGS. 9 and 13, the conductor element 1 has a circular cross-sectional shape and the conductor element 1 is arranged vertically and horizontally.
• the present invention can also be applied to a close-packed type aggregate conductor in which the cross-sectional shape is circular and the conductor wires 1 are arranged in a close-packed manner.
• FIG. 21 is a perspective view of the collective conductor 10 according to the present embodiment.
• this collective conductor 10 has a plurality of conductors integrated so as to be aligned in the width direction (lateral direction in the figure) and the height direction (vertical direction in the figure) in an untwisted state. Consists of line 3.
• the collective conductor 10 is preferably used as a coil of a motor driven by an inverter.
• the conductor wire 3 includes a linear conductor wire 1 having a rectangular cross section and a covering layer 2 provided so as to cover the conductor wire 1.
• the rectangular cross-sectional shape of the conductor wire 3 is a partial shape obtained by dividing the rectangular overall cross-sectional shape of the collective conductor 10, respectively.
• the rectangular shape that is the cross-sectional shape of the conductor wire 3 is a shape as shown in Figs. That is, the rectangular shape has a square cross section with a right corner as shown in FIG. 23, a cross section rectangle with a right corner as shown in FIG. 24, and a corner with R as shown in FIG. A square with a cross-section, a rectangle with a rounded corner, as shown in Figure 26, As shown in FIG. 27, a shape in which a pair of opposing sides are parallel and the other is in an arc shape (cross-sectional track shape) is included.
• the conductor wires 3 are bonded to each other via the covering layer 2 and are integrally formed.
• the covering layer 2 may be made of a material that itself has binding properties, or that has a binding layer on the outermost periphery of the covering layer. Examples thereof include those having a cross-sectional structure as shown in FIGS. 28 to 30 which are cross-sectional views.
• the covering layer 2 may be formed by the insulating layer 2a and the binding layer 2b laminated on the insulating layer 2a. Further, as shown in FIG. 29, the insulating layer 2a may be sandwiched between a pair of binding layers 2b. Furthermore, as shown in FIG. 30, the covering layer 2 may be formed by the binding layer 2 b itself.
• the length of the long side is 1 to 1.5 times the length of the short side (preferably 1 to 1.2 times), m rows X n columns (for example, m and n are integers, preferably m ⁇ l, n ⁇ 2. More preferably, l ⁇ m ⁇ 4, 5 ⁇ n ⁇ 20.
• m ⁇ 1, n ⁇ 5 the advantage as a collective conductor (difference from a single wire) is reduced, and when 4 ⁇ m, 20 and n, it tends to be difficult to unite in an untwisted state. )
• the space factor of the conductor wire 1 with respect to the entire aggregate conductor 10 is improved, and the surface area of the conductor wire 1 is increased. Therefore, it is possible to reduce the size and weight of motors (including conductor wires through which high-frequency alternating current flows) used in electric vehicles such as hybrid vehicles.
• the coating layer 2 is composed of a tape material 2 wound around the surface of the conductor wire 1.
• the tape material 2 is made of an insulating resin such as polyimide, aramid, polyester and nylon.
• the thickness of the tape material 2 is, for example, about 10 to 300 m.
• the covering layer 2 is preferably formed as a thin film of about 10 m, for example. As a result, the cross-sectional area of the covering layer 2 can be reduced, and the space factor of the conductor wire 1 in the conductor wire 3 can be improved.
• the covering layer 2 can be formed by winding (vertically) the tape material 2 around the axis of the conductor wire 1 as shown in FIG.
• the tape material 2 can be spirally wound around the axis of the conductor wire 1. In this case, from the viewpoint of improving insulation, the tape material 2 is small. It is preferable to wind in a spiral while overlapping each other.
• the thickness of the binder provided on the surface of the coating layer 2 is 0.5 m to 3 ⁇ m.
• the binding material may or may not be uniformly formed on the surface of the conductor wire 3 as long as each conductor wire 3 can be fixed in the assembly conductor 10.
• Each of the unwinding rolls 20 is wound with a conductor wire 3 formed by covering the conductor element wire 1 with the tape material 2.
• a binder is provided on the surface of the conductor wire 3 in advance.
• the first die 22a is formed of a cylindrical body having a rectangular cross section, and corrects the arrangement of the plurality of conductor wires 3 supplied from the first guide rolls 21 to the width direction. And it is arranged in the height direction.
