WO2011118634A1 - 高周波電線及び高周波コイル - Google Patents
高周波電線及び高周波コイル Download PDFInfo
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- WO2011118634A1 WO2011118634A1 PCT/JP2011/056984 JP2011056984W WO2011118634A1 WO 2011118634 A1 WO2011118634 A1 WO 2011118634A1 JP 2011056984 W JP2011056984 W JP 2011056984W WO 2011118634 A1 WO2011118634 A1 WO 2011118634A1
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- 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
- H01B13/0006—Apparatus or processes specially adapted for manufacturing conductors or cables for reducing the size of conductors or cables
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C3/00—Profiling tools for metal drawing; Combinations of dies and mandrels
- B21C3/02—Dies; Selection of material therefor; Cleaning thereof
- B21C3/04—Dies; Selection of material therefor; Cleaning thereof with non-adjustable section
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/001—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by extrusion or drawing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
- B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
- B23K20/233—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer
- B23K20/2333—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded without ferrous layer one layer being aluminium, magnesium or beryllium
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C21/00—Alloys based on aluminium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/023—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material only coatings of metal elements only
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/023—Alloys based on aluminium
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B1/00—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors
- H01B1/02—Conductors or conductive bodies characterised by the conductive materials; Selection of materials as conductors mainly consisting of metals or alloys
- H01B1/026—Alloys based on copper
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B5/00—Non-insulated conductors or conductive bodies characterised by their form
- H01B5/02—Single bars, rods, wires, or strips
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/30—Insulated conductors or cables characterised by their form with arrangements for reducing conductor losses when carrying alternating current, e.g. due to skin effect
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F27/00—Details of transformers or inductances, in general
- H01F27/28—Coils; Windings; Conductive connections
- H01F27/2823—Wires
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21C—MANUFACTURE OF METAL SHEETS, WIRE, RODS, TUBES OR PROFILES, OTHERWISE THAN BY ROLLING; AUXILIARY OPERATIONS USED IN CONNECTION WITH METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL
- B21C1/00—Manufacture of metal sheets, metal wire, metal rods, metal tubes by drawing
- B21C1/003—Drawing materials of special alloys so far as the composition of the alloy requires or permits special drawing methods or sequences
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49002—Electrical device making
- Y10T29/49117—Conductor or circuit manufacturing
Definitions
- the present invention relates to a high-frequency electric wire and a high-frequency coil, and more particularly to a high-frequency electric wire and a high-frequency coil used for windings, litz wires, cables and the like of various high-frequency devices.
- Patent Document 2 a high-frequency electric wire is manufactured by twisting a plurality of composite conductors composed of a central conductor and an outer conductor and recrystallizing them by heat treatment.
- this electric wire can sufficiently suppress the proximity effect. It is difficult, and is easily damaged or deformed during manufacturing, and it is difficult to sufficiently stabilize the characteristics as a coil.
- JP 2009-129550 A Japanese Unexamined Patent Publication No. Sho 62-76216 JP 2005-108654 A International Publication No. 2006/046358 JP 2002-150633 A
- an object of the present invention is to provide a high-frequency wire and a high-frequency coil that can suppress AC resistance and can suppress heat generation and power consumption.
- a central conductor made of aluminum or an aluminum alloy, a coating layer made of copper covering the central conductor and having a fibrous structure in the longitudinal direction, and formed between the central conductor and the coating layer.
- An intermetallic compound layer having a volume resistivity larger than that of the coating layer, and the cross-sectional area of the coating layer is 15% or less with respect to the total cross-sectional area of the central conductor, the intermetallic compound layer, and the coating layer.
- a high frequency electric wire is provided.
- a high-frequency coil using a high-frequency wire is made of a central conductor made of aluminum or an aluminum alloy and copper covering the central conductor, and has a fibrous structure in the longitudinal direction.
- a high-frequency coil having a total cross-sectional area of 15% or less with respect to the total cross-sectional area is provided.
- FIG. 13A is a photograph of an optical microscope showing a cross section of a processed structure of tough pitch copper (TPC) manufactured by the SCR method.
- FIG. 13B is a photograph of an optical microscope showing a cross section of a processed structure of a copper wire manufactured by a dip forming method.
