WO2020034300A1 - 一种具有方形截面形状的漆包线制造方法 - Google Patents

一种具有方形截面形状的漆包线制造方法 Download PDF

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Publication number
WO2020034300A1
WO2020034300A1 PCT/CN2018/106361 CN2018106361W WO2020034300A1 WO 2020034300 A1 WO2020034300 A1 WO 2020034300A1 CN 2018106361 W CN2018106361 W CN 2018106361W WO 2020034300 A1 WO2020034300 A1 WO 2020034300A1
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wire
section
enameled wire
length
wires
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PCT/CN2018/106361
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English (en)
French (fr)
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沈晓宇
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浙江东尼电子股份有限公司
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Publication of WO2020034300A1 publication Critical patent/WO2020034300A1/zh

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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
    • 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
    • H01B13/065—Insulating conductors with lacquers or enamels

Definitions

  • the present invention relates to the technical field of enameled wire, and in particular, to a method for manufacturing an enameled wire having a square cross-sectional shape.
  • Enameled wire is composed of two parts: conductor and insulation layer. It is widely used as electric wire for motors, compilers and other motor coils. Enameled wire is generally made by annealing and softening the bare wire, and then painting and baking multiple times. Enameled wire is divided into round enameled wire and flat enameled wire. Compared with round enameled wire, flat enameled wire has higher power conversion efficiency, and has better flexibility and flexibility. It is especially suitable for electrical and electronic equipment.
  • Invention patent CN106409403B discloses a flat enameled wire manufacturing process, and specifically discloses that the process includes: (1) smelting copper-aluminum alloy, rolling and stretching until a strip-shaped alloy wire of a desired thickness is obtained; (2) configuring resistance Coating solution for oxidation layer, the strip alloy wire is immersed in the container filled with the coating solution, so that the surface of the strip alloy wire is wrapped with the desired thickness of the anti-oxidation layer; Polyurethanes, self-adhesive paints and lubricants of the required thickness are available.
  • the invention improves from the perspective of raw materials, reduces the use of copper materials, makes the three-phase resistance of the enameled wire lower than that of general copper enameled wire, and the enameled wire has better performances such as no-load speed and maximum torque.
  • the present invention proposes a method for manufacturing an enameled wire having a square cross-sectional shape with high dimensional accuracy and uniform paint film.
  • the invention provides a method for manufacturing an enameled wire with a square cross-sectional shape, including:
  • Step S01 drawing a copper wire to obtain a strip-shaped wire of a desired thickness
  • Step S02 the rolled wire is subjected to a rolling process, and the strip-shaped wire is rolled into a flat wire;
  • step S03 the flat wire is shaped by a mold to form a regular wire with a square cross-section
  • Step S04 coating an insulating film on the wire having a square cross-section shape
  • Step S05 winding to obtain a molded enameled wire.
  • the step S01 further includes:
  • Step S11 drawing the hard copper wire from a raw material state into a medium-sized strip-shaped wire by using a medium-pulling machine
  • step S12 the micro-sized wire is drawn into a micro-sized wire by using a micro-drawing machine.
  • step S03 is specifically: shaping the flat conductive wire by using a mold, and shaping to have rounded chamfers at the four corners of the cross section.
  • step S04 further includes:
  • Step S41 annealing and shaping the conductive wires
  • step S05 includes: cooling the conductive wire after applying the insulating film, and obtaining a molded enameled wire by using a winding machine.
  • the ratio of the length of the wide side to the length of the narrow side of the cross-section after coating is 1.0-10.0.
  • the ratio of the chamfered radius to the narrow side length of the cross-section after coating is 0.15-0.50.
  • the length of the narrow side of the cross-section after coating is 0.05-0.5 mm.
  • the invention discloses a method for manufacturing an enameled wire with a square cross-sectional shape.
  • the manufactured enameled wire has high dimensional accuracy, uniform paint film thickness, and high power conversion rate.
  • FIG. 1 is a flow chart of a conventional enameled wire processing process
  • FIG. 2 is a flowchart of a method for manufacturing an enameled wire with a square cross-sectional shape according to the present invention
  • FIG. 3 is a cross-sectional view of an enameled wire having a square enameled wire manufacturing method according to the present invention
  • FIG. 5 is a schematic diagram of a filling rate range after a coil is wound according to FIG. 3 to form a coil. .
  • FIG. 1 shows a conventional process flow of an enameled wire.
  • the raw material copper wire is stretched until a strip-shaped wire of a desired thickness is obtained, and then annealing, coating, and winding to form an enameled wire are sequentially performed.
  • the enameled wire produced by the current general manufacturing process is a round enameled wire, and its power conversion efficiency is not high enough.
  • the present invention provides a method for manufacturing an enameled wire with a square cross-sectional shape, including:
  • step S03 the flat wire is shaped by a mold to form a regular wire with a square cross-section
  • Step S04 coating an insulating film on the wire having a square cross-section shape