• the second die 22b is a correction jig for correcting the plurality of conductor wires 3 to be aligned in the width direction and the height direction, like the first die 22a. That is, the plurality of conductor wires 3 are bonded to each other by the first die 22a, the binding processing chamber 23, and the second die 22b to form a single collective conductor 10.
• the second guide roll 24 winds up the collective conductor 10 supplied from the second die 22b.
• the take-up roll 25 is configured to guide.
• the take-up roll 25 is a second guide roll
• the collective conductor 10 guided by 24 is wound up.
• the surface of the conductor wire 1 having a rectangular cross section is subjected to, for example, nickel metal plating to form the conductor wire 3 having the coating layer 2 on the surface.
• the surface of the conductor wire 3 is dip-coated with an epoxy varnish to provide a binder on the surface.
• the conductor wire 3 to which the binder is applied is turned into a plurality of unwinding rolls.
• each unwinding roll 20 is set in the collective conductor manufacturing apparatus 50, and the conductor wire 3 is unwound from each unwinding roll 20 and passed through the first guide roll 21, as shown in FIG.
• a plurality of conductor wires 3 are arranged in alignment inside the first die 22a and the second die 22b.
• the binding processing chamber 23 is operated to heat the conductor wires 3 arranged in alignment. At this time, the adjacent conductor wires 3 are fused and integrated with each other, and the aggregate conductor 10 is obtained.
• the assembly conductor 10 is wound around the winding roll 25 via the second guide roll 24.
• the collective conductor 10 can be manufactured as described above.
• each conductor wire 3 constituting the collective conductor 10 is a partial shape obtained by dividing the rectangular overall cross-sectional shape of the collective conductor 10 without a gap. In other words, it has a rectangular cross section, and the side surfaces of each conductor wire 3 are tightly bound via a binder, so that the conductor space factor in the aggregate conductor 10 can be improved. it can.
• each conductor wire 3 constituting the aggregated conductor 10 is bundled in a non-twisted state, the aggregated conductor 10 itself does not form a local coil, thereby suppressing the generation of eddy currents. Can do. Therefore, according to the collective conductor 10 of the present embodiment, the generation of eddy currents can be suppressed and the conductor space factor in the collective conductor 10 can be improved.
• the assembly conductor 10 of the present embodiment is configured by bundling a plurality of conductor wires 3 in a non-twisted state, the surface current of the assembly conductor 10 is increased by increasing the surface area of the conductor wire 1. Can be increased. Furthermore, since the eddy currents cancel each other out between the adjacent conductor wires 3, the AC resistance can be lowered and the current loss can be reduced. Therefore, when the above-described collective conductor 10 is applied to a motor, the motor efficiency can be increased.
• each conductor wire 1 is covered with the covering layer 2 formed of the tape material 2, so that the conductors adjacent to each other in an integrated state are used.
• the wires 1 can be insulated from each other by the tape material 2.
• the conductor wires 3 since the conductor wires 3 are fixed to each other by the binder, the conductor wires 3 can be held in an aligned state even by deformation such as bending. it can. Since the assembly conductor 10 can be easily formed rather than being formed directly from a single conductor wire, it can be adapted to coils having various shapes.
• each conductor wire 3 is bound by a binding material made of grease, the bound state can be released by solvent treatment, heating, or the like.
• the collective conductor 10 is a rectangular wire having a rectangular cross section, handling is easy.
• FIG. 22 is a perspective view of the collective conductor 10 and shows Embodiment 8 of the present invention.
• the collective conductor 10 is formed by bundling a plurality of conductor wires 3 having the above-described rectangular cross section formed by the conductor wire 1 and the coating layer 2 made of the tape material 2 in a non-twisted state. Tape material 7 is wrapped around the outermost layer.
• the tape material 7 is preferably made of an insulating resin, and is preferably formed of the same material as the tape material 2.
• FIG. 22 shows an example in which the tape material 7 is formed by winding (vertically) in the length direction of a bundle of a plurality of conductor wires 3.
• the tape material 7 can be spirally wound in the length direction of the bundle of conductor wires 3. In this case, from the standpoint of improving insulation, it is preferable to wind the tape material 2 in a spiral manner with little overlap.
• the pressure resistance in the outermost layer of the collective conductor 10 can be improved.
• the plurality of conductor wires 3 can be fixed to each other only by the tape material 7 to form the aggregate conductor 10. As shown in FIG. 21, a plurality of conductor wires 3 are bonded together through a binding material, and the tape material 7 is wound around the outermost layer (outer peripheral surface).
• FIG. 31 to FIG. 35 are enlarged cross-sectional views showing a rectangular cross section of the conductor wire 3 constituting the assembly conductor according to the present embodiment.