- FIG. 14A is a photograph of an optical microscope showing a cross section of a recrystallized structure of tough pitch copper (TPC) manufactured by the SCR method.
- FIG. 14B is a photograph of an optical microscope showing a cross section of a recrystallized structure of a copper wire manufactured by a dip forming method. It is a mimetic diagram showing an example of a wire drawing die concerning an embodiment of the invention. It is a schematic diagram which shows the division of the shear stress at the time of wire drawing.
- FIG. 17A is a schematic diagram (part 1) showing a stress distribution analysis result during wire drawing according to the embodiment of the present invention.
- FIG. 17B is a schematic diagram (part 2) illustrating the stress distribution analysis result during wire drawing according to the embodiment of the present invention.
- FIG.17 (c) is a schematic diagram (the 3) which shows the stress distribution analysis result at the time of wire drawing which concerns on embodiment of this invention.
- FIG. 19A is a graph (part 1) showing an energy dispersive X-ray spectroscopic analysis (EDS) result according to Example 1 of the present invention.
- FIG.19 (b) is a graph (the 2) which shows the EDS analysis result which concerns on Example 1 of this invention.
- FIG.19 (c) is a graph (the 3) which shows the EDS analysis result which concerns on Example 1 of this invention.
- FIG. 19D is a graph (No. 4) showing the EDS analysis result according to Example 1 of the present invention.
- FIG. 20A is a top view of the reactor according to the second embodiment of the present invention.
- FIG.20 (b) is a side view of the reactor which concerns on Example 2 of this invention.
- FIG.20 (c) is another side view of the reactor which concerns on Example 2 of this invention. It is a table
- the high-frequency electric wire As shown in FIG. 1, the high-frequency electric wire according to the embodiment of the present invention includes a center conductor 1 made of aluminum (Al) or an aluminum alloy, a coating layer 2 made of copper (Cu) covering the center conductor 1, and An intermetallic compound layer (alloy layer) 3 having a volume resistivity higher than that of the coating layer 2 formed between the central conductor 1 and the coating layer 2 so that the composition changes in a gradient from the central conductor 1 to the coating layer 2.
- a center conductor 1 made of aluminum (Al) or an aluminum alloy
- a coating layer 2 made of copper (Cu) covering the center conductor 1
- An intermetallic compound layer (alloy layer) 3 having a volume resistivity higher than that of the coating layer 2 formed between the central conductor 1 and the coating layer 2 so that the composition changes in a gradient from the central conductor 1 to the coating layer 2.
- the cross-sectional area of the covering layer 2 is 15% or less with respect to the entire cross-sectional area of the high-frequency electric wire including the central conductor 1, the intermetallic compound layer 3, and the covering layer 2, and is preferably about 3% to 15%. Is about 3% to 10%, more preferably about 3% to 5%. As the ratio of the cross-sectional area of the covering layer 2 to the entire high-frequency electric wire is smaller, the high-frequency resistance can be reduced.
- the overall diameter of the high-frequency electric wire is preferably about 0.05 mm to 0.6 mm.
- center conductor 1 for example, aluminum for electrical use (EC aluminum) or Al—Mg—Si based alloy (JIS6000 series) can be used, but the volume resistivity of the aluminum alloy is larger than that of EC aluminum. Therefore it is more desirable.
- EC aluminum aluminum for electrical use
- Al—Mg—Si based alloy JIS6000 series
- the intermetallic compound layer 3 is generated by drawing the central conductor 1 covered with the covering layer 2 using a die combined in a plurality of stages each having an area reduction rate of 20% or more in the drawing process of the high-frequency electric wire. Is done.
- the thickness of the intermetallic compound layer 3 is about 10 nm to 1 ⁇ m.
- the intermetallic compound layer 3 includes, for example, Cu 9 Al 4 and CuAl 2 .
- the volume resistivity of the intermetallic compound layer 3 is larger than the volume resistivity of the coating layer 2 and is, for example, about 10 ⁇ -cm to 40 ⁇ -cm.
