WO2018164134A1 - 電線およびその製造方法 - Google Patents
電線およびその製造方法 Download PDFInfo
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- WO2018164134A1 WO2018164134A1 PCT/JP2018/008617 JP2018008617W WO2018164134A1 WO 2018164134 A1 WO2018164134 A1 WO 2018164134A1 JP 2018008617 W JP2018008617 W JP 2018008617W WO 2018164134 A1 WO2018164134 A1 WO 2018164134A1
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- outer layer
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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
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
- H01B13/222—Sheathing; Armouring; Screening; Applying other protective layers by electro-plating
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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
- 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
- H01B13/0036—Details
-
- 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
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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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- 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
- B21C1/02—Drawing metal wire or like flexible metallic material by drawing machines or apparatus in which the drawing action is effected by drums
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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
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
- B21C37/042—Manufacture of coated wire or bars
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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
- B21C37/00—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape
- B21C37/04—Manufacture of metal sheets, bars, wire, tubes or like semi-manufactured products, not otherwise provided for; Manufacture of tubes of special shape of bars or wire
- B21C37/045—Manufacture of wire or bars with particular section or properties
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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
- H01B13/06—Insulating conductors or cables
- H01B13/08—Insulating conductors or cables by winding
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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
- 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
- H01F27/32—Insulating of coils, windings, or parts thereof
- H01F27/324—Insulation between coil and core, between different winding sections, around the coil; Other insulation structures
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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
- H01F27/34—Special means for preventing or reducing unwanted electric or magnetic effects, e.g. no-load losses, reactive currents, harmonics, oscillations, leakage fields
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F5/00—Coils
- H01F5/02—Coils wound on non-magnetic supports, e.g. formers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F5/00—Coils
- H01F5/06—Insulation of windings
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01F—MAGNETS; INDUCTANCES; TRANSFORMERS; SELECTION OF MATERIALS FOR THEIR MAGNETIC PROPERTIES
- H01F3/00—Cores, Yokes, or armatures
- H01F3/06—Cores, Yokes, or armatures made from wires
Definitions
- the present invention relates to an electric wire and a manufacturing method thereof.
- This application claims priority based on Japanese Patent Application No. 2017-046682 for which it applied to Japan on March 10, 2017, and uses the content here.
- An electric wire having a structure in which a layer made of a magnetic metal is provided on the outer periphery of a metal wire is used (see, for example, Patent Document 1).
- an insulating coating and a magnetic metal plating layer are provided on the outer periphery of a copper wire or the like.
- an insulating coating is formed on the outer periphery of a copper wire or the like, and then a magnetic metal plating layer is formed on the outer periphery of the insulating coating by a plating method.
- the magnetic metal plating layer when the magnetic metal plating layer is formed thick, the magnetic permeability of the magnetic metal plating layer tends to be low. Therefore, when this enameled wire is applied to a coil of a high frequency device, there is a possibility that the power transmission efficiency is reduced and heat is generated due to the high frequency resistance. In addition, since the hardness of the magnetic metal plating layer tends to be high, this enameled wire is easily damaged when coiled and is difficult to handle.
- the present invention has been made in view of the above circumstances, and it is an object of the present invention to provide an electric wire that is excellent in magnetic properties and hardly damaged even when a magnetic metal layer is formed thick, and a method for manufacturing the same.
- the method for manufacturing an electric wire according to the first aspect of the present invention includes a cylindrical outer layer body made of a magnetic metal containing iron and a metal, and the ratio of the outer layer body to the inner diameter is 85.1%.
- the core body having an outer diameter of 99.4% or less is prepared, and the inner surface of the outer layer body and the outer surface of the core body are mechanically polished, and the inner surface of the outer layer body and the core body are prepared.
- hydrochloric acid By treating at least one of the outer surfaces with hydrochloric acid, placing the core body inside the outer layer body to obtain a base material, and drawing the base material through a wire drawing die, An electric wire having a center conductor formed by the core body and an outer layer formed by the outer layer body and covering the center conductor is obtained.
- the method for manufacturing an electric wire according to the second aspect of the present invention includes a cylindrical outer layer body made of a magnetic metal containing iron and a metal, and the ratio of the outer layer body to the inner diameter is 85.1%.
- a core body having an outer diameter of 99.4% or less is prepared, and an inner surface of the outer layer body and a spiral polishing mark are formed around the axis of the core body. It is formed by the core body by subjecting the outer surface to mechanical polishing, arranging the core body inside the outer layer body to obtain a base material, and drawing the base material through a wire drawing die.
- An electric wire having a central conductor and an outer layer formed by the outer layer body and covering the central conductor is obtained.
- At least one of the inner surface of the outer layer body and the outer surface of the core body may be treated with an acid.
- the area reduction rate in one drawing may be 10% or more and 20% or less.
- the electric wire according to the third aspect of the present invention is composed of a central conductor composed of metal and a magnetic metal containing iron, has a thickness of 3 ⁇ m or more, a Vickers hardness of less than 350 Hv, and the center An outer layer covering the conductor.
- the outer layer may have a Cl concentration of 0.1 wt% or less.
- a high-frequency coil according to a fourth aspect of the present invention includes the electric wire according to the aspect described above, and a support body that has a trunk portion and the electric wire is wound around the trunk portion.
- the manufacturing method of the high frequency coil which concerns on the 5th aspect of this invention prepares the electric wire which concerns on the said aspect, and the support body which has a trunk
- the concentration of impurities (for example, chlorine) contained in the outer layer can be lowered. Since the impurity concentration of the outer layer is low, the magnetic characteristic distribution of the outer layer is uniform, and even if the outer layer is formed thick, the magnetic characteristics are unlikely to deteriorate. Therefore, when the electric wire is applied to a coil of a high-frequency device, it is possible to avoid a decrease in power transmission efficiency and heat generation due to the high-frequency resistance. Moreover, according to the manufacturing method which concerns on the said aspect, the hardness of an outer layer can be restrained low compared with the manufacturing method using a plating method. For this reason, when the electric wire is coiled, the electric wire is not easily damaged.
- impurities for example, chlorine
- the manufacturing method which concerns on the said aspect the time required for formation of an outer layer can be shortened compared with the manufacturing method using a plating method.
- waste liquid treatment costs can be reduced. Therefore, the manufacturing cost can be reduced.
- the electric wire according to an embodiment of the present invention is composed of, for example, a central conductor made of metal and a magnetic metal containing iron, has a thickness of 3 ⁇ m or more, has a Vickers hardness of less than 350 Hv, and An outer layer covering the central conductor.
- FIG. 1 is a cross-sectional view showing an electric wire 10 according to an embodiment of the present invention.
- FIG. 1 is a view showing a cross section orthogonal to the length direction of the electric wire 10.
