EP0673044B1 - Mehrlagig isolierter Draht für Hochfrequenz Transformatorwindung - Google Patents

Mehrlagig isolierter Draht für Hochfrequenz Transformatorwindung Download PDF

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Publication number
EP0673044B1
EP0673044B1 EP95108611A EP95108611A EP0673044B1 EP 0673044 B1 EP0673044 B1 EP 0673044B1 EP 95108611 A EP95108611 A EP 95108611A EP 95108611 A EP95108611 A EP 95108611A EP 0673044 B1 EP0673044 B1 EP 0673044B1
Authority
EP
European Patent Office
Prior art keywords
conductor
wire
layered
insulating
insulating layer
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP95108611A
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English (en)
French (fr)
Other versions
EP0673044A3 (de
EP0673044A2 (de
Inventor
Tadashi Yamaguchi
Masataka Muramatsu
Naoki Katagiri
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Totoku Electric Co Ltd
Original Assignee
Totoku Electric Co Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Totoku Electric Co Ltd filed Critical Totoku Electric Co Ltd
Priority to EP95108611A priority Critical patent/EP0673044B1/de
Priority to DE1992617089 priority patent/DE69217089T2/de
Priority claimed from EP92307575A external-priority patent/EP0583521B2/de
Publication of EP0673044A2 publication Critical patent/EP0673044A2/de
Publication of EP0673044A3 publication Critical patent/EP0673044A3/xx
Application granted granted Critical
Publication of EP0673044B1 publication Critical patent/EP0673044B1/de
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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
    • H01B7/02—Disposition of insulation
    • H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation
    • 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
    • H01B7/02—Disposition of insulation
    • H01B7/0241—Disposition of insulation comprising one or more helical wrapped layers of insulation
    • 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
    • H01F27/323—Insulation between winding turns, between winding layers

Definitions

  • This device relates to an insulated wire for a winding suited to be used in a high frequency transformer, a high frequency reactor, or a high frequency coil used in such devices such as a switching power source.
  • a magnet wire manufactured by forming an insulating layer made of such a material as polyurethane resin or polyester resin on a single wire conductor has been used as an insulated wire for a winding for a switching power source.
  • a safety transformer for such a device as a switching power source must follow the following restrictions based on IEC (International Electrotechnical Commission) or UL (Standards of Underwriter's Laboratories, Inc.,) as well as on other various types of safety standard;
  • GB-A-2230208 discloses a further conductor for use in a transformer winding, according to the preamble of claim 1.
  • a high frequency in a range from several tens kHz to several hundred kHz is now used for a switching frequency to improve the switching efficiency.
  • This invention was made to solve the problems as described above, and the object is to provide an insulated electric wire for a winding to be used in a transformer, which satisfies the various types of requirements for safety as described above and can contribute to reduction of heat emission from a transformer even if the switching frequency is in a high frequency band area.
  • this invention provides a multi-layered insulated electric wire for a winding to be used in a high frequency transformer comprising: at least three insulating layers, around a conductor, any two of said at least three insulating layers providing an insulating resistance of 3.75 KV for one minute; characterised by:
  • a small diameter conductor such as copper wire, copper alloy wire, or a tin-or solder-plated copper wire is generally used a conductor for the element wire.
  • a diameter of a conductor is selected case by case according to a specification of a transformer, but generally a conductor having a cross-sectional area in a range from approximately 0.032 mm2 (AWG 32) to 0.52 mm2 (AWG 20) is used, taking into account the high frequency characteristics of a bundled conductor.
  • an extruded layer manufactured by extruding a heat-resistant resin such as various types of fluorine resin or various types of engineering plastics several times over a conductor is available. If necessary, each layer may be colored differently by, for instance, using a resin having a different color for each insulating layer respectively, to clearly identify each insulating layer.
  • each layer of three insulating layers is independent and can be separated from other layers means that each layer can be separated from other layers and exists as one independent layer.
  • a means for separating an insulating layer such a method as using a stripper, removing an insulating layer by giving a slit flaw to the insulating layer, or removing an insulating layer by removing an insulating layer by burning and cutting the insulating layer with a heated knife, is available.
  • a coating for magnet wire is formed by applying insulating paints several times around a conductor and fusing the paints, and each layer cannot be separated from other layers, so that sometimes a magnetic wire is not recognised as a multi-layered insulating wire.
  • a bundled conductor according to this invention is manufactured by bundling a plurality of small diameter conductors almost in parallel into a conductor having a round cross section , or by giving an extremely long twisting pitch, which is twenty times or more larger than an outer diameter of the bundled conductor, so that element wires contacting each other in the bundled conductor form a point contact continuity