- a winding such as a transformer or a reactor is used that has a copper wire 100 as shown in FIG. 2 insulated with polyurethane, polyester, polyesterimide, polyamideimide, polyimide, or the like. Since the coaxial cable is a high-frequency current signal, the skin effect characteristics are taken into account.
- a copper-coated aluminum wire hereinafter referred to as “CCA wire” in which the copper layer 102 is thinly coated on the outside of the aluminum wire 101 as shown in FIG. Is used).
- the diameter of the winding or the litz wire is generally used for the purpose of reducing the AC loss.
- the high frequency electric wire which concerns on embodiment of this invention, even if it is not a litz wire, the further suppression effect is provided to the thin diameter electric wire for suppressing the increase in alternating current resistance.
- FIG. 6 shows the relationship between the frequency and the skin effect depth (skin depth) in a single wire model of a single electric wire.
- the skin effect depth means the depth from the electric wire surface at which the current density is 1 / e (about 0.37) of the surface.
- FIG. 6 shows that when the applied frequency is about 100 kHz or less, the influence of the skin effect is small when the wire diameter is 0.5 mm (equivalent to twice the skin effect depth of about 0.25 mm).
- FIG. 7 and 8 show AC resistance-frequency characteristics due to the skin effect and proximity effect in a single-wire model of a single wire having a diameter of 0.4 mm, as a ratio (Rac / Rdc) of AC resistance Rac and DC resistance Rdc, respectively.
- the external magnetic field H is 37.8 A / mm.
- Rac / Rdc significantly increases as the frequency increases. This increasing tendency depends on the strength of the external magnetic field. That is, the proximity effect is dominant in the AC loss due to the high-frequency current in the thinned winding.
- the theoretical calculation results here show that the aluminum wire has smaller proximity effect characteristics than the copper wire.
- proximity effect it has become clear that the method of increasing the volume resistivity of the conductor is effective, except for reducing the conductor wire diameter as much as possible. It is desirable to select from the conductor materials that are used.
- copper and aluminum which are general-purpose conductor materials, are compared, aluminum having a conductivity of about 61% of copper has superior proximity effect reduction characteristics.
- the surface is covered with an oxide film, and it is extremely difficult to remove the thin line particularly from the viewpoint of the proximity effect countermeasure. Therefore, attention was paid to the CCA wire in which the outer side of the aluminum wire was covered with copper with a thin wall.
- Fig. 9 shows a high-frequency transformer model as an example of high-frequency power equipment.
- the high-frequency transformer model includes a magnetic core 10, and a first winding 11 and a second winding 12 that wind around the magnetic core 10. Since not only the magnetic flux due to the current flowing through the adjacent first and second windings 11 and 12, but also the leakage magnetic flux from the magnetic core 10 flows into the first and second windings 11 and 12, the external magnetic flux Eddy current loss will occur. For this reason, in the high frequency transformer model, the increase in AC resistance is larger than that of a single wire model of a single wire.
- FIG. 10 shows Rac / Rdc as a theoretical calculation value of the AC resistance-frequency characteristics of the high-frequency transformer model shown in FIG. It can be seen that in this actual model, the AC resistance of the aluminum wire is greatly reduced as compared with the copper wire.
- the above-mentioned superiority of the aluminum wire is due to the fact that the volume resistivity of aluminum is larger than that of copper.
- the aluminum wire has difficulty in solderability. For this reason, it is considered that a CCA wire that can compensate for the disadvantages of aluminum is practically suitable.
- eddy current flows through the copper layer, and the original characteristics of the aluminum wire are impaired. .
- Eddy currents flowing from the central conductor 1 toward the coating layer 2 can be suppressed, and the skin effect and proximity effect can be suppressed.
- the intermetallic compound layer 3 is generated at the interface between the central conductor 1 and the covering layer 2, thereby reducing the proximity effect by equivalently reducing the thickness of the covering layer 2.
- the high frequency electric wire according to the embodiment of the present invention and a high frequency electric wire recrystallized by heat treatment at a recrystallization temperature or higher will be described as a comparative example.
- the high frequency electric wire according to the embodiment of the present invention is generated by drawing the central conductor 1 covered with the covering layer 2 using dies combined in a plurality of stages, it is schematically shown in FIG.