- the electric wire 10 is a conductor having a two-layer structure including a center conductor 1 and an outer layer 2 covering the center conductor 1.
- the center conductor 1 is made of metal.
- Examples of the metal constituting the central conductor 1 include metals having high conductivity such as aluminum-containing materials and copper-containing materials.
- aluminum-containing material aluminum (Al) or an aluminum alloy can be used.
- electrical aluminum (EC aluminum), Al—Mg—Si alloys (JIS6000 series), etc. can be used.
- copper-containing material copper (Cu) or a copper alloy can be used.
- the constituent material of the center conductor 1 may be an alloy material containing both aluminum and copper.
- the constituent material of the center conductor 1 may be a nonmagnetic material or a magnetic material.
- the central conductor 1 has a circular cross section perpendicular to the length direction.
- the outer layer 2 is made of a magnetic metal containing iron.
- iron Fe
- Fe alloys include FeSi alloys (FeSiAl, FeSiAlCr, etc.), FeAl alloys (FeAl, FeAlSi, FeAlSiCr, FeAlO, etc.), FeCo alloys (FeCo, FeCoB, FeCoV, etc.), FeNi alloys (FeNi, FeNiMo, FeNiCr, etc.).
- FeNiSi etc. (Permalloy etc.), FeTa alloys (FeTa, FeTaC, FeTaN etc.), FeMg alloys (FeMgO etc.), FeZr alloys (FeZrNb, FeZrN etc.), FeC alloys, FeN alloys, FeP alloys FeNb alloy, FeHf alloy, FeB alloy and the like. Since the outer layer 2 is made of a magnetic metal, the magnetic field can be prevented from entering the central conductor 1.
- the thickness of the outer layer 2 is 3 ⁇ m or more, preferably 10 ⁇ m or more. By setting the thickness of the outer layer 2 to 3 ⁇ m or more, it is possible to sufficiently enhance the effect of preventing a decrease in power transmission efficiency and heat generation when applied to a coil of a high-frequency device.
- the thickness of the outer layer 2 can be set to 1000 ⁇ m or less, for example. When the thickness of the outer layer 2 exceeds 1000 ⁇ m, the influence of the skin effect is strong in high-frequency applications, and current flows only on the surface of the wire, so the amount of current that can be flowed becomes small.
- the surface area increases and the amount of current that can flow increases.
- the thickness of the outer layer 2 is preferably uniform in the direction around the axis of the electric wire 10.
- the cross-sectional area of the outer layer 2 can be 20% or less with respect to the cross-sectional area of the entire electric wire 10 including the central conductor 1 and the outer layer 2.
- the cross-sectional area ratio (the cross-sectional area ratio of the outer layer 2 with respect to the entire electric wire 10) is preferably 3% to 15%, and more preferably 3% to 5%.
- the outer diameter of the outer layer 2 can be set to 0.05 mm to 0.6 mm, for example.
- the Vickers hardness of the outer layer 2 is preferably less than 350 Hv. By setting the Vickers hardness of the outer layer 2 within this range (less than 350 Hv), for example, when the coil is bent using the electric wire 10, the electric wire 10 is less likely to be damaged. Vickers hardness can be measured according to, for example, JIS Z 2244: 2009.
- the chlorine (Cl) concentration in the outer layer 2 is preferably 0.1 wt% or less.
- the chlorine (Cl) concentration can be measured using, for example, EPMA (for example, “JXA-8900M” manufactured by JEOL) (measurement conditions: voltage 15 kV, probe current 5 ⁇ 10 ⁇ 8 A).
- an intermetallic compound layer (not shown) whose composition changes in a gradient from the central conductor 1 to the outer layer 2 may be formed between the central conductor 1 and the outer layer 2.
- the intermetallic compound layer is made of, for example, an alloy including the constituent material of the central conductor 1 and the constituent material of the outer layer 2.
- the method for manufacturing an electric wire according to the first embodiment of the present invention includes a cylindrical outer layer body made of a magnetic metal containing iron and a metal, and the ratio of the outer layer body to the inner diameter is 85.1.
- a core body having an outer diameter of 99.4% or less and subjecting the inner surface of the outer layer body and the outer surface of the core body to mechanical polishing, the inner surface of the outer layer body and the core
- hydrochloric acid By treating at least one of the outer surfaces of the body with hydrochloric acid, placing the core body inside the outer layer body to obtain a base material, and drawing the base material through a wire drawing die
- An electric wire having a center conductor formed by the core body and an outer layer formed by the outer layer body and covering the center conductor is obtained.
- FIG. 2 is a cross-sectional view showing a base material 20 used in the method of manufacturing an electric wire according to the first embodiment.
- the core body 11 and the outer layer body 12 are prepared.
- the core body 11 is comprised from the metal which is a constituent material of the above-mentioned center conductor 1, for example, an aluminum containing material, a copper containing material, etc.
- the core body 11 has a shape in which a cross section perpendicular to the length direction is circular.
- the outer layer body 12 is made of a magnetic metal that is a constituent material of the outer layer 2 described above, such as an FeNi alloy (permalloy or the like).
- the outer layer body 12 is formed in a cylindrical shape (tubular), and for example, a raw material of an iron pipe or a steel pipe can be used.
- the outer layer body 12 is formed continuously and seamlessly around the entire circumference of the cylinder.
- the outer layer body 12 is, for example, a rolled material.
- the cylindrical raw material used for forming the outer layer body 12 is preferably a material having a low content of impurities such as chlorine. For example, it is preferable to use a raw material having a chlorine (Cl) concentration of 0.1 wt% or less.
- the thickness of the outer layer body 12 is desirably uniform in the direction around the axis of the base material 20.
- the core body 11 is arranged inside the outer layer body 12 by inserting the core body 11 through the outer layer body 12. Thereby, the base material 20 is obtained.
- the base material 20 has a structure having a core body 11 and an outer layer body 12 surrounding the core body 11.
- the ratio of the outer diameter D11 of the core body 11 to the inner diameter D12 of the outer layer body 12, that is, “D11 / D12” is preferably 85.1% or more and 99.4% or less.
- the diameter ratio (D11 / D12) is 85.1% or more, when the base material 20 is drawn, the central axis of the core body 11 and the central axis of the outer layer body 12 are not easily displaced, and the wire drawing is performed. A suitable stress for joining the core body 11 and the outer layer body 12 is obtained by the die.
- the thickness of the outer layer 2 is less likely to be biased. Therefore, the outer layer 2 is less likely to be damaged due to the stress concentration on the thin portion of the outer layer 2.
- the diameter ratio (D11 / D12) is 99.4% or less, the operation of inserting the core body 11 through the outer layer body 12 becomes easy.
- the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 are subjected to mechanical polishing.