  • Step S05 winding to obtain a molded enameled wire.
  • step S01 further includes:
  • step S11 the hard copper wire is drawn from the raw material state into a medium-sized bar-shaped wire by using a medium-drawing machine.
  • a copper wire with a diameter of 1.13 mm is first drawn by using a medium-drawing machine to a 0.25-mm-diameter wire.
  • step S12 the micro-sized wire is drawn into a micro-sized wire with a micro-drawing machine.
  • a micro-drawing machine For example, a 0.25 mm diameter wire is drawn with a micro-drawing machine to a micro-level wire.
  • the cross section of the strip-shaped wire is circular. After each drawing step, a laser is used to check whether the drawn wire is uniform.
  • the strip conductor is rolled into a flat conductor by rotating the two sides of the strip conductor in opposite directions.
  • the flattened wire after rolling is approximately uniform in thickness, but the rolling around is not smooth enough, and it is necessary to perform shaping in step S03.
  • Step S03 is specifically: using a mold to shape the flat wire, the four corners of which are shaped to have a rounded chamfer.
  • the cross section of the flat wire after rolling in step S02 is an irregular cross section, that is, it is not a square or rectangular cross section.
  • the opposite sides are relatively parallel and become rectangular or square.
  • the die is a diamond wire drawing die, which has a shaping hole therein, and a cross-section with a quadrangular arc-shaped chamfered cross-section is formed through the shaping hole to facilitate subsequent coating film uniformity and good electrical performance.
  • Step S04 further includes:
  • Step S41 annealing and shaping the conductive wires
  • step S42 an insulating film made of PU and PA materials is coated on the outer wires.
  • the shaped wire is annealed in an oven, and the hard wire is annealed into a soft wire.
  • the insulating film is made of PU and PA materials and coated on the outside of the wire. After that, the conductive wire coated with the insulating film is cooled, and a laser is used to detect whether the thickness of the conductive wire coated with the insulating film is uniform. Finally, a winding machine is used to obtain the formed enameled wire.
  • the cross section of the enameled wire manufactured by the above method is square.
  • the enameled wire with a square cross-section is wound in a parallel winding manner, and the gap between adjacent enameled wires is small, and the conductor filling rate is high.
  • this enameled wire is used to wind the wireless charging receiving coil (as shown in Figure 4).
  • the four wires are fed together. After winding, its filling rate is much higher than 78.5%.
  • the ratio of the wide side length (W) to the narrow side length (N) of the square section is 1.0-10.0.
  • the wide side length W refers to a lateral distance from one side to the other side of the cross section of the conductor.
  • the narrow side length N refers to the longitudinal distance from the side of the cross section of the conductor to the lower side.
  • the length of the narrow side is 0.05-0.5 mm.
  • the ratio of the length of the wide side to the length of the narrow side of the square section is 1.0, then the length of the wide side is 0.05mm, and the square section is a square section with a side length of 0.05mm.
  • the ratio of the length of the wide side to the length of the narrow side of the square section is 10.0, then the length of the wide side is 0.5mm, and the square section is a rectangular section of 0.05mm * 0.5mm.
  • the ratio of the wide side length to the narrow side length of the square section is 1.0, then the wide side length is 0.5mm, and the square section is a square section with a side length of 0.5mm;
  • the ratio of the wide side length to the narrow side length of the square section is 10.0, then the wide side length is 5mm, and the square section is a rectangular section of 0.5mm * 5mm.
  • the ratio of the chamfered radius R to the length of the narrow side is 0.15-0.50.
  • the chamfer radius to narrow side length ratio is 0.15, and the chamfer radius is 0.0075 mm;
  • the narrow side length is 0.5 mm, the chamfer The ratio of the radius to the length of the narrow side is 0.5, and the chamfered radius is 0.25 mm.
  • the ratio of the chamfer radius to the length of the narrow side is 0.15, and the radius of the chamfer is 0.075 mm; when the length of the narrow side is 0.5 mm, the chamfer The ratio of the corner radius to the narrow side length is 0.5, and the chamfer radius is 0.25 mm.
  • FIG. 5 shows the filling rate range of the enameled wire with different square cross-section shapes after the coil is wound according to the present invention, showing 4 cases, respectively: the chamfer radius is 0.2mm, and the ratio of the length of the wide side to the length of the narrow side is 1.0 -2.0 (one division per 0.1); chamfer radius is 0.3mm, the ratio of the length of the wide side to the length of the narrow side is 1.0-2.0 (one cell per 0.1); the radius of the chamfer is 0.4mm, the length of the wide side and the narrow side The length ratio is 1.0-2.0 (one cell per 0.1); the chamfer radius is 0.5mm, and the ratio of the length of the wide side to the length of the narrow side is 1.0-2.0 (one cell per 0.1).
  • the filling rate is at least 96%, gradually increases, and rises to a maximum of about 99%.
  • the filling rate decreases by 4% -7% for every 0.1mm increase.
  • the filling rate is 78.54%.
  • the narrow side length to length ratio is 2.0, the filling rate can reach about 90%.
  • the method according to the present invention can be used for batch production of enameled wire with good continuity of the enameled film according to the sectional size requirements of the enameled wire.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Insulated Conductors (AREA)
  • Non-Insulated Conductors (AREA)