- the center conductor 1 and the coating layer 2 become a processed structure, and have a fibrous structure in the longitudinal direction.
- the processed structure is a structure that has undergone cold processing.
- Cold processing means processing performed at or below the recrystallization temperature.
- the fibrous structure means a structure in which crystal grains are drawn in the drawing direction by drawing. As an example of such a processed structure, FIG.
- FIG. 13 (a) shows a cross section of a processed structure of 0.9 mm diameter tough pitch copper (TPC) manufactured by the SCR (Southwire Continuous Rod) method
- FIG. A cross section of a processed structure of oxygen free copper (OFC) having a diameter of 0.9 mm manufactured by a dip forming method is shown.
- the high frequency electric wire according to the comparative example has a recrystallized structure that is recrystallized by heat treatment at a temperature higher than the recrystallization temperature, as schematically shown in FIG.
- the recrystallized structure means a structure in which a crystal grain that is distorted by cold working is replaced by a crystal without distortion by recrystallization.
- FIG. 14 (a) shows a cross section of a recrystallized structure of 0.9 mm diameter tough pitch copper (TPC) manufactured by the SCR method
- FIG. 14 (b) shows a manufactured by the dip forming method.
- 1 represents a cross section of a recrystallized structure of oxygen-free copper (OFC) having a diameter of 0.9 mm.
- the high-frequency electric wire according to the embodiment of the present invention has a higher specific resistance value than the high-frequency electric wire according to the comparative example, the proximity effect can be further suppressed. Furthermore, since the high-frequency electric wire according to the embodiment of the present invention has a Vickers hardness higher than that of the high-frequency electric wire according to the comparative example, it is difficult to be damaged or deformed during manufacturing, and the characteristics as a coil are more stable.
- a central conductor 1 made of aluminum or aluminum alloy having a diameter of about 9.5 mm to 12.0 mm is prepared.
- the surface of the central conductor 1 is coated with a coating layer 2 on the surface of the central conductor 1 by performing TIG welding or plasma welding or the like while applying a copper tape having a thickness of about 0.1 mm to 0.4 mm to the surface of the central conductor 1.
- the base conductor 1 made of the center conductor 1 covered with the covering layer 2 is manufactured by forming the center conductor 1 covered with the covering layer 2 into a diameter of about 9.3 mm to 12.3 mm using a skin pass.
- the base material is drawn by passing through a multi-stage drawing die of about 25 to 26 passes.
- the wire drawing die 20 includes an entrance part 21, an approach part 22, a reduction part 23, a bearing part 24, and a back relief part 25.
- the base material 4 is processed into a diameter d2 that is smaller than the diameter d1 before drawing in the reduction part 23.
- the surface area reduction per pass (wire drawing die) is about 20% or more. Desirably, it is about 20% to 29%.
- the area reduction rate of the wire drawing die is about 20% or more, preferably about 20% to 29%, a large shear stress in the same direction can be continuously generated. Due to this shear heat generation, an intermetallic compound layer 3 composed of the material of the center conductor 1 and the material of the coating layer 2 is formed at the interface between the center conductor 1 and the coating layer 2. By passing through a plurality of wire drawing dies, the diameter of the high frequency electric wire is finally reduced to about 0.6 mm or less.
- the area reduction rate of the dies combined in a plurality of stages in the wire drawing step is set to 20% or more, so that the central conductor is not subjected to heat treatment after wire drawing.
- the intermetallic compound layer 3 is formed between 1 and the covering layer 2, and the high frequency electric wire shown in FIG. 1 can be manufactured.
- FIGS. 17 (a) to 17 (c) show the finite element method (FEM) analysis results of the longitudinal cross-sectional stress distribution during wire drawing.
- FEM finite element method
- the central conductor 1 is formed by gradually drawing using a plurality of drawing dies having an area reduction rate of 20% or more and generating relatively large shearing heat continuously and periodically.
- the intermetallic compound layer 3 can be generated in a good bonded state so that the composition changes in a gradient between the coating layer 2 and the coating layer 2.
- Example 1 As Example 1 of the present invention, an intermetallic compound layer 3 is formed between a central conductor 1 and a covering layer 2 as shown in FIG. 1 using a plurality of wire drawing dies each having a surface reduction ratio of 20% or more.