• the assembly conductor 10 of the present embodiment is integrated so as to be aligned in the width direction (lateral direction in the figure) and the height direction (vertical direction in the figure) in an untwisted state. With multiple conductor wires 3 It is configured.
• the conductor wire 3 includes a linear conductor wire 1 having a rectangular cross section and a covering layer 2 provided so as to cover the conductor wire 1.
• the rectangular cross-sectional shape of the conductor wire 3 is a partial shape obtained by dividing the rectangular overall cross-sectional shape of the collective conductor 10, respectively.
• the rectangular shape that is the cross-sectional shape of the conductor wire 3 is a shape as shown in FIGS. That is, the rectangular shape has a square cross section with a right corner as shown in FIG. 31, a cross section rectangle with a right corner as shown in FIG. 32, and a corner as R as shown in FIG. A cross-sectional square, a cross-sectional rectangle with a rounded corner as shown in Fig. 34, and a shape with a pair of opposite sides parallel and the other arc-shaped as shown in Fig. 35 (cross-sectional track Etc.).
• the covering layer 2 is made of a metal or a metal compound having a larger electric resistance than the conductor wire 1.
• the electric resistance value means the electric resistance values of the conductor wire 1 and the covering layer 2 at 20 ° C.
• the conductor element wire 1 is copper or a copper alloy
• the conductor wire 1 is copper or a copper alloy
• Nickel or nickel alloy, tin or tin alloy, and the like can be formed on the outer periphery of the conductor wire 1 by plating, vapor deposition, or the like.
• an oxide of the conductor wire 1 can be applied as the coating layer. That is, when the conductor wire 1 is copper or a copper compound, the copper oxide film becomes the coating layer 2. It becomes. These oxide films can be formed by continuously passing the conductor wire 1 through an acid atmosphere.
• a sulfur film, a nitride film, etc. can be applied to the coating layer 2, and these coating layers 2 should be formed by vapor deposition, chemical treatment, or the like. Can do.
• the coating layer 2 preferably has a layer thickness (film thickness) of, for example, about 0.01 to 10 m.
• 1S Coating layer 2 Depends on the formation method and type.
• the covering layer 2 can be formed thinner than a known insulating layer (insulating layer formed by electrodeposition electrodeposition), which is preferable in that the proportion of the conductor wire 1 in the aggregated conductor 10 can be increased.
• the conductor wires 3 can be integrated together via the binding layer.
• binder As a material of the binder (binder), as a fusion material, a resin having heat-fusibility such as polyvinyl propylal, polyamide, epoxy, and polyester, or alcohol soluble.
• the adhesive include EVA-based, acrylic-based, urethane-based, epoxy-based, black-prene-based, cyanoacrylate-based, silicone-based, and the like. Examples include tolyl, PVC, and butyl acetate resins.
• the binder is made of the above-described resin, the insulation between the conductor wires 1 can be improved.
• the layer thickness of the binder is 0.5 m to 3 ⁇ m.
• the binder material is uniformly formed on the outermost periphery of the conductor wire 3. There may be some places or parts that do not exist, but from the viewpoint that each conductor wire 3 will not be scattered even if the assembly conductor 10 is processed (bending, twisting, etc.), the binder is applied to the entire outermost surface of the conductor wire 3. Preferred to form.
• Each of the unwinding rolls 20 is wound with a conductor wire 3 formed by covering a conductor element wire 1 with a coating layer 2 such as a nickel plating film.
• a binder is provided on the surface of the conductor wire 3 in advance.
• the surface of the conductor wire 1 having a rectangular cross section is subjected to, for example, nickel metal plating to form the conductor wire 3 having the coating layer 2 on the surface.
• the surface of the conductor wire 3 is dip-coated with an epoxy varnish to provide a binder on the surface.
• the conductor wire 3 coated with the binder is wound around a plurality of unwinding rolls 20, respectively.
• each unwinding roll 20 is set in the collective conductor manufacturing apparatus 50, and the conductor wire 3 is unwound from each unwinding roll 20 and passed through the first guide roll 21, as shown in FIG.
• a plurality of conductor wires 3 are arranged in alignment inside the first die 22a and the second die 22b.
• the binding processing chamber 23 is operated to heat the conductor wires 3 arranged in an aligned state. At this time, the adjacent conductor wires 3 are fused and integrated with each other, and the aggregate conductor 10 is obtained.
• the assembly conductor 10 is wound around the winding roll 25 via the second guide roll 24.