Abstract

一种具有方形截面形状的漆包线制造方法，属于漆包线技术领域。本发明方法包括：步骤S01，将铜线拉丝得到所需厚度的条形导线；步骤S02，对拉丝后的导线进行压延处理，将条形导线压延呈扁平状导线；步骤S03，利用模具将具有扁平状的导线进行整形处理，整形为规整的具有方形截面形状的导线；步骤S04，在具有方形截面形状的导线外涂覆绝缘膜；步骤S05，绕线获得成型漆包线。本发明制造出的漆包线尺寸精度高，漆膜厚度均匀，电能转换率高。

Description

一种具有方形截面形状的漆包线制造方法 技术领域
本发明涉及漆包线技术领域，尤其涉及一种具有方形截面形状的漆包线制造方法。
 背景技术
漆包线由导体和绝缘层两部分组成，其广泛用作电动机、编译器等电机的线圈用电线。漆包线一般是将裸线经退火软化，然后再经过多次涂漆，烘焙而成。漆包线分为圆漆包线和扁平漆包线，扁平漆包线与圆漆包线相比，电能转化效率更高，且具有更佳的柔软性和挠性，特别适合用于电气、电子设备。
发明专利CN106409403B公开了一种扁平漆包线制造工艺，并具体公开了该工艺包括：（1）熔炼铜铝合金，轧制、拉伸，直至得到所需厚度的条形合金导线；（2）配置抗氧化层用覆层液，条形合金导线浸入注满覆层液的容器中，使条形合金导线表面包裹所需厚度的抗氧化层；（3）在抗氧化层的两侧，依次涂覆所需厚度的聚氨酯、自粘漆和润滑剂，即得。该发明从原材料的角度进行改进，减少了铜材料的使用量，使得制成的漆包线三相电阻比一般铜漆包线低，且该漆包线空载转速、最大扭矩等各项性能更优。
 技术问题
本发明针对现有技术存在的问题，提出了一种漆包线尺寸精度高、漆膜均匀的具有方形截面形状的漆包线制造方法。
 技术解决方案
本发明是通过以下技术方案得以实现的：
本发明一种具有方形截面形状的漆包线制造方法，包括：
步骤S01，将铜线拉丝得到所需厚度的条形导线；
步骤S02，对拉丝后的导线进行压延处理，将条形导线压延呈扁平状的导线；
步骤S03，利用模具将扁平状的导线进行整形处理，整形为规整的具有方形截面形状的导线；
步骤S04，在具有方形截面形状的导线外涂覆绝缘膜；
步骤S05，绕线获得成型漆包线。
作为优选，所述步骤S01进一步包括：
步骤S11，利用中拉机将硬质铜线从原材料状态拉丝成中型尺寸的条形导线；
步骤S12，利用微拉机将中型尺寸的条形导线拉丝成微型尺寸的条形导线。
作为优选，步骤S03具体为：利用模具将扁平状的导线进行整形，整形为截面四角处具有圆弧形倒角。
作为优选，步骤S04进一步包括：
步骤S41, 退火处理整形后的导线；
步骤S42，在导线外涂覆PU和PA材料构成的绝缘膜。
作为优选，步骤S05具体包括：对涂覆绝缘膜后的导线进行冷却，利用绕线机获得成型漆包线。
作为优选，涂膜后的截面的宽边长度与窄边长度比为1.0-10.0。
作为优选，涂膜后的截面的倒角半径与窄边长度比为0.15-0.50。
作为优选，涂膜后的截面的窄边长度为0.05-0.5mm。
 有益效果
本发明一种具有方形截面形状的漆包线制造方法，制造出的漆包线尺寸精度高，漆膜厚度均匀，电能转换率高。
 附图说明
图1为现有漆包线加工工艺流程图；