- the mechanical polishing can be performed using a polishing tool such as a file, a drill, or a brush.
- An abrasive (abrasive grain) may be used together with the polishing tool.
- the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 can be roughened to form minute surface irregularities.
- the oxide film on the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 is removed by mechanical polishing.
- the arithmetic average roughness Ra (JIS B 0601 (2013)) of the outer surface 11a and the inner surface 12a subjected to the mechanical polishing may be, for example, 10 ⁇ m or more and 200 ⁇ m or less.
- the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 are roughened to form surface irregularities, whereby the core body 11 and the outer layer body 12 are easily joined in the wire drawing step described later. Become. Therefore, when the electric wire 10 becomes thin in the process of wire drawing, excessive stress is not applied to the outer layer 2, and wire drawing can be performed without causing disconnection.
- At least one of the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 is treated with hydrochloric acid (acid treatment agent).
- the concentration of hydrochloric acid can be, for example, 0.1 mol / l to 12.1 mol / l (preferably 1 mol / l to 7 mol / l).
- the pH of the acid treatment agent is, for example, pH 2 or less.
- the temperature condition of the treatment with hydrochloric acid is, for example, 10 to 40 ° C., but the treatment with acid may be performed under a heating condition exceeding 40 ° C.
- the treatment with hydrochloric acid is preferably a method in which the core body 11 and the outer layer body 12 are immersed in an acid treatment agent.
- the treatment time with hydrochloric acid may be, for example, 1 to 30 minutes (preferably 1 to 10 minutes).
- the oxide film on the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 is removed.
- the treatment with hydrochloric acid may be performed on both the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12, or may be performed only on one of the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12. Good.
- the order of treatment with hydrochloric acid and mechanical polishing is not particularly limited, and treatment with hydrochloric acid may be performed first, or mechanical polishing may be performed first.
- a base material 20A shown in FIG. 3 may be used instead of the base material 20 shown in FIG.
- FIG. 3 is a view showing a base material 20A using an outer layer body 12A which is a modification of the outer layer body 12.
- the outer layer body 12A is formed in a cylindrical shape (tubular shape).
- the outer layer body 12A is different from the outer layer body 12 shown in FIG. 2 in that there is a discontinuous portion (seam) 13 in a part in the direction around the axis.
- the outer layer body 12 ⁇ / b> A can be formed into a cylindrical shape (tubular shape) by curving so as to wrap the core body 11 in a state where a strip-like (ribbon-like) or flat plate-like raw material is vertically attached to the core body 11.
- the raw material having a strip shape or a flat plate shape is, for example, a rolled material.
- a material having a low content of impurities such as chlorine is preferably used for the strip-shaped or flat-shaped raw material used for forming the outer layer body 12A.
- the ratio of the outer diameter of the core body 11 to the inner diameter of the outer layer body 12A is preferably 85.1% or more and 99.4% or less. .
- FIG. 4 is a schematic view showing a wire drawing die 30 applicable to the manufacturing method according to the present embodiment.
- the wire drawing die 30 has a structure in which the inner diameter gradually decreases from the entrance portion 31 to the reduction portion 32.
- the base material 20 is introduced into the reduction part 32 through the entrance part 31 and processed into a diameter d2 smaller than the diameter d1 before drawing.
- the wire drawing may be performed only once, the area reduction rate can be increased by performing the wire drawing process a plurality of times using other wire drawing dies 30 having different inner diameter dimensions. That is, the base material 20 can be drawn in stages using a plurality of drawing dies 30.
- the area reduction rate in a single wire drawing process can be, for example, 10% or more.
- the area reduction rate in a single wire drawing process can be, for example, 20% or less.
- the efficiency of wire drawing can be increased.
- the shearing force applied to the outer layer body 12 can be suppressed, and the breakage (for example, disconnection) of the electric wire can be prevented.
- the area reduction ratio is “the cross-sectional area difference before and after the drawing of the base material 20 / the cross-sectional area of the base material 20 before the drawing”.
- the area reduction ratio can be calculated from the cross-sectional area of the base material 20 orthogonal to the axial direction of the base material 20 and the cross-sectional area orthogonal to the axial direction of the bearing portion 33 in the internal space of the bearing portion 33.
- the cumulative area reduction rate can be set to 70% or more, for example.
- the wire 10 shown in FIG. 1 is obtained by such wire drawing.
- the base material 20 in which the core body 11 is arranged inside the outer layer body 12 is produced, and then the base material 20 is drawn to obtain the electric wire 10.
- the manufacturing method according to the present embodiment hardly mixes impurities (for example, chlorine) into the outer layer 2.
- impurities for example, chlorine
- impurities contained in the plating solution remain in the plating film, so that an outer layer containing a large amount of impurities is formed.
- the manufacturing method according to the above-described embodiment since impurities are not mixed into the outer layer 2 during processing, the impurity concentration of the outer layer 2 is lower than that in the case where the outer layer 2 is formed by plating. For this reason, the magnetic characteristic distribution of the outer layer 2 becomes uniform, and even if the outer layer 2 is formed thick, the magnetic characteristic is hardly deteriorated. Therefore, when the electric wire 10 is applied to a coil of a high frequency device, it is possible to avoid a decrease in power transmission efficiency and heat generation due to the high frequency resistance. Moreover, the manufacturing method according to the embodiment can keep the hardness of the outer layer 2 low compared to a manufacturing method using a plating method.
- the manufacturing method according to the embodiment can reduce the time required for forming the outer layer 2 as compared with a manufacturing method using a plating method. In addition, waste liquid treatment costs can be reduced. Therefore, the manufacturing cost can be reduced.
- the electric wire 10 is manufactured by the above-described manufacturing method, impurities (for example, chlorine) are hardly mixed into the outer layer 2. Since the outer layer 2 has a low impurity concentration, the magnetic characteristic distribution of the outer layer 2 is uniform, and even if the outer layer 2 is formed thick, the magnetic characteristics are unlikely to deteriorate. Therefore, when the electric wire 10 is applied to a coil of a high frequency device, the power transmission efficiency is reduced and heat is hardly generated due to the high frequency resistance. Moreover, the electric wire 10 can suppress the hardness of the outer layer 2 low as mentioned above. Therefore, when the electric wire 10 is coiled, it is hard to produce a damage. Therefore, the electric wire 10 excellent in handleability can be obtained. Further, the manufacturing cost of the electric wire 10 can be reduced as described above.
- impurities for example, chlorine
- the electric wire manufacturing method includes a cylindrical outer layer body made of a magnetic metal containing iron and a metal, and the ratio of the outer layer body to the inner diameter is 85.1. %, And a core body having an outer diameter of 99.4% or less, and the core body so as to form a spiral polishing mark around the inner surface of the outer layer body and the axis of the core body
- the outer surface of the outer layer body is subjected to mechanical polishing, the core body is disposed inside the outer layer body to obtain a base material, and the base material is drawn through a wire drawing die, thereby forming the core body.
