JP4190779B2 - Manufacturing method of resin insulation coated edgewise coil - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a resin insulation coated edgewise coil, a method for producing an insulation coated edgewise coil, an insulation coated rectangular electric wire, and a method for producing a resin insulation coated rectangular electric wire. BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin insulation coated edgewise coil and an insulation coated edgewise coil that are equivalent on the inner peripheral side, an insulation coated rectangular electric wire used for carrying out the method, and a method for producing the same.
[0002]
[Prior art]
FIG. 11 is a perspective view showing an example of a conventional resin insulation coated rectangular electric wire. 12 is a cross-sectional view taken along the line PP ′ of FIG.
The resin insulation-coated rectangular electric wire 51 has a structure in which a resin insulation coating 52 having a constant coating thickness τ ′ is formed around a rectangular conductor 1 having a flat rectangular cross section.
The dimensions of the resin insulation covered rectangular electric wire 51 are, for example, a width W of 2 mm, a thickness h of the rectangular conductor 1 of 0.18 mm, and a coating thickness τ of 0.1 mm.
[0003]
FIG. 13 is a perspective view showing a resin insulation coated edgewise coil 500 manufactured by edgewise winding the resin insulation coated flat wire 51 (a coil winding method in which the longitudinal direction of the flat cross section of the flat wire is a radial direction). . In addition, the reference code of the resin insulated coated rectangular electric wire after winding is changed to 51a.
The inner diameter d of the resin insulation coating edgewise coil 500 is, for example, 5 mm.
[0004]
FIG. 14 is an end view taken along the line QQ ′ of FIG. FIG. 15 is an enlarged view of a broken line portion α ′ in FIG.
The coating thickness τo on the outer peripheral side is smaller than the coating thickness τi on the inner peripheral side of the resin insulation coating 52. For example, the coating thickness τo on the outer peripheral side is 0.071 mm while the coating thickness τi on the inner peripheral side is 0.128 mm. That is, the ratio of the outer peripheral coating thickness τo to the inner peripheral coating thickness τi is preferably 1, but in practice it is 0.55.
The reason why the coating thickness changes in this way is that the inner peripheral length of the ring formed by edgewise winding is compressed by the contraction stress and the outer peripheral length of the ring is extended by the extension stress.
[0005]
The coating thickness of the resin insulation coating edgewise coil 500 will be considered with reference to FIGS.
As shown in FIG. 16, the width in the longitudinal direction of the flat cross section of the resin insulation coating 52 is W, the total length is L, and the coating thickness is τ. Then, assuming a portion a, b having a minute width δ at both ends in the longitudinal direction of the flat cross section and a portion c having a minute width δ having a distance e from the portion a in the longitudinal direction, the volume of these portions a, b, c is defined as Va. , Vb, Vc.
Volumes Va, Vb, and Vc are expressed by the following equations.
Va = Vb = Vc = L × τ × δ (1)
[0006]
Next, as shown in FIG. 17, the resin insulation coating 52 is edgewise wound with an inner diameter d so that the portion a is on the inner peripheral side and the portion b is on the outer peripheral side. The minute widths δ of the portions a, b, and c are unchanged, and the thicknesses are τi, τo, and τc. Let VA, VB, VC be the volumes of the parts a, b, c after edgewise winding.
Volumes VA, VB, and VC are expressed by the following equations.
VA = π × d × τi × δ (2)
VB = π × (d + 2 × W) × τo × δ (3)
VC = π × (d + 2 × e) × τc × δ (4)
[0007]
If the volume is assumed to be unchanged before and after edgewise winding,
Va = VA (5)
Vb = VB (6)
Vc = VC (7)
Therefore, from the above equations (1), (2) and (5),
L × τ × δ = π × d × τi × δ
If you organize,
τi / τ = L / (π × d) (8)
Similarly,
τo / τ = L / {π × (d + 2 × W)} (9)
τc / τ = L / {π × (d + 2 × e)} (10)
It is.
[0008]
Here, if the length in the part c is the same before and after the edgewise winding,
L = π × (d + 2 × e) (11)
So if you substitute this,
τi / τ = (d + 2 × e) / d (12)
τo / τ = (d + 2 × e) / (d + 2 × W) (13)
τc / τ = 1 (14)
It becomes.