• the assembly conductor 10 of the present embodiment can be manufactured.
• each conductor wire 3 constituting the collective conductor 10 is a partial shape obtained by dividing the rectangular overall cross-sectional shape of the collective conductor 10 without a gap. In other words, it has a rectangular cross section, and the side surfaces of each conductor wire 3 are tightly bound via a binder, so that the conductor space factor in the aggregate conductor 10 can be improved. it can.
• each conductor wire 3 constituting the aggregated conductor 10 is bundled in a non-twisted state, the aggregated conductor 10 itself does not form a local coil, thereby suppressing the generation of eddy currents. Can do. Therefore, according to the collective conductor 10 of the present embodiment, the generation of eddy currents can be suppressed and the conductor space factor in the collective conductor 10 can be improved.
• the collective conductor 10 of the present embodiment is configured by bundling a plurality of conductor wires 3 in a non-twisted state, the surface area of the conductor wire 1 in the collective conductor 10 is increased to increase the skin current. Can be increased. Furthermore, since the eddy currents cancel each other out between the adjacent conductor wires 3, the AC resistance can be lowered and the current loss can be reduced. did Therefore, when the above-mentioned collective conductor 10 is applied to a motor, the motor efficiency can be increased.
• the covering layer 2 can be formed thin by plating, vapor deposition, or the like, so that the conductor space factor in the collective conductor 10 and each conductor wire 3 is improved. It is further preferable in terms of increasing motor efficiency.
• the conductor wires 3 are fixed to each other by the binder, the conductor wires 3 can be held in an aligned state even by deformation such as bending. it can. Since the assembly conductor 10 can be easily formed rather than being formed directly from a single conductor wire, it can be adapted to coils having various shapes.
• the covering layer 2 is made of a metal such as nickel having a larger electrical resistance value than the conductor wire 1 made of copper, for example. By doing so, it is possible to ensure necessary and sufficient insulation between the conductor wires 1. Moreover, it is preferable at the point which can endure use conditions of comparatively high temperature.
• each conductor wire 3 is bound by a binding material made of grease, the bound state can be released by solvent treatment, heating, or the like.
• the collective conductor 10 is a rectangular wire having a rectangular cross section, handling is easy.
• 36 to 39 show an embodiment 10 of the collective conductor and the method for manufacturing the same according to the present invention.
• FIG. 36 shows an example of the collective conductor 10 of the present embodiment.
• This collective conductor 10 is a coil that is wound a plurality of times so as to be fitted into the slot of the stator core of the inverter motor.
• the collective conductor 10 is formed in a strip shape in which a plurality of conductor wires 3 are bundled in an untwisted state.
• the collective conductor 10 may be formed to have a uniform width in the length direction, or may be formed to gradually increase in width from one end to the other end. Even if the thickness of the assembly conductor 10 is uniform in the length direction, one end force gradually decreases in thickness toward the other end. It may be made.
• the collective conductor 10 is formed to have a length of 4 to 5 m, a width of 3 to 4 mm, and a thickness of 0.5 to 1. Omm, for example.
• the assembly conductor 10 is inserted into the stator motor slot of the inverter motor in the thickness direction. Therefore, the width and thickness are equal to each other, or the thickness may be larger than the width. is there.
• the collective conductor 10 is not particularly limited, for example, whether the entire cross-sectional shape is a vertically or horizontally long rectangle, or a trapezoid having oblique sides on both sides in the width direction.
• the plurality of conductor wires 3 constituting the collective conductor 10 have an m-row x n-column alignment structure (for example, m ⁇ l, n ⁇ 2, m and n are integers) in the cross section, etc. It may be arranged regularly or irregularly, but an m-row x n-column alignment structure is preferred in terms of productivity, reproducibility, and stability of coil characteristics. Better ,.
• Each conductor wire 3 may be composed of the conductor element wire 1 or may be configured to include the conductor element wire 1 and the insulating coating layer 2 on the surface thereof. In the latter case, the insulation is maintained even if the assembly conductor 10 is bent or twisted.
• the cross-sectional shape may be a polygon such as a triangle or a hexagon, but it is shown in FIG. 7 from the viewpoint of productivity.
• a rectangular shape is preferred.
• Figure 7 (a) shows a square cross section with a right corner
• Figure 7 (b) shows a rectangular cross section with a right corner
• Figure 7 (c) shows a corner R.
• Fig. 7 (d) shows a rectangular cross section with a corner of R
• Fig. 7 (e) shows a shape with a pair of opposite sides parallel and an arc (transverse).