- a high-frequency electric wire hereinafter referred to as “5% CCA wire” in which the cross-sectional area of the covering layer 2 is 5% of the cross-sectional area of the entire high-frequency electric wire was produced.
- 5% CCA wire high-frequency electric wire
- TIG welding was performed on a central conductor 1 made of aluminum having a diameter of 9.5 mm while a 0.15 mm-thick copper tape was applied in a longitudinal manner, and the base material was formed by molding to 9.25 mm in diameter with a skin pass. .
- This base material was pulled down from a diameter of 9.25 mm to a diameter of 0.4 mm through a multi-stage (26 passes) wire drawing die.
- the area reduction rate in the 23rd to 21% and 11th to 26th passes was set to 21% to 20%.
- the copper / aluminum interface was observed using a transmission electron microscope (TEM).
- TEM transmission electron microscope
- FIG. 18 shows a TEM photograph of 5% CCA line.
- a black part shows copper
- a white part shows aluminum
- a gray part shows an intermetallic compound layer.
- the intermetallic compound layer 3 is generated in an excellent bonded state so that the composition changes in a gradient from the central conductor 1 to the coating layer 2.
- the point analysis results by spectroscopic analysis (EDS) are shown in FIGS. 19 (a) to 19 (d), respectively.
- FIG. 19 (b) aluminum atoms are rich on the central conductor 1 side of the intermetallic compound layer 3, and as shown in FIG. 19 (d), copper is on the covering layer 2 side of the intermetallic compound layer 3. It was confirmed that the atoms were rich. From FIG. 19A to FIG. 19D, it can be seen that the metal material constituting the intermetallic compound layer 3 is distributed in a gradient from the central conductor 1 to the coating layer 2. Further, the composition of the intermetallic compound layer 3, Cu 9 Al 4 and CuAl 2 are mainly the resistivity of Cu 9 Al 4 and CuAl 2 is about 10 ⁇ -cm or more at Usudaira shape. Since the specific resistance of copper is 1.724 ⁇ -cm, the specific resistance of the intermetallic compound layer is more than five times that of copper, which is a sufficiently large value.
- Example 2 As Example 2 of the present invention, as shown in FIGS. 20 (a) to 20 (c), 5% CCA wire drawn to 0.4 mm is coated with polyurethane (hereinafter referred to as “5% CCA winding”). And a reactor including a magnetic core 32 and a 5% CCA winding 31 disposed around the magnetic core 32 was manufactured. Fourteen 5% CCA windings 31 were used, and the number of turns was 80 turns. Moreover, the reactor was each produced using the aluminum winding and the copper winding as a comparative example. Direct current resistance and alternating current resistance were measured using each manufactured reactor.
- 5% CCA winding polyurethane
- FIG. 21 shows the characteristics of a 5% CCA winding according to Example 2 of the present invention compared to an aluminum winding and a copper winding. It can be seen that when the 5% CCA winding is compared with the copper winding in the reactor having the inductances substantially matched, the AC resistance is reduced to about half even though the DC resistance is 1.57 times.
- Example 3 in addition to the reactor using the same 5% CCA winding as in the second example of the present invention, the cross-sectional area of the covering layer 2 shown in FIG. High-frequency electric wire winding (hereinafter referred to as “15% CCA winding”) which is 15%, and high-frequency electric wire winding (hereinafter referred to as “10”) in which the cross-sectional area of the covering layer 2 is 10% of the cross-sectional area of the entire electric wire.
- 15% CCA winding which is 15%
- 10 high-frequency electric wire winding
- % CCA winding a winding of a high-frequency electric wire (hereinafter referred to as“ alloy ”) using an aluminum alloy (JIS6063 alloy) as the central conductor 1 and having a covering layer 2 having a cross-sectional area of 5% of the cross-sectional area of the entire electric wire.
- Reactors using aluminum 5% CCA windings were produced under the same conditions as reactors using 5% CCA windings.
- FIG. 22 and 23 show a 15% CCA winding, a 10% CCA winding, a 5% CCA winding, an alloy aluminum 5% CCA winding according to Example 3 of the present invention, and a copper winding according to a comparative example.