[0009]
As a numerical example, if d = 5 mm, W = 2 mm, e = 0.7 mm,
τi / τ = 1.28 (15)
τo / τ = 0.71 (16)
It becomes. That is, the coating thickness τi on the inner peripheral side is 28% thicker than the original coating thickness τ, and the coating thickness τo on the outer peripheral side is 29% thinner than the original coating thickness τ.
[0010]
[Problems to be solved by the invention]
In the conventional resin insulation coating edgewise winding coil 500, the coating thickness of the resin insulation coating 52 on the outer peripheral side is smaller than that on the inner peripheral side, and there is a problem that the insulation performance on the outer peripheral side is lower than that on the inner peripheral side.
In addition, in the conventional resin insulation coated flat electric wire 51, when the edgewise winding is performed, the coating thickness of the resin insulation coating 52 on the outer peripheral side is smaller than the inner peripheral side, and the insulation performance on the outer peripheral side is smaller than that on the inner peripheral side. There is a problem that decreases.
Therefore, an object of the present invention relates to a resin insulation coated edgewise coil, a method for producing an insulation coated edgewise coil, an insulation coated rectangular electric wire, and a method for producing a resin insulation coated rectangular electric wire. Provided are a resin insulation-coated edgewise coil and an insulation-coated edgewise coil that are equivalent on the outer peripheral side and the inner peripheral side of the wire, a method for manufacturing the insulation-coated edgewise coil, and a method for manufacturing the same. It is in.
[0011]
[Means for Solving the Problems]
In a first aspect, the present invention is a resin insulation-coated edgewise coil obtained by edgewise winding a resin insulation-coated rectangular electric wire, the coating thickness of the resin insulation coating on the outer peripheral side of the coil and the resin insulation on the inner peripheral side of the coil Provided is a resin insulation coated edgewise coil characterized in that the ratio of the coating thickness of the coating is 0.9 or more and 1.1 or less.
In the resin insulation coated edgewise coil according to the first aspect, since the difference in coating thickness is 10% or less, the same insulation performance can be obtained on the outer peripheral side and the inner peripheral side of the coil. That is, it is possible to prevent a disadvantage that the insulating performance on the outer peripheral side is lower than that on the inner peripheral side.
[0012]
In a second aspect, the present invention provides an insulation-coated rectangular electric wire in which an insulation coating is formed around a flat conductor having a flat cross section so that the coating thickness changes from one end side to the other end side in the longitudinal direction of the flat cross section. An insulating coated edgewise coil manufacturing method is provided, wherein edgewise winding is performed so that the end surface on the side with the larger coating thickness becomes the outer peripheral surface of the coil.
In the insulation-coated edgewise coil according to the second aspect, an insulation-coated rectangular electric wire formed with an insulation coating so that the coating thickness changes from one end side to the other end side in the longitudinal direction of the flat cross section is used, and the coating thickness is large. Since the edgewise winding is performed so that the side becomes the outer peripheral surface of the coil, the insulating coating on the outer peripheral side is extended compared to the inner peripheral side, and the coating thickness of the insulating coating is equal on the outer peripheral side and the inner peripheral side of the coil Become. Therefore, it is possible to prevent the inconvenience that the insulation performance on the outer peripheral side is lower than that on the inner peripheral side.
[0013]
In a third aspect, the present invention relates to a flat conductor having a flat cross section, and an insulating coating formed around the flat conductor so that the coating thickness changes from one end side to the other end side in the longitudinal direction of the flat cross section. An insulation-coated flat electric wire characterized by comprising:
In the insulation-coated flat wire according to the third aspect, the insulation thickness is equalized between the outer peripheral side and the inner peripheral side of the coil by performing edgewise winding so that the side with the larger coating thickness becomes the outer peripheral surface of the coil. An insulating coated edgewise coil can be manufactured.
[0014]
In a fourth aspect, the present invention provides the insulation coated rectangular electric wire having the above structure, wherein the material of the insulation coating is any one of polyolefin resin, polyester resin, polyamide resin, FEP, PFA, ETFE, or a combination thereof. An insulating coated rectangular electric wire is provided.
In the insulation-coated flat electric wire according to the fourth aspect, a resin insulation coating excellent in insulation, flexibility, durability, strength and the like can be formed.
[0015]
In a fifth aspect, the present invention provides a resin insulated coated rectangular electric wire characterized in that resin is extruded from a trapezoidal slit whose opening width changes from one end side to the other end side to cover the periphery of a traveling rectangular conductor. A manufacturing method is provided.