- a core body 11 and an outer layer body 12 are prepared.
- the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 are subjected to mechanical polishing.
- the mechanical polishing can be performed using, for example, a file, a drill, a brush, an abrasive (abrasive grain), or the like.
- the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 can be roughened to form minute surface irregularities.
- the oxide film on the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 is removed by mechanical polishing.
- a spiral polishing mark is formed around the axis of the core body 11 by mechanical polishing, and the surface is roughened.
- at least one of the polishing tool (file, drill, brush, etc.) and the core body 11 is used as the core body 11.
- a method of rotating around the axis while relatively moving in the axial direction is possible.
- the arithmetic average roughness Ra (JIS B 0601 (2013)) of the outer surface 11a and the inner surface 12a subjected to the mechanical polishing may be, for example, 10 ⁇ m or more and 200 ⁇ m or less.
- spiral polishing marks surface irregularities
- the core body 11 and the outer layer body 12 are joined in the wire drawing step described later. It becomes easy. Therefore, when the electric wire 10 becomes thin in the process of wire drawing, excessive stress is not applied to the outer layer 2, and wire drawing can be performed without causing disconnection.
- At least one of the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 may be treated with an acid.
- the treatment with an acid is, for example, a treatment with an acid treatment agent that is an inorganic acid or an aqueous solution of an inorganic acid.
- the inorganic acid include one or more of hydrochloric acid, nitric acid, sulfuric acid and the like.
- the concentration of hydrochloric acid can be, for example, 0.1 mol / l to 12.1 mol / l (preferably 1 mol / l to 7 mol / l).
- the concentration of nitric acid can be, for example, 0.1 mol / l to 14 mol / l (preferably 1 mol / l to 10 mol / l).
- the concentration of sulfuric acid can be, for example, 0.1 mol / l to 18.25 mol / l (preferably 1 mol / l to 10 mol / l).
- the pH of the acid treatment agent is, for example, pH 2 or less.
- the temperature condition for the treatment with the acid is, for example, 10 to 40 ° C., but the treatment with the acid may be performed under a heating condition exceeding 40 ° C.
- the treatment with an acid is preferably a method in which at least one of the core body 11 and the outer layer body 12 is immersed in an acid treatment agent.
- the treatment time with the acid may be, for example, 1 to 30 minutes (preferably 1 to 10 minutes).
- the oxide film on the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 is removed by the treatment with the acid.
- the treatment with acid may be performed on both the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12, or may be performed only on one of the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12. Good.
- the order of the acid treatment and the mechanical polishing is not particularly limited, and the acid treatment may be performed first, or the mechanical polishing may be performed first. In the present embodiment, the treatment with acid may not be performed.
- a base material 20A shown in FIG. 3 may be used instead of the base material 20 shown in FIG.
- the base material 20 in which the core body 11 is arranged inside the outer layer body 12 is produced, and then the base material 20 is drawn to obtain the electric wire 10.
- the impurity concentration of the outer layer 2 is lower than when formed by a plating method. For this reason, the magnetic characteristic distribution of the outer layer 2 becomes uniform, and even if the outer layer 2 is formed thick, the magnetic characteristic is hardly deteriorated. Therefore, when the electric wire 10 is applied to a coil of a high frequency device, it is possible to avoid a decrease in power transmission efficiency and heat generation due to the high frequency resistance.
- the manufacturing method according to the embodiment can keep the hardness of the outer layer 2 low compared to a manufacturing method using a plating method. Therefore, when the electric wire 10 is coiled, the electric wire 10 is not easily damaged. Therefore, the electric wire 10 excellent in handleability can be obtained. Furthermore, the manufacturing method according to the embodiment can reduce the time required for forming the outer layer 2 as compared with a manufacturing method using a plating method. In addition, waste liquid treatment costs can be reduced. Therefore, the manufacturing cost can be reduced.
- the electric wire 10 is manufactured by the above-described manufacturing method, impurities (for example, chlorine) are hardly mixed into the outer layer 2. Since the outer layer 2 has a low impurity concentration, the magnetic characteristic distribution of the outer layer 2 is uniform, and even if the outer layer 2 is formed thick, the magnetic characteristics are unlikely to deteriorate. Therefore, when the electric wire 10 is applied to a coil of a high frequency device, the power transmission efficiency is reduced and heat is hardly generated due to the high frequency resistance. Moreover, the electric wire 10 can suppress the hardness of the outer layer 2 low as mentioned above. Therefore, when the electric wire 10 is coiled, it is hard to produce a damage. Therefore, the electric wire 10 excellent in handleability can be obtained. Further, the manufacturing cost of the electric wire 10 can be reduced as described above.
- impurities for example, chlorine
- FIG. 5 is a cross-sectional view of an electric wire 10 ⁇ / b> A that is a first modification of the electric wire 10.
- the electric wire 10 ⁇ / b> A is different from the electric wire 10 of FIG. 1 in that an insulating coating layer 3 is provided on the outer peripheral surface of the outer layer 2.
- the insulating coating layer 3 is made of an insulating material such as polyester, polyurethane, polyimide, polyesterimide, or polyamideimide.
- FIG. 6 is an example of a high-frequency coil using the electric wire 10A shown in FIG.
- a support body 73 having a body portion 71 and flanges 72 formed at both ends of the body portion 71 is used.
- the electric wire 10 ⁇ / b> A is wound around the trunk portion 71.
- the high-frequency coil 70 includes the electric wire 10 ⁇ / b> A, the body portion 71, and the flange portions 72 formed at both ends of the body portion 71, and the wire 10 ⁇ / b> A is wound around the body portion 71.
- a support 73 formed.
- the high-frequency coil 70 prepares the electric wire 10 ⁇ / b> A and the support body 73 having the body portion 71 and the flange portions 72 formed at both ends of the body portion 71, and winds the wire 10 ⁇ / b> A around the body portion 71. May be manufactured.
- the example which used the electric wire 10A was shown for manufacture of the high frequency coil 70, it is not limited to the case where the electric wire 10A is used, For example, even if it uses the above-mentioned electric wire 10 and the electric wire 10B shown below. Good.
- the high-frequency coil may include an electric wire and a support body that has a body portion and the wire is wound around the body portion.
- the high frequency coil may be manufactured by preparing an electric wire and a support body having a trunk portion and winding the electric wire around the trunk portion.
- FIG. 7 is a cross-sectional view showing an electric wire 10 ⁇ / b> B that is a second modification of the electric wire 10.
- the electric wire 10B is different from the electric wire 10 of FIG. 1 in that the central conductor 1A includes a main conductor 41 and a conductor layer 42 formed on the outer peripheral surface of the main conductor 41.