- the AC resistance vs. frequency characteristics for each of the aluminum winding and aluminum winding are shown. From FIG. 22 and FIG. 23, it can be seen that the 15% CCA winding, the 10% CCA winding, and the 5% CCA winding greatly reduce the AC resistance compared to the copper winding. Furthermore, it can be seen that in the alloy aluminum 5% CCA winding, the AC resistance is greatly reduced as compared with the copper winding and the aluminum winding.
- the proximity effect is known to be proportional to the fourth power of the wire diameter.
- the strand has been described as the high-frequency electric wire according to the embodiment of the present invention, it can be used as an assembly wire in which a plurality of the strands are bundled or a plurality of litz wires twisted together. In the case of a wire or a litz wire, the AC resistance can be more effectively suppressed.
- the high frequency electric wire includes a high frequency transformer, a motor, a reactor, a choke coil, an induction heating device, a magnetic head, a high frequency power supply cable, a DC power supply unit, a switching power supply, an AC adapter, and an eddy current detection method.
- the present invention can be applied to various devices such as a displacement sensor / flaw detection sensor such as a non-contact power supply device such as an IH cooking heater, a coil or a power supply cable, or a high-frequency current generator.
- a high frequency electric wire such as when using the high frequency electric wire according to the embodiment of the present invention as a coil or as a litz wire, in order to maintain a processed structure (longitudinal fibrous structure). Deform without heat treatment. Further, heat treatment may be performed at a temperature higher than the recrystallization temperature in order to improve flexibility. However, in that case, the processed structure is lost. Moreover, in order to make each resistance value of the center conductor 1 and the coating layer 2 higher, heat treatment may be performed at a temperature lower than the recrystallization temperature. When heat treatment is performed, the high frequency electric wire may be deformed while performing the heat treatment, or the heat treatment may be performed after the high frequency electric wire is deformed. Moreover, heat processing may be performed with respect to the whole high frequency electric wire, and may be performed locally.
- the high frequency electric wire and high frequency coil of the present invention include a high frequency transformer, a motor, a reactor, a choke coil, an induction heating device, a magnetic head, a high frequency power supply cable, a DC power supply unit, a switching power supply, an AC adapter, an eddy current detection method, etc.
- -It can be used in the electronic equipment industry including the manufacturing industry of various devices such as flaw detection sensors, IH cooking heaters, non-contact power supply devices such as coils or power supply cables, and high-frequency current generators.