In the method for producing a resin insulation-coated flat wire according to the fifth aspect, since the resin is extruded from the trapezoidal slit, it is possible to form a resin insulation coating whose coating thickness varies from one end side to the other end side.
[0016]
DETAILED DESCRIPTION OF THE INVENTION
Embodiments of the present invention will be described below with reference to the drawings. Note that the present invention is not limited thereby.
[0017]
-First embodiment-
FIG. 1 is a perspective view showing a resin insulation coated rectangular electric wire according to the first embodiment. 2 is a cross-sectional view taken along the line PP ′ of FIG. For the convenience of illustration, the vertical direction is enlarged.
The resin insulation-coated rectangular electric wire 10 has a flat conductor 1 having a flat rectangular cross section, and a coating thickness linearly changing from one end side to the other end side in the longitudinal direction of the flat rectangular cross section around the flat conductor 1. And a resin insulation coating 2 formed.
[0018]
The width of the resin insulation-coated rectangular electric wire 10 is W, the coating thickness at one end in the longitudinal direction of the flat section of the resin insulation coating 2 is τa, the coating thickness at the other end is τb, and the coating thickness at a distance e from one end is τc. When edgewise winding is performed with the inner diameter d so that the portion of the distance e from one end maintains the original length,
τa = τc × d / (d + 2 × e) (17)
τb = τc × (d + 2 × W) / (d + 2 × e) (18)
And it is sufficient. However, in reality, there is a deformation in the radial direction, so some adjustment is required.
[0019]
As a numerical example, if τc = 0.1 mm, d = 5 mm, W = 2 mm, e = 0.7 mm,
τa = 0.078mm
τb = 0.140mm
Basically, you need to make some adjustments. This compensates in advance for the fact that after the edgewise winding, the coating thickness on the inner peripheral side is 28% thicker than the original coating thickness τa and the coating thickness on the outer peripheral side is 29% thinner than the original coating thickness τb. It is the thickness to keep.
[0020]
The material of the flat conductor 1 is, for example, copper, copper alloy, aluminum, aluminum alloy, or a combination of these metals.
[0021]
The material of the resin insulation coating 2 is, for example, polyolefin resin, polyester resin, polyamide resin, FEP (tetrafluoroethylene-hexafluoropropylene copolymer resin), PFA (tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer). Resin), ETFE (tetrafluoroethylene-ethylene copolymer resin), or a combination of these thermoplastic resins.
[0022]
FIG. 3 is an explanatory view showing a process for manufacturing the above-mentioned resin insulation coated flat electric wire 10.
The flat conductor 1 drawn out from a feeder (not shown) is inserted into the resin coating machine 21.
The resin coating machine 21 extrudes the resin J in the hopper 22 from a trapezoidal slit 23 of a die (not shown) by an extrusion mechanism to cover the periphery of the traveling flat conductor 1. Since the opening width of the trapezoidal slit 23 linearly changes from one end side to the other end side as shown in FIG. 4, the trapezoidal slit 23 linearly extends from one end side to the other end side in the longitudinal direction of the flat rectangular section of the flat conductor 1. A resin insulation-coated rectangular electric wire 10 on which the resin insulation coating 2 having a varying coating thickness is formed is obtained. Thereafter, the resin insulation-coated rectangular electric wire 10 is wound around a winder (not shown).
[0023]
FIG. 5 is a perspective view showing a resin insulation coated edgewise coil 100 manufactured by edgewise winding the resin insulation coated flat electric wire 10. It should be noted that the reference numeral of the resin-insulated flat wire after winding is changed to 10a.
The inner diameter d of the resin insulation coating edgewise coil 100 is, for example, 5 mm.
[0024]
When edgewise winding is performed, the resin insulation-coated rectangular electric wire 10 is wound so that the side with the larger coating thickness, that is, the side with the coating thickness τb becomes the outer peripheral side of the coil.
Moreover, it winds so that the part of distance e = W / 3 may maintain the original length from one end.
[0025]
FIG. 6 is an end view taken along the line QQ ′ of FIG. FIG. 7 is an enlarged view of a broken line portion α in FIG.
The coating thickness τc is uniform from the inner circumference side to the outer circumference side of the coil. In the above numerical example, τc = 0.1 mm.