- the main conductor 41 is made of, for example, an aluminum-containing material.
- the conductor layer 42 is made of, for example, a copper-containing material.
- the above embodiments exemplify apparatuses and methods for embodying the technical idea of the present invention, and the technical idea of the present invention specifies the material, shape, structure, arrangement, etc. of components. It is not what you do.
- the ratio of the outer diameter of the core body to the inner diameter of the outer layer body may be a measured value before mechanical polishing and acid treatment are performed, or at least one of mechanical polishing and acid treatment is performed. It may be a later measured value.
- the measured values of the inner diameter of the outer layer body and the outer diameter of the core body hardly change before mechanical polishing and acid treatment and after mechanical polishing and acid treatment.
- the electric wire 10 obtained by the manufacturing method according to the embodiment 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 eddy current detection. It can be used in the electronic equipment industry including the manufacturing industry of various devices such as non-contact power supply devices or high-frequency current generators, such as displacement sensors, flaw detection sensors, IH cooking heaters, coils, and power supply cables.
- the electric wire 10 can be used in a device that supplies a high-frequency current of 100 kHz or more.
- the electric wire 10 shown in FIG. 1 was produced as follows. As shown in FIG. 2, a core body 11 and an outer layer body 12 were prepared. In Test Examples 1 to 4, 7 to 9, the core body 11 is made of a copper-containing material (Cu-based). In Test Examples 10 to 12 and 15 to 18, the core body 11 is made of an aluminum-containing material (Al-based). Table 2 shows the specifications of the outer layer body 12. Table 3 shows the specifications of the core body 11. The length of the core body 11 and the outer layer body 12 was 80 cm. The surfaces of the core body 11 and the outer layer body 12 were washed with a metal cleaner manufactured by Sankyo Chemical.
- one or both of the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 were treated with an acid.
- hydrochloric acid concentration 7 mol / l
- nitric acid concentration 10 mol / l
- Table 1 shows the acid treatment agents used.
- the processing time is shown in parentheses.
- the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 were subjected to mechanical polishing.
- a file or a rotary drill was used as a polishing tool.
- Refine Tech # 240 was used.
- a rotary drill Hitachi Electronic Hand Grazing (KC-20) manufactured by Hitachi Koki was used. In both cases of the file and the rotary drill, the core body 11 and the outer layer body 12 were polished in the longitudinal direction or the spiral direction at a speed of 50 mm / s.
- polishing marks in the longitudinal direction of the core body 11 and the outer layer body 12 were formed on the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12.
- spiral polishing marks surface irregularities around the axis of the core body 11 were formed on the outer surface 11 a of the core body 11.
- the core body 11 was inserted through the cylindrical outer layer body 12 to obtain a base material 20.
- the base material 20 was passed through a plurality of wire drawing dies 30 to perform wire drawing step by step to obtain the electric wire 10.
- the area reduction rate in a single wire drawing process was 10% to 20%.
- the outer diameter of the electric wire 10 is 0.4 mm.
- the outer diameter of the electric wire 10 is 1.0 mm.
- the relative permeability of the outer layer 2 was measured.
- a VSM device made by Toei Scientific Industry was used. The measurement conditions are as follows. Magnetic field application direction: longitudinal direction of electric wire Magnetic field range: -8 ⁇ 10 5 to 8 ⁇ 10 5 A / m Measuring position of relative permeability: 1 ⁇ 10 4 A / m
- the Vickers hardness of the outer layer 2 was measured.
- the Vickers hardness was measured using a Vickers hardness tester (Vickers tester HM-200 manufactured by Mitutoyo) at a test force of 0.1 to 0.5 N and a holding time of 15 sec.
- the thickness of the outer layer 2 was measured. The results are shown in Table 1.
- the “diameter ratio” is a ratio of the outer diameter D11 of the core body 11 to the inner diameter D12 of the outer layer body 12 in FIG. 2, that is, a value of “D11 / D12”.
- Test Examples 5, 6, 13, 14 An electric wire was produced by forming an outer layer on the outer peripheral surface of the central conductor by plating.
- the central conductor (outer diameter 0.4 mm) is made of an aluminum-containing material.
- the center conductor (outer diameter: 1.0 mm) is made of a copper-containing material.
- the outer diameter of the center conductor 1 is 1.0 mm.
- the outer layer is made of iron (Fe).
- the plating conditions are as follows. Plating solution composition: FeCl 2 .4H 2 O (300 g / l), CaCl 2 (335 g / l) Bath temperature: 90 ° C Current density: 6.5 A / dm 2 pH: 1.0 The results are shown in Table 1.
- the diameter ratio “D11 / D12” between the core body 11 and the outer layer body 12 is in the range of 85.1% or more and 99.4% or less.
- the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 were mechanically polished. Further, at least the outer surface 11a of the core body 11 was treated with hydrochloric acid.
- the relative permeability can be increased even when the outer layer 2 is thick. confirmed.
- the hardness of the outer layer 2 was low.
- the diameter ratio “D11 / D12” between the core body 11 and the outer layer body 12 is in the range of 85.1% or more and 99.4% or less.
- the outer surface 11a of the core body 11 and the inner surface 12a of the outer layer body 12 were mechanically polished.
- spiral polishing marks surface irregularities
- the relative permeability can be increased even when the outer layer 2 is thick. confirmed.
- the hardness of the outer layer 2 was low.