图2为本发明一种具有方形截面形状的漆包线制造方法的流程框图；
图3为依据本发明一种具有方形漆包线制造方法制造漆包线的截面图；
图4为依据图3漆包线绕制成线圈的截面图；
图5为依据图3漆包线绕制成线圈后的填充率范围示意图。。
 本发明的最佳实施方式
以下是本发明的具体实施例并结合附图，对本发明的技术方案作进一步的描述，但本发明并不限于这些实施例。
图1示出了现有漆包线加工工艺流程。首先对将原材料铜线拉伸，直至得到所需厚度的条形导线，之后依次进行退火、涂膜以及卷绕为成型漆包线。利用目前通用的制造工艺所制成的漆包线为圆漆包线，其电能转换效率不够高。
现有在上述工艺基础上制造扁平漆包线，一般在退火涂膜前进行压延，将条线漆包线导线部分压延成扁平状。然而，该方法制成的漆包线漆膜连续性差。且扁平状的漆包线呈各种截面形态，且截面形状为不规整的方形或椭圆形，甚至是多边形，当用于绕制线圈时，各线圈间隙差异不同，难以优化利用线圈空间。
为此，如图2，本发明提供一种具有方形截面形状的漆包线制造方法，包括：
步骤S01，将铜线拉丝得到所需厚度的条形导线；
步骤S02，对拉丝后的导线进行压延处理，将条形导线压延呈扁平状的导线；
步骤S03，利用模具将扁平状的导线进行整形处理，整形为规整的具有方形截面形状的导线；
步骤S04，在具有方形截面形状的导线外涂覆绝缘膜；
步骤S05，绕线获得成型漆包线。
具体地，所述步骤S01进一步包括：
步骤S11，利用中拉机将硬质铜线从原材料状态拉丝成中型尺寸的条形导线，如将1.13mm直径的铜线先利用中拉机拉丝到0.25mm直径的条形导线。
步骤S12，利用微拉机将中型尺寸的条形导线拉丝成微型尺寸的条形导线，如将0.25mm直径的导线利用微拉机拉丝到微米级别的条形导线。
其中，所述条形导线的截面呈圆形。在每次拉丝步骤结束后，利用激光检测拉丝成型的条形导线是否均匀。
之后，利用压机，如两个压力轮作用在条形导线两侧，通过两两反方向旋转作用条形导线两侧的方式，将条形导线压延为扁平状导线。且，压延后的扁平状导线大致均匀厚度，但四周压延不够圆滑，需通过步骤S03进行整形。
步骤S03具体为：利用模具将扁平状导线进行整形，整形为截面的四角具有圆弧形倒角。步骤S02压延后的扁平状导线的截面为不规整截面，即不是正方形或长方形截面，在利用步骤S03模具规整后，使得对边相对平行，呈长方形或正方形。该模具为金刚石拉丝模，其内具有整形孔，通过该整形孔形成截面成具有四角圆弧形倒角的方形截面，以便于后续涂膜均匀，电性能良好。
步骤S04进一步包括：
步骤S41, 退火处理整形后的导线；
步骤S42，在导线外涂覆PU和PA材料构成的绝缘膜。
将整形后的导线通过烤箱进行退火处理，将硬质导线退火为软质导线，利用PU和PA材料制成绝缘膜，涂覆在导线外。之后，对涂覆绝缘膜后的导线进行冷却，且利用激光检测涂覆绝缘膜的导线厚度是否均匀。最后，利用绕线机获得成型漆包线。
如图3、4，利用上述方法制造的漆包线，其截面为方形。该具有方形截面形状的漆包线采用平行绕线的方式绕制线圈，相邻漆包线之间空隙较小，导体填充率高。例如，采用该漆包线绕制无线充电接收线圈（如图4），绕制时4根线一起进线。绕制后，其填充率远高于78.5%。