• the surface is track-like).
• These conductor wires 3 can be obtained by forming a wire by drawing or rolling so that the cross-sectional shape becomes a desired cross-sectional shape from a circular bus bar. Also, these conductor wires 3 may be misaligned even if they have the same cross-sectional shape, different from each other, or mixed with the same and different ones. You can! /.
• the coating layer 2 protects the conductor wire 1 from external damage, has insulation, heat resistance, flexibility, and the like depending on the usage environment of the collective conductor 10.
• the material is appropriately selected, for example, amideimide resin, polyamide resin, polyimide resin, polyester resin, urethane resin, acrylic resin, epoxy resin, and the like.
• Coating layer 2 dissolves rosin
• the layer thickness is 1 to 10 ⁇ m
• the layer thickness is 1 ⁇ 5 m (preferably 1 to 3 ⁇ m).
• the formation of the covering layer 2 by electrodeposition coating is a point where the space factor is increased and the uniform covering layer 2 can be formed on the conductor wire 3 having a rectangular cross section. Is preferred.
• amideimide resin polyamide resin, and polyimide resin are preferable.
• urethane resin is preferable from the viewpoint of easy thermal decomposition when soldering. From the viewpoint of heat resistance and flexibility, acrylic resin is preferable.
• the coating layer 2 may be formed of an oxide film of the conductor wire 1.
• the layer thickness is 0.01 to 20 / ⁇ ⁇ .
• the covering layer 2 may be a metal layer formed of a metal or metal compound layer having a higher electrical resistance than the conductor wire 1 or a metal compound (nitride, sulfide, etc.) layer.
• the layer thickness is 0.1-20 / ⁇ ⁇ .
• Each of the plurality of conductor wires 3 is partially provided with a binder 4a on the outermost periphery, and is bound to the adjacent conductor wire 3 via the binder 4a.
• each conductor wire 3 is separated from the adjacent conductor wire 3 by the thickness of the binder 4a, and no current flows between the conductor wires 3, so there is no need for an insulating layer.
• the material can be reduced, thereby improving the space factor.
• each of the plurality of conductor wires 3 is preferably provided such that the outermost binder 4a is not in contact with the binder 4a of the adjacent conductor wire 3. According to this, it is possible to prevent the space factor from being lowered due to an unnecessarily wide interval between the conductor wires 3 due to the binding between the binding materials 4a.
• Binder 4a is made of, for example, a fusion material such as polybula bratile resin, polyamide resin (including polyamide alcohol-soluble resin), epoxy resin, polyester resin,
• EVA resin acrylic resin, urethane resin, epoxy resin, black-prene resin, cyanoacrylate resin, silicone resin, nitrile resin, PVC resin, Adhesives such as acetic acid bullock resin.
• polyamide-based alcohol-soluble resins are preferred from the viewpoint that they can be re-adhered or released by alcohol immersion.
• the collective conductor 10 having the above configuration is placed in the slot of the stator core of the inverter motor to form a laminated structure to constitute a coil.
• a plurality of conductor wires 3 are in close contact with each other via a binding material 4a partially attached to the outermost periphery of each conductor wire 3, and are connected between the conductor wires 3. Since the layer of the dressing 4a is not formed, the distance between them can be reduced, and as a result, a high conductor space factor can be obtained.
• the conductor 10 is composed of a plurality of conductor wires 3, and the conductor surface area is larger than that of a single conductor wire, so that the current loss due to the skin effect is small and a large current can flow. .
• the conductor wire 1 having a predetermined cross-sectional shape is drawn.
• the conductor wire 1 may have a circular cross-sectional shape, a polygon such as a quadrangle or a hexagon, or a circle, or an irregular shape.
• it can be performed by dipping treatment, electrodeposition coating treatment, surface oxidation treatment, plating treatment, etc., in which the conductor wire 1 is dipped in a solution in which rosin is dissolved and then dried.
• the binder 4a is adhered to the surface of the conductor wire 3.
• this step can be performed by a method in which a solution in which cocoon is dissolved is attached to the surface of the conductor wire 3 via a roll 31 and dried.
• a roll 31 having circumferentially extending protrusions 32 provided at intervals in the thickness direction is used at the periphery, and a part of the roll 31 is placed in the solution tank 33. Immerse in the solution and run the conductor wire 3 in the length direction while rotating the roll 31 and contacting the periphery of the roll 31. The solution held between the protrusions 32 is continuously adhered to the surface of the conductor wire 3.