Although the coating thickness may be different between the inner and outer peripheral sides of the coil due to subtle deformation of the flat conductor 1 and variations in the viscosity of the resin insulation coating 2, the ratio of the coating thickness is 0.9. It is within 1.1 and below.
[0026]
According to the resin insulation coating edgewise coil 100, since the difference in coating thickness between the inner circumference side and the outer circumference side of the coil is 10% or less, equivalent insulation performance can be obtained on the outer circumference side and the inner circumference side of the coil.
Moreover, according to the said resin insulation coating flat electric wire 10, it can be used conveniently for manufacture of the said resin insulation coating edgewise coil 100. FIG.
[0027]
-Second Embodiment-
If the resin insulation coatings 2-1, 2-2, 2-3 having a three-layer structure are formed as in the resin insulation coating flat electric wire 20 shown in FIG. 8, the insulation, durability, etc. can be further improved. .
[0028]
-Third embodiment-
The present invention can also be applied to the case of spiral winding like the resin insulation coated edgewise coil 200 shown in FIG.
[0029]
-Fourth Embodiment-
The present invention can also be applied to the case of alpha winding like the resin insulation coated edgewise coil 300 shown in FIG. In FIG. 10, the coil crossover portion 300a is shown exaggerated, but actually it is shorter.
[0030]
【The invention's effect】
According to the resin insulation coated edgewise coil and the manufacturing method thereof of the present invention, there is no difference in the coating thickness between the inner peripheral side and the outer peripheral side of the coil, so that the insulating performance on the outer peripheral side is lower than the inner peripheral side. Can be eliminated. Accordingly, it is possible to suitably manufacture a noise filter, a power inductor, a transformer, a choke coil, a voice coil and the like having a small inner diameter and good insulation characteristics.
[0031]
Moreover, according to the resin insulation coating flat electric wire of this invention and its manufacturing method, the insulation coating edgewise coil of this invention can be manufactured suitably.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a resin insulation covered flat electric wire according to a first embodiment.
FIG. 2 is a cross-sectional view taken along the line PP ′ of FIG.
FIG. 3 is a perspective view showing a process for manufacturing the resin insulated coated rectangular electric wire of FIG. 1;
4 is a front view showing a process of manufacturing the resin insulation-coated rectangular electric wire of FIG. 1. FIG.
5 is a perspective view showing a resin insulation-coated edgewise coil manufactured by edgewise winding the resin insulation-coated rectangular electric wire of FIG. 1. FIG.
6 is a QQ ′ end view of FIG. 5;
7 is a partially enlarged view of FIG. 6. FIG.
FIG. 8 is a cross-sectional view showing a resin insulation-coated rectangular electric wire according to a second embodiment.
FIG. 9 is a perspective view showing an example of a conventional resin insulation coated rectangular electric wire.
10 is a cross-sectional view taken along the line PP ′ of FIG. 9;
11 is a perspective view showing a conventional resin insulation coated edgewise coil manufactured by edgewise winding the resin insulation coated rectangular electric wire of FIG. 9; FIG.
12 is a QQ ′ end view of FIG. 11. FIG.
13 is a partially enlarged view of FIG.
FIG. 14 is a perspective view in which only a resin insulation coating is cut out.
FIG. 15 is an explanatory diagram showing a difference in coating thickness between the inner peripheral side and the outer peripheral side of the coil.
FIG. 16 is a perspective view of a resin insulation coating before edgewise winding.
FIG. 17 is a plan view of the resin insulation coating after edgewise winding.
[Explanation of symbols]
10, 20 Resin insulation coated flat wire 1 Flat conductor 2 Resin insulation coating 100 Resin insulation coating Edgewise coil τi, τo Coating thickness

Claims (1)

In the resin-coated machine, a flat conductor having a flat cross section is formed in a trapezoidal slit whose opening width increases linearly from one end side to the other end side, and the longitudinal direction of the flat cross section is directed from the one end side to the other end side. While passing the resin, the resin is coated around the flat conductor , and the rectangular conductor is formed with an insulating coating with a coating thickness increasing from one end to the other end in the longitudinal direction of the flat cross section. A method of manufacturing a resin insulation coated edgewise coil, wherein edgewise winding is performed so that an end face on the side having a larger coating thickness becomes an outer peripheral surface of the coil.

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