具体地，方形截面的宽边长度(W)与窄边长度（N）之比为1.0-10.0。所述宽边长度W指的是自导体横截面的一侧边至另一侧边的横向距离。所述窄边长度N指的是自导体横截面上边至下边的纵向距离。
其中，所述窄边长度为0.05-0.5mm。例如，当窄边长度为0.05mm时，方形截面的宽边长度与窄边长度之比为1.0，则宽边长度为0.05mm，则方形截面为边长为0.05mm的正方形截面；当窄边长度为0.05mm时，方形截面的宽边长度与窄边长度之比为10.0，则宽边长度为0.5mm，则方形截面为0.05mm*0.5mm的长方形截面。又如，当窄边长度为0.5mm时，方形截面的宽边长度与窄边长度之比为1.0，则宽边长度为0.5mm，则方形截面为边长为0.5mm的正方形截面；当窄边长度为0.5mm时，方形截面的宽边长度与窄边长度之比为10.0，则宽边长度为5mm，则方形截面为0.5mm*5mm的长方形截面。
所述倒角半径R与窄边长度比为0.15-0.50。例如，当所述窄边长度为0.05mm时，所述倒角半径与窄边长度比为0.15，所述倒角半径为0.0075mm；当所述窄边长度为0.5mm时，所述倒角半径与窄边长度比为0.5，所述倒角半径为0.25mm。又如，当所述窄边长度为0.5mm时，所述倒角半径与窄边长度比为0.15，所述倒角半径为0.075mm；当所述窄边长度为0.5mm时，所述倒角半径与窄边长度比为0.5，所述倒角半径为0.25mm。
图5示出了本发明具有不同方形截面形状的漆包线绕制线圈后的填充率范围，示出了4种情况，分别为：倒角半径为0.2mm，宽边长度与窄边长度比为1.0-2.0（每0.1为一格）；倒角半径为0.3mm，宽边长度与窄边长度比为1.0-2.0（每0.1为一格）；倒角半径为0.4mm，宽边长度与窄边长度比为1.0-2.0（每0.1为一格）；倒角半径为0.5mm，宽边长度与窄边长度比为1.0-2.0（每0.1为一格）。
当倒角半径为0.2mm，宽边长度与窄边长度比自1.0上升到2.0的过程中，填充率至少为96%，逐渐上升，上升到最高约99%。随着倒角半径增大，每增大0.1mm，填充率就会下降4%-7%。图中可见，当倒角半径为0.5mm，宽边长度与窄边长度比为1.0时，填充率为78.54%，此处填充率接近圆漆包线绕制线圈时的填充率，当宽边长与窄边长按长度比为2.0时，填充率可达到约90%。
图中四种情况可见，当倒角半径不变时，随着宽边长度与窄边长度比增大，填充率增大。也就是说，当窄边长度一定时，即厚度一致时，长度比越大，宽边长度越大；而当宽边长度一定时，长度比越大，窄边长度越小，即厚度越薄。且四种情况对比，倒角半径为0.5mm的一组，填充率增长幅度较于其他两组更明显。
本发明方法根据漆包线截面尺寸要求，可用于批量性生产漆膜连续性好的漆包线。
本领域的技术人员应理解，上述描述及附图中所示的本发明的实施例只作为举例而并不限制本发明。本发明的目的已经完整有效地实现。本发明的功能及结构原理已在实施例中展示和说明，在没有背离所述原理下，本发明的实施方式可以有任何变形或修改。