• linear binders 4a extending in the length direction are provided on the surface of the conductor wire 3 at intervals in the width direction.
• the method shown in FIG. 37 (b) uses a roll 31 in which ridges 32 formed of a nonwoven fabric or the like extending in the circumferential direction on the periphery are provided at intervals in the thickness direction, and a part of the roll 31 is used. Is immersed in the solution in the solution tank 33, the solution is absorbed by the ridge 32, the amount of absorption is adjusted by the adhesion amount adjusting roll 34, the roll 31 is rotated, and the conductor wire 3 is put in contact with the peripheral edge of the roll 31. It travels in the length direction and causes the solution absorbed by the ridges 32 to continuously adhere to the surface of the conductor wire 3. Also in this method, the linear binder 4a extending in the length direction is provided on the surface of the conductor wire 3 at intervals in the width direction.
• FIG. 38 (a) if a roll 31 having a protrusion 32 extending in a direction inclined with respect to the circumferential direction is used, the length of the surface of the conductor wire 3 is increased. If a roll 31 having a large number of streaks 35 is used as shown in FIG. 38 (b), a linear binder 4a extending in a direction inclined with respect to the direction is provided at intervals. If a roll 31 having protrusions 32 extending in a direction orthogonal to the circumferential direction is used as shown in FIG. 38 (c), a large number of dotted binders 4a are provided on the surface of the wire 3. A linear binding material 4a extending in the width direction is provided on the surface of the substrate at intervals in the length direction.
• the solution in which the resin is dissolved is ejected from the spray nozzle 36 and continuously adhered to the surface of the conductor wire 3 traveling in the length direction, and dried. It can be done by the method.
• the plurality of conductor wires 3 are bundled in an untwisted state.
• the plurality of conductor wires 3 may have the same cross-sectional shape, or may be different from each other, and may be mixed with or different from the same. ! /.
• the conductor assembly 3 is manufactured by integrating the plurality of conductor wires 3.
• the binder 4a is heated to melt and the conductor wires 3 are brought into close contact with each other via the binder 4a.
• the binder of polyamide-based alcohol-soluble resin is immersed in alcohol. This can be performed by a method in which 4a is gelled and the conductor wires 3 are brought into close contact with each other through the binder 4a. Note that the degree of binding may be increased by passing a die through at least one of the front and rear of the unit. [Embodiment 11 of the Invention]
• FIG. 40 shows an example of the collective conductor 10 of the present embodiment.
• the collective conductor 10 does not have a covering layer, and the conductor wire 1 itself constitutes the conductor wire 3. In this case, since there is no coating layer, a higher conductor space factor can be obtained as compared with that of the tenth embodiment.
• FIG. 41 shows an example of the collective conductor 10 of the present embodiment.
• the collective conductor 10 forms a coil by being wound a plurality of times so as to be fitted into the slot 30b of the stator core 30 of the inverter motor (see FIG. 42).
• the collective conductor 10 is formed in a strip shape by integrating a plurality of conductor wires 3 in a non-twisted state.
• the collective conductor 10 is formed so that the width at one end gradually becomes wider toward the other end.
• the collective conductor 10 may be formed with a uniform thickness in the length direction, or may be formed with a gradually decreasing thickness as the one end force goes toward the other end.
• the collective conductor 10 has, for example, a length of 4 to 5 m, a width of 3 to 4 mm and a thickness of 0.5 to 1. Omm at one end, and a width of 5 to 5 at the other end: LO mm and a thickness of 0.2. It is developed to ⁇ 0.5mm respectively.
• the assembly conductor 10 has a thickness direction in which the inverter motor stator core 30 is inserted into the slot 30b, and therefore the width is equal to the thickness, or the thickness is larger than the width. There is a case.
• the collective conductor 10 may have, for example, an overall transverse cross-sectional shape that is vertically long or horizontally long (Fig. 41 (a)), or a trapezoid having oblique sides on both sides in the width direction ( In this way, the assembly conductor 10 can be stored densely in the slot 30b, and the resulting module can be obtained. It is not particularly limited as long as it improves the characteristics of a single unit.
• the advantages of the aggregate conductor 10 are great, and the pulling force can be easily integrated in a non-twisted state.
• they may be arranged regularly as described above, or may be arranged irregularly, an aligned structure of m rows X n rows is preferable from the viewpoint of productivity and reproducibility.
• Each conductor wire 3 has a cross section of a partial shape obtained by dividing the entire cross section.