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- Organic Chemistry (AREA)
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- Insulated Conductors (AREA)
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Abstract
Description
本発明の実施の形態に係る高周波電線は、図1に示すように、アルミニウム(Al)又はアルミニウム合金からなる中心導体1と、中心導体1を被覆する銅(Cu)からなる被覆層2と、中心導体1と被覆層2と間に、中心導体1から被覆層2にかけて傾斜的に組成が変化するように形成され、被覆層2よりも体積抵抗率が大きい金属間化合物層(合金層)3とを備える。
次に、本発明の実施の形態に係る高周波電線の製造方法を説明する。なお、以下に示す製造方法は一例であり特に限定されるものではない。本発明の実施の形態に係る高周波電線は種々の製造方法により製造することが可能である。
本発明の実施例1として、減面率がそれぞれ20%以上の複数の伸線ダイスを用いて、図1に示すように中心導体1と被覆層2の間に金属間化合物層3が形成され、被覆層2の断面積が高周波電線全体の断面積の5%である高周波電線(以下、「5%CCA線」という。)を作製した。まず、直径9.5mmのアルミニウムからなる中心導体1の上に0.15mm厚の銅テープを縦添え方式で添わせながらTIG溶接し、スキンパスで直径9.25mmに成形し、母材を作製した。この母材を、複数段(26パス)の伸線ダイスを通し、直径9.25mmから直径0.4mmに引き落とした。伸線ダイスのリダクション角度αは一律8°(全角2α=16°)とし、第1パス~第3パスの減面率を29%~24%、第4パス~第10パスの減面率を23%~21%、第11パス~第26パスの減面率を21%~20%とした。
本発明の実施例2として、図20(a)~図20(c)に示すように、0.4mmに線引きした5%CCA線にポリウレタンを被覆した巻線(以下、「5%CCA巻線」という。)を作製し、磁心32と、磁心32の周りに配置された5%CCA巻線31を備えるリアクトルを作製した。5%CCA巻線31は14本用い、その巻数を80ターンとした。また、比較例としてアルミニウム巻線及び銅巻線を用いてリアクトルをそれぞれ作製した。作製した各リアクトルを用いて直流抵抗及び交流抵抗を測定した。
本発明の実施例3として、本発明の第2の実施例と同様の5%CCA巻線を用いたリアクトルの他に、図1に示した被覆層2の断面積が電線全体の断面積の15%である高周波電線の巻線(以下、「15%CCA巻線」という。)、被覆層2の断面積が電線全体の断面積の10%である高周波電線の巻線(以下、「10%CCA巻線」という。)、中心導体1としてアルミニウム合金(JIS6063合金)を使用し、被覆層2の断面積が電線全体の断面積の5%である高周波電線の巻線(以下、「合金アルミ5%CCA巻線」という。)を用いたリアクトルを、5%CCA巻線を用いたリアクトルと同じ条件でそれぞれ作製した。
本発明は上記の実施の形態によって記載したが、この開示の一部をなす論述及び図面はこの発明を限定するものであると理解すべきではない。この開示から当業者には様々な代替実施の形態、実施例及び運用技術が明らかとなろう。
Claims (6)
- アルミニウム又はアルミニウム合金からなる中心導体と、
前記中心導体を被覆する銅からなり、長手方向に繊維状組織を有する被覆層と、
前記中心導体と前記被覆層との間に形成され、前記被覆層よりも体積抵抗率が大きい金属間化合物層とを備え、
前記被覆層の断面積が、前記中心導体、前記金属間化合物層及び前記被覆層を合わせた全体の断面積に対して15%以下であることを特徴とする高周波電線。 - 前記金属間化合物が、前記中心導体から前記被覆層にかけて傾斜的に組成が変化するように形成されていることを特徴とする請求項1に記載の高周波電線。
- 前記金属間化合物層は、前記被覆層が被覆された前記中心導体を減面率がそれぞれ20%以上の複数段のダイスを用いて伸線することにより形成されることを特徴とする請求項1又は2に記載の高周波電線。
- 前記金属間化合物層の厚さが10nm~1μmであることを特徴とする請求項1~3のいずれか1項に記載の高周波電線。
- 前記金属間化合物層の体積抵抗率が10μΩ-cm以上であることを特徴とする請求項1~4のいずれか1項に記載の高周波電線。
- 高周波電線を使用した高周波コイルであって、
前記高周波電線が、
アルミニウム又はアルミニウム合金からなる中心導体と、
前記中心導体を被覆する銅からなり、長手方向に繊維状組織を有する被覆層と、
前記中心導体と前記被覆層との間に形成され、前記被覆層よりも体積抵抗率が大きい金属間化合物層とを備え、
前記被覆層の断面積が、前記中心導体、前記金属間化合物層及び前記被覆層を合わせた全体の断面積に対して15%以下であることを特徴とする高周波コイル。
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CN201180015433.9A CN102822907B (zh) | 2010-03-23 | 2011-03-23 | 高频电线及高频线圈 |
JP2011538787A JP4879373B2 (ja) | 2010-03-23 | 2011-03-23 | 高周波電線及び高周波コイル |
KR1020127027195A KR101487211B1 (ko) | 2010-03-23 | 2011-03-23 | 고주파 전선 및 고주파 코일 |
EP11759439.0A EP2551856B1 (en) | 2010-03-23 | 2011-03-23 | High frequency cable and high frequency coil |
US13/624,395 US9123456B2 (en) | 2010-03-23 | 2012-09-21 | High frequency cable, high frequency coil and method for manufacturing high frequency cable |
US14/336,507 US9478328B2 (en) | 2010-03-23 | 2014-07-21 | High frequency cable, high frequency coil and method for manufacturing high frequency cable |
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JP4879373B2 (ja) | 2012-02-22 |
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US9478328B2 (en) | 2016-10-25 |
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