Claims (8)

  1. 一种具有方形截面形状的漆包线制造方法，其特征在于，包括：
    步骤S01，将铜线拉丝得到所需厚度的条形导线；
    步骤S02，对拉丝后的导线进行压延处理，将条形导线压延呈扁平状的导线；
    步骤S03，利用模具将扁平状的导线进行整形处理，整形为规整的具有方形截面形状的导线；
    步骤S04，在具有方形截面形状的导线外涂覆绝缘膜；
    步骤S05，绕线获得成型漆包线。
  2. 根据权利要求1所述的一种具有方形截面形状的漆包线制造方法，其特征在于，所述步骤S01进一步包括：
    步骤S11，利用中拉机将硬质铜线从原材料状态拉丝成中型尺寸的条形导线；
    步骤S12，利用微拉机将中型尺寸的条形导线拉丝成微型尺寸的条形导线。
  3. 根据权利要求1所述的一种具有方形截面形状的漆包线制造方法，其特征在于，步骤S03具体为：利用模具将扁平状的导线进行整形，整形为截面四角处具有圆弧形倒角。
  4. 根据权利要求1所述的一种具有方形截面形状的漆包线制造方法，其特征在于，步骤S04进一步包括：
    步骤S41, 退火处理整形后的导线；
    步骤S42，在导线外涂覆PU和PA材料构成的绝缘膜。
  5. 根据权利要求1所述的一种具有方形截面形状的漆包线制造方法，其特征在于，步骤S05具体包括：对涂覆绝缘膜后的导线进行冷却，利用绕线机获得成型漆包线。
  6. 根据权利要求3所述的一种具有方形截面形状的漆包线制造方法，其特征在于，涂膜后的截面的宽边长度与窄边长度比为1.0-10.0。
  7. 根据权利要求6所述的一种具有方形截面形状的漆包线制造方法，其特征在于，涂膜后的截面的倒角半径与窄边长度比为0.15-0.50。
  8. 根据权利要求7所述的一种具有方形截面形状的漆包线制造方法，其特征在于，涂膜后的截面的窄边长度为0.05-0.5mm。
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