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Abstract
Description
本願は、2017年3月10日に日本に出願された特願2017-046682号に基づき優先権を主張し、その内容をここに援用する。
前記エナメル線を作製するには、銅線等の外周に絶縁被覆を形成した後、絶縁被覆の外周に、めっき法により磁性金属めっき層を形成する。
前記外層のCl濃度は、0.1wt%以下であってもよい。
本発明の第四態様に係る高周波コイルは、上記態様に係る電線と、胴部を有し、前記胴部に前記電線が巻きつけられた支持体と、を備える。
本発明の第五態様に係る高周波コイルの製造方法は、上記態様に係る電線と、胴部を有する支持体と、を準備し、前記電線を前記胴部に巻きつける。
よって、電線を高周波機器のコイルに適用した場合において、高周波抵抗による電力伝送効率の低下および発熱を回避できる。
また、上記態様に係る製造方法によれば、めっき法を用いる製造方法に比べて、外層の硬度を低く抑えることができる。そのため、電線をコイル化する際に、電線に破損が生じにくい。よって、取扱い性に優れた電線が得られる。
さらに、上記態様に係る製造方法によれば、めっき法を用いる製造方法に比べて、外層の形成に要する時間を短縮できる。また、廃液処理コストも削減できる。よって、製造コスト低減が可能である。
本発明の一実施形態に係る電線は、例えば、金属から構成される中心導体と、鉄を含有する磁性金属から構成され、厚みが3μm以上であり、ビッカース硬さが350Hv未満であり、かつ、前記中心導体を覆う外層と、を備える。
図1は、本発明の一実施形態に係る電線10を示す断面図である。図1は、電線10の長さ方向に直交する断面を示す図である。
図1に示すように、電線10は、中心導体1と、中心導体1を覆う外層2とを備えた二層構造の導体である。
中心導体1は、金属から構成される。中心導体1を構成する金属としては、アルミニウム含有材料、銅含有材料などの高導電率の金属が挙げられる。
アルミニウム含有材料としては、アルミニウム(Al)、アルミニウム合金が使用できる。例えば、電気用アルミニウム(ECアルミニウム)、Al-Mg-Si系合金(JIS6000番台)などが使用可能である。
銅含有材料としては、銅(Cu)、銅合金が使用できる。
中心導体1の構成材料は、アルミニウムと銅との両方を含む合金材料であってもよい。中心導体1の構成材料は、非磁性の材料であってよいし、磁性材料であってもよい。
中心導体1は、長さ方向に直交する断面が円形である。
鉄合金としては、FeSi系合金(FeSiAl、FeSiAlCrなど)、FeAl系合金(FeAl、FeAlSi、FeAlSiCr、FeAlOなど)、FeCo系合金(FeCo、FeCoB、FeCoVなど)、FeNi系合金(FeNi、FeNiMo、FeNiCr、FeNiSiなど)(パーマロイ等)、FeTa系合金(FeTa、FeTaC、FeTaNなど)、FeMg系合金(FeMgOなど)、FeZr系合金(FeZrNb、FeZrNなど)、FeC系合金、FeN系合金、FeP系合金、FeNb系合金、FeHf系合金、FeB系合金などが挙げられる。
外層2は、磁性金属から構成されるため、中心導体1への磁界の侵入を抑制することができる。
外層2の厚さは、例えば1000μm以下とすることができる。外層2の厚さが1000μmを超えると高周波用途では表皮効果の影響が強く線材表面にしか電流が流れないため流せる電流量が小さくなる。一方、外層2の厚さが1000μm以下の線を複数本用意することで表面積が大きくなり流せる電流量も多くなる。
外層2の厚さは、電線10の軸周り方向において均一であることが望ましい。
外層2の外径は、例えば0.05mm~0.6mmとすることができる。
ビッカース硬さは、例えばJIS Z 2244:2009に準じて測定することができる。
塩素(Cl)濃度は、例えば、EPMA(例えばJEOL製「JXA-8900M」)(測定条件:電圧15kV,プローブ電流5×10-8A)を用いて測定することができる。
本発明の第一実施形態に係る電線の製造方法は、鉄を含有する磁性金属から構成される筒状の外層体と、金属から構成され、かつ、前記外層体の内径に対する比が85.1%以上、99.4%以下である外径を有するコア体と、を準備し、前記外層体の内面、および、前記コア体の外面に機械研磨を施し、前記外層体の前記内面および前記コア体の前記外面のうち少なくとも一方を塩酸により処理し、前記外層体の内側に、前記コア体を配置して母材を得て、前記母材を伸線ダイスに通して伸線加工することによって、前記コア体によって形成された中心導体と、前記外層体によって形成されて前記中心導体を覆う外層と、を有する電線を得る。
次に、図1に示す電線10を製造する方法を例として、本実施形態に係る電線の製造方法について説明する。
図2は、第1実施形態に係る電線の製造方法に用いられる母材20を示す断面図である。
図2に示すように、コア体11と、外層体12とを用意する。
コア体11は、前述の中心導体1の構成材料である金属、例えば、アルミニウム含有材料、銅含有材料などから構成される。コア体11は、長さ方向に直交する断面が円形となる形状である。
外層体12は、円筒状(管状)に形成されており、例えば鉄管や鋼管の原料材を用いることができる。外層体12は、円筒の全周において継ぎ目無く連続して形成されている。外層体12は、例えば圧延材である。外層体12の形成に使われる円筒状の原料材は、塩素などの不純物の含有量が少ない材料を用いることが好ましい。例えば、塩素(Cl)の濃度が、0.1wt%以下である原料材を用いることが好ましい。
外層体12の厚さは、母材20の軸周り方向において均一であることが望ましい。
径比(D11/D12)が85.1%以上であることによって、母材20を伸線加工する際に、コア体11の中心軸と外層体12の中心軸とがずれにくくなり、伸線ダイスによって、コア体11と外層体12との接合に適切な応力が得られる。また、コア体11の中心軸と外層体12の中心軸とのずれが起こりにくいため、外層2の厚さに偏りが生じにくい。そのため、外層2の薄い箇所に応力が集中することによる外層2の破損が起こりにくい。
径比(D11/D12)が99.4%以下であることによって、コア体11を外層体12に挿通させる操作が容易となる。
機械研磨は、例えばヤスリ、ドリル、ブラシなどの研磨器具などを用いて行うことができる。前記研磨器具とともに研磨剤(砥粒)を使用してもよい。機械研磨によって、コア体11の外面11aおよび外層体12の内面12aを粗面化し、微小な表面凹凸を形成することができる。また、機械研磨によって、コア体11の外面11aおよび外層体12の内面12aにおける酸化膜が除去される。
機械研磨を施した外面11aおよび内面12aの算術平均粗さRa(JIS B 0601(2013))は、例えば10μm以上、200μm以下としてよい。
塩酸による処理の温度条件は、例えば10~40℃であるが、酸による処理は、40℃を越える加温条件下で行ってもよい。
塩酸による処理は、コア体11および外層体12を酸処理剤に浸漬させる方法が好ましい。
塩酸による処理の処理時間は、例えば1~30分間(好ましくは1~10分間)としてよい。