• each conductor wire 3 may have a polygonal shape such as a quadrangle or a hexagonal cross-sectional shape, but it is preferable that the cross-sectional shape is a square in terms of productivity. Even if the plurality of conductor wires 3 have the same cross-sectional shape or different from each other, they can be misaligned even if they are the same or different. You can! /.
• Each conductor wire 3 includes a conductor wire 1 and a coating layer 2 provided on the outer periphery thereof.
• the coating layer 2 is generally a material having electrical insulation properties as long as the resistance value is larger than that of the conductor wire 1.
• amideimide resin, polyamide resin, polyimide resin It is formed of ester resin, urethane resin, acrylic resin, epoxy resin or the like.
• the coating layer 2 is formed by dubbing treatment or electro-deposition coating on a solution in which coconut resin is dissolved.
• the layer thickness is 1 to: LO / zm
• the layer thickness is 1 to 5 m (preferably 1 to 3 ⁇ m).
• amideimide resin and polyamide resin are preferred, and polyimide resin is also preferred, and urethane resin is preferred from the viewpoint of being easily pyrolyzed when soldered.
• a material corresponding to the use of the assembly conductor 10 for which acrylic resin is preferred may be applied.
• the covering layer 2 may be formed of an oxide film of the conductor wire 1.
• Each conductor wire 3 does not have the coating layer 2 and may be composed of only the conductor wire 1.
• the plurality of conductor wires 3 are integrally formed in close contact with adjacent ones via the binder 4a.
• the binder 4a may be provided in a distant manner in the length direction, which is not necessarily provided on the entire surface of the conductor wire 3. However, from the viewpoint of preventing the conductor wire 3 from being separated.
• the binder 4a is preferably provided on the entire surface.
• the binder 4a may be configured to cover the outer periphery of the collective conductor 10.
• the binder 4a has, for example, a thickness of 0.5 to 3 ⁇ m.
• the collective conductor 10 having the above configuration is wound from the wide end to the narrow end in the slot 30b of the stator core 30 of the inverter motor, which is formed to have a narrower width from the bottom toward the opening.
• Form the coil for example, the slot 30b has a bottom width of 6 to 8 mm, an opening width of 3 to 4 mm, and a depth of 90 to 100 mm.
• This laminated structure is a laminated structure of the aggregated conductors 10 having a large width on the bottom side of the slot 30b and a small width on the opening side. Therefore, as shown in FIG. The dead space formed on both sides of the structure is small.
• FIG. 42 (b) when the cross-sectional shape of the collective conductor 10 is a trapezoid having a hypotenuse on both sides in the width direction, the wide side in the thickness direction is the bottom side and the width in the slot 30b.
• the conductor 10 is composed of a plurality of conductor wires 3, and the conductor surface area is larger than that of a single conductor wire. Therefore, current loss due to the skin effect is small, and a large current can flow. .
• the conductor wire 1 having a predetermined cross-sectional shape is drawn.
• the conductor wire 1 may have a circular cross-sectional shape, a polygon such as a quadrangle or a hexagon, or a circle, or an irregular shape.
• a date pin that is dried after dipping the conductor wire 1 in a solution in which rosin is dissolved It can be performed by a coating process, an electrodeposition coating process, a surface oxidation process, a plating process, and the like.
• the binder 4a is adhered to the surface of the conductor wire 3 in the following manner.
• This step can be performed by, for example, a dipping treatment in which the conductor wire 3 is immersed in a solution in which the resin is dissolved and then dried.
• the plurality of conductor wires 3 are integrated into a uniform width in an untwisted state.
• the plurality of conductor wires 3 may have the same cross-sectional shape, different from each other, or may be mixed with the same and different ones, or may be misaligned! /.
• a plurality of conductor wires 3 are integrated to form a strip 15 having a uniform width.
• the binder 4a is heated to melt the binder 4a, and the binder 4a is brought into close contact with each other.
• the binder 4a of the polyamide-based alcohol-soluble resin is gelled and immersed in alcohol. It can be carried out by a method of bringing the material 4a into close contact with each other.
• the belt-like body 15 is not particularly limited as long as the cross-sectional shape is a vertically or horizontally long rectangle or a trapezoid having oblique sides on both sides in the width direction. Note that the degree of binding may be increased by passing a die through at least one of the front and rear sides of the unit.
• the strip conductor 15 having a uniform width is formed and processed so that the width gradually increases toward the other end and toward the other end.
• the aggregate conductor 10 is formed so that the thickness gradually decreases from one end to the other end.