なお、塩酸による処理は、コア体11の外面11aおよび外層体12の内面12aの両方に施してもよいし、コア体11の外面11aおよび外層体12の内面12aのうち一方にのみ施してもよい。
図3は、外層体12の変形例である外層体12Aを用いた母材20Aを示す図である。
図3に示すように、外層体12Aは、円筒状(管状)に形成されている。外層体12Aは、軸周り方向の一部に不連続となった箇所(継ぎ目)13がある点で、図2に示す外層体12と異なる。
母材20Aにおいても、母材20(図2参照)と同様に、外層体12Aの内径に対するコア体11の外径の比は、85.1%以上、99.4%以下であることが好ましい。
図4は、本実施形態に係る製造方法に適用可能な伸線ダイス30を示す模式図である。
図4に示すように、伸線ダイス30は、エントランス部31からリダクション部32にかけて徐々に内径が小さくなる構造を有する。
伸線加工は1回のみであってもよいが、内径寸法が異なる他の伸線ダイス30を用いて、複数回にわたり伸線工程を行うことによって、減面率を高めることができる。すなわち、複数の伸線ダイス30を用いて段階的に母材20の伸線を行うことができる。
減面率は「母材20の伸線前後の断面積差/母材20の伸線前の断面積」である。減面率は、母材20の軸方向に直交する母材20の断面積と、ベアリング部33の内部空間におけるベアリング部33の軸方向に直交する断面積と、によって算出することができる。
累積減面率は、例えば、70%以上とすることができる。
このような伸線加工により、図1に示す電線10が得られる。
本実施形態に係る製造方法は、めっき法を用いる製造方法と異なり、外層2に不純物(例えば塩素など)が混入しにくい。めっき法を用いる製造方法では、めっき液に含まれる不純物(例えば塩素など)がめっき膜中に残留することで、不純物を多く含んだ外層が形成される。上述の実施形態に係る製造方法によれば、加工中に外層2に不純物が混入することがないため、外層2の不純物濃度がめっき法で形成した場合よりも低くなる。そのため、外層2の磁気特性分布が均一となり、外層2を厚く形成しても磁気特性の低下が起こりにくい。よって、電線10を高周波機器のコイルに適用した場合において、高周波抵抗による電力伝送効率の低下および発熱を回避できる。
また、実施形態に係る製造方法は、めっき法を用いる製造方法に比べて、外層2の硬度を低く抑えることができる。そのため、電線10をコイル化する際に、電線10に破損が生じにくい。よって、取扱い性に優れた電線10が得られる。
さらに、実施形態に係る製造方法は、めっき法を用いる製造方法に比べて、外層2の形成に要する時間を短縮できる。また、廃液処理コストも削減できる。よって、製造コスト低減が可能である。
また、電線10は、上述のように、外層2の硬度を低く抑えることができる。そのため、電線10をコイル化する際に破損が生じにくい。よって、取扱い性に優れた電線10が得られる。
さらに、電線10は、上述のように、製造コスト低減が可能である。
本発明の第2実施形態に係る電線の製造方法は、鉄を含有する磁性金属から構成される筒状の外層体と、金属から構成され、かつ、前記外層体の内径に対する比が85.1%以上、99.4%以下である外径を有するコア体と、を準備し、前記外層体の内面、および、前記コア体の軸周りにおいて螺旋状の研磨痕を形成するように前記コア体の外面に機械研磨を施し、前記外層体の内側に、前記コア体を配置して母材を得て、前記母材を伸線ダイスに通して伸線加工することによって、前記コア体によって形成された中心導体と、前記外層体によって形成されて前記中心導体を覆う外層と、を有する電線を得る。
次に、第2実施形態に係る電線の製造方法について説明する。なお、本実施形態において、第1実施形態との共通部分については同じ符号を用い、説明を省略する場合がある。
図2に示すように、コア体11と、外層体12と、を用意する。
コア体11の外面11aおよび外層体12の内面12aには、機械研磨を施す。
機械研磨は、例えばヤスリ、ドリル、ブラシ、研磨剤(砥粒)などを用いて行うことができる。機械研磨によって、コア体11の外面11aおよび外層体12の内面12aが粗面化し、微小な表面凹凸を形成することができる。また、機械研磨によって、コア体11の外面11aおよび外層体12の内面12aにおける酸化膜が除去される。
機械研磨を施した外面11aおよび内面12aの算術平均粗さRa(JIS B 0601(2013))は、例えば10μm以上、200μm以下としてよい。
塩酸の濃度は、例えば0.1mol/l~12.1mol/l(好ましくは1mol/l~7mol/l)とすることができる。硝酸の濃度は、例えば0.1mol/l~14mol/l(好ましくは1mol/l~10mol/l)とすることができる。硫酸の濃度は、例えば0.1mol/l~18.25mol/l(好ましくは1mol/l~10mol/l)とすることができる。酸処理剤のpHは、例えばpH2以下である。
酸による処理の温度条件は、例えば10~40℃であるが、酸による処理は、40℃を越える加温条件下で行ってもよい。
酸による処理は、コア体11および外層体12のうち少なくとも一方を酸処理剤に浸漬させる方法が好ましい。酸による処理の処理時間は、例えば1~30分間(好ましくは1~10分間)としてよい。
なお、酸による処理は、コア体11の外面11aおよび外層体12の内面12aの両方に施してもよいし、コア体11の外面11aおよび外層体12の内面12aのうち一方にのみ施してもよい。
なお、本実施形態では、酸による処理は行わなくてもよい。
本工程では、第1実施形態と同様に、図4に示す伸線ダイス30を用いて、母材20を伸線加工し、図1に示す電線10を得る。
本実施形態に係る製造方法によれば、外層2の不純物濃度がめっき法で形成した場合よりも低くなる。そのため、外層2の磁気特性分布が均一となり、外層2を厚く形成しても磁気特性の低下が起こりにくい。よって、電線10を高周波機器のコイルに適用した場合において、高周波抵抗による電力伝送効率の低下および発熱を回避できる。
また、実施形態に係る製造方法は、めっき法を用いる製造方法に比べて、外層2の硬度を低く抑えることができる。そのため、電線10をコイル化する際に、電線10に破損が生じにくい。よって、取扱い性に優れた電線10が得られる。
さらに、実施形態に係る製造方法は、めっき法を用いる製造方法に比べて、外層2の形成に要する時間を短縮できる。また、廃液処理コストも削減できる。よって、製造コスト低減が可能である。
また、電線10は、上述のように、外層2の硬度を低く抑えることができる。そのため、電線10をコイル化する際に破損が生じにくい。よって、取扱い性に優れた電線10が得られる。
さらに、電線10は、上述のように、製造コスト低減が可能である。
電線10Aは、外層2の外周面に絶縁被覆層3が設けられている点で、図1の電線10と異なる。絶縁被覆層3は、例えば、ポリエステル、ポリウレタン、ポリイミド、ポリエステルイミド、ポリアミドイミドなどの絶縁材料から構成される。
換言すれば、高周波コイル70は、電線10Aと、胴部71と、前記胴部71の両端に形成された鍔部72と、を有し、かつ、前記胴部71に前記電線10Aが巻きつけられた支持体73と、を備える。
例えば、高周波コイル70は、電線10Aと、胴部71および前記胴部71の両端に形成された鍔部72を有する支持体73と、を準備し、前記電線10Aを前記胴部71に巻きつけて、製造してもよい。
図6では、高周波コイル70の製造に、電線10Aを用いた例を示したが、電線10Aを用いる場合に限定されず、例えば、上述の電線10、および、以下に示す電線10Bを用いてもよい。
また、上述の例では、支持体73に鍔部72が設けられた例を示したが、鍔部72が設けられていない支持体を用いてもよい。
換言すれば、高周波コイルは、電線と、胴部を有し、前記胴部に前記電線が巻きつけられた支持体と、を備えていてもよい。
また、高周波コイルは、電線と、胴部を有する支持体と、を準備し、前記電線を前記胴部に巻きつけて製造してもよい。
電線10Bは、中心導体1Aが、主部導体41と、主部導体41の外周面に形成された導体層42とから構成される点で、図1の電線10と異なる。主部導体41は、例えばアルミニウム含有材料などから構成される。導体層42は、例えば銅含有材料などから構成される。
外層体の内径に対するコア体の外径の比(径比)は、機械研磨および酸処理が施される前の測定値であってもよいし、機械研磨および酸処理の少なくとも一方が施された後の測定値であってもよい。通常、外層体の内径およびコア体の外径の測定値は機械研磨および酸処理の前、ならびに、機械研磨および酸処理の後でほとんど変わらない。
電線10は、例えば100kHz以上の高周波電流を通電する機器で使用できる。
図1に示す電線10を、次のようにして作製した。
図2に示すように、コア体11および外層体12を用意した。試験例1~4,7~9では、コア体11は銅含有材料(Cu系)から構成される。試験例10~12,15~18では、コア体11はアルミニウム含有材料(Al系)から構成される。
外層体12の仕様を表2に示す。コア体11の仕様を表3に示す。コア体11および外層体12の長さは80cmとした。
コア体11および外層体12の表面は、三協化学製のメタルクリーナーで洗浄した。
酸による処理には、塩酸(濃度7mol/l)または硝酸(濃度10mol/l)を酸処理剤として使用した。表1に、使用した酸処理剤を示す。併せて、カッコ内に処理時間を示す。
機械研磨は、ヤスリまたは回転ドリルを研磨器具として使用した。ヤスリとしては、リファインテック製の#240を使用した。回転ドリルとしては、日立工機製の日立電子ハンドグライング(KC-20)を使用した。ヤスリ、回転ドリルのいずれの場合も、コア体11および外層体12を、50mm/sの速度で長手方向または螺旋方向に研磨した。
ヤスリを用いた場合は、コア体11の外面11aおよび外層体12の内面12aに、コア体11および外層体12の長手方向の研磨痕(表面凹凸)が形成された。回転ドリルを用いた場合は、コア体11の外面11aに、コア体11の軸周りにおける螺旋状の研磨痕(表面凹凸)が形成された。
図4に示すように、母材20を、複数の伸線ダイス30に通して段階的に伸線を行い、電線10を得た。一度の伸線加工における減面率は10%~20%とした。
試験例1~4,7~9では、電線10の外径は0.4mmである。
試験例10~12,15~18では、電線10の外径は1.0mmである。
比透磁率の測定には、東栄科学産業製のVSM装置を使用した。測定条件は以下のとおりである。
磁場印加方向:電線の長手方向
磁場範囲:-8×105~8×105A/m
比透磁率の測定位置:1×104A/m
ビッカース硬さは、ビッカース硬さ試験機(Mitutoyo社製のビッカース試験機HM-200)を用いて、試験力0.1~0.5N,保持時間15secにて測定した。
電線10について、外層2の厚さを測定した。
結果を表1に示す。
「伸線加工」では、伸線加工が問題なく可能であった場合、「良」と評価した。また、伸線加工において断線が発生した場合、「断線」と記載した。
中心導体の外周面にめっき法によって外層を形成することによって電線を作製した。
試験例5,6では、中心導体(外径0.4mm)はアルミニウム含有材料から構成される。試験例13,14では、中心導体(外径1.0mm)は銅含有材料から構成される。中心導体1の外径は1.0mmである。
いずれの試験例(試験例5,6,13,14)も、外層は、鉄(Fe)から構成される。
めっき液組成:FeCl2・4H2O(300g/l),CaCl2(335g/l)
浴温:90℃
電流密度:6.5A/dm2
pH:1.0
結果を表1に示す。
試験例7,15~17では、めっき法により外層を形成する試験例5,6,13,14とは異なり、外層2が厚い場合でも、比透磁率を高い値とすることができたことが確認された。また、試験例7,15~17では、外層2の硬さが低かった。
試験例8,9,18では、めっき法により外層を形成する試験例5,6,13,14とは異なり、外層2が厚い場合でも、比透磁率を高い値とすることができたことが確認された。また、試験例8,9,18では、外層2の硬さが低かった。
Claims (8)
- 電線の製造方法であって、
鉄を含有する磁性金属から構成される筒状の外層体と、金属から構成され、かつ、前記外層体の内径に対する比が85.1%以上、99.4%以下である外径を有するコア体と、を準備し、
前記外層体の内面、および、前記コア体の外面に機械研磨を施し、
前記外層体の前記内面および前記コア体の前記外面のうち少なくとも一方を塩酸により処理し、
前記外層体の内側に、前記コア体を配置して母材を得て、
前記母材を伸線ダイスに通して伸線加工することによって、前記コア体によって形成された中心導体と、前記外層体によって形成されて前記中心導体を覆う外層と、を有する電線を得る、
電線の製造方法。 - 電線の製造方法であって、
鉄を含有する磁性金属から構成される筒状の外層体と、金属から構成され、かつ、前記外層体の内径に対する比が85.1%以上、99.4%以下である外径を有するコア体と、を準備し、
前記外層体の内面、および、前記コア体の軸周りにおいて螺旋状の研磨痕を形成するように前記コア体の外面に機械研磨を施し、
前記外層体の内側に、前記コア体を配置して母材を得て、
前記母材を伸線ダイスに通して伸線加工することによって、前記コア体によって形成された中心導体と、前記外層体によって形成されて前記中心導体を覆う外層と、を有する電線を得る、
電線の製造方法。 - 前記外層体の前記内面および前記コア体の前記外面のうち少なくとも一方を酸により処理する、請求項2に記載の電線の製造方法。
- 前記母材を伸線加工するにあたり、一度の伸線加工における減面率は10%以上、20%以下である、請求項1~3のうちいずれか1項に記載の電線の製造方法。
- 電線であって、
金属から構成される中心導体と、鉄を含有する磁性金属から構成され、厚みが3μm以上であり、ビッカース硬さが350Hv未満であり、かつ、前記中心導体を覆う外層と、を備える、
電線。 - 前記外層のCl濃度は、0.1wt%以下である、請求項5に記載の電線。
- 請求項5に記載の電線と、
胴部を有し、前記胴部に前記電線が巻きつけられた支持体と、を備える、
高周波コイル。 - 請求項5に記載の電線と、胴部を有する支持体と、を準備し、
前記電線を前記胴部に巻きつける、
高周波コイルの製造方法。
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