• This step is performed by, for example, a method of setting and pressing the belt-like body 15 in a mold in which grooves corresponding to the shape of the collective conductor 10 are formed, each surrounded by a plurality of molding rollers movable in the axial direction. This can be done by, for example, passing the strip 15 through the region and changing the roller spacing along the length. Note that, as shown in FIG.
• the conductor wire 1 is configured so that the conductor wire 1 is covered with the covering layer 2.
• the conductor wire 1 is not limited to this, and the conductor wire 1 is not limited to this. It may constitute the conductor wire 3 itself.
• the plurality of conductor wires 3 are integrally formed of the binding material 4a.
• the present invention is not particularly limited to this, and a plurality of conductor wires 3 may be integrated and an insulating tape may be wound around the outer periphery to form an integrated structure.
• FIG. 44 shows an example of the collective conductor 10 of the present embodiment.
• the collective conductor 10 constitutes a coil by being wound a plurality of times so as to be fitted into the slot 30b of the stator core 30 of the inverter motor.
• the collective conductor 10 is formed in a strip shape by integrating a plurality of conductor wires 3.
• the collective conductor 10 is formed so that the width at one end gradually becomes wider toward the other end.
• the aggregate conductor 10 may be formed with a uniform thickness in the length direction, or may be formed with a gradually decreasing thickness from one end to the other end.
• Each conductor wire 3 has a cross section of a partial shape obtained by dividing the entire cross section.
• Each conductor wire 3 may have, for example, a circular cross-sectional shape or a polygon such as a quadrangle or a hexagon.
• the plurality of conductor wires 3 may have the same cross-sectional shape, may be different from each other, or may be a mixture of the same and different ones. Good.
• the conductor wire 1 having a predetermined cross-sectional shape is drawn.
• the conductor wire 1 may have a circular cross-sectional shape, a polygon such as a quadrangle or a hexagon, or a circle, or an irregular shape.
• a conductor wire 3 having a coating layer 2 formed on the surface of the conductor wire 1 is produced.
• This step is, for example, a date pin in which the conductor wire 1 is dipped in a solution in which coconut resin is dissolved and then dried. It can be performed by a coating process, an electrodeposition coating process, a surface oxidation process, a plating process, and the like.
• the binding material 4a is adhered to the surface of the conductor wire 3 in the following manner.
• This step can be performed by, for example, a dipping treatment in which the conductor wire 3 is immersed in a solution in which the resin is dissolved and then dried.
• the plurality of conductor wires 3 are bundled in a uniform width in an untwisted state or in a twisted state in one direction.
• the plurality of conductor wires 3 may have the same cross-sectional shape, may be different from each other, or may be a mixture of the same and different ones.
• a plurality of conductor wires 3 are integrated to form a strip 15 having a uniform width.
• the binder 4a is heated to melt the binder 4a, and the binder 4a is brought into close contact with each other.
• the binder 4a of the polyamide-based alcohol-soluble resin is gelled and immersed in alcohol. It can be carried out by a method of bringing the material 4a into close contact with each other.
• the belt-like body 15 is not particularly limited as long as the cross-sectional shape is a vertically or horizontally long rectangle or a trapezoid having oblique sides on both sides in the width direction. In addition, let's increase the degree of unity through a die on at least one side of the unity.
• the strip conductor 15 having a uniform width is formed and processed so that the width gradually increases toward the other end and toward the other end.
• the aggregate conductor 10 is formed so that the thickness gradually decreases from one end to the other end.
• This step is performed by, for example, a method of setting and pressing the belt-like body 15 in a mold in which grooves corresponding to the shape of the collective conductor 10 are formed, each surrounded by a plurality of molding rollers movable in the axial direction. This can be done by, for example, passing the strip 15 through the region and changing the roller spacing along the length. Note that, as shown in FIG.
• the conductor wire 1 is configured to cover the conductor wire 1 with the covering layer 2.
• the conductor wire 1 does not have the covering layer 2 and is not limited to this. It may constitute the conductor wire 3 itself.
• the plurality of conductor wires 3 are integrally formed of the binder 4a. Although not limited to this, a plurality of conductor wires 3 are bundled and an insulating tape is wound around the outer periphery to form a single unit. The structure formed integrally by twisting may be sufficient.
• the present invention can improve the conductor space factor in the collective conductor, and is therefore useful as a conductor for a coil of a motor driven by an inverter.

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• 2007
  • 2007-02-06 DE DE112007000364T patent/DE112007000364T5/de not_active Withdrawn
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  • 2007-02-06 WO PCT/JP2007/052037 patent/WO2007097189A1/ja active Application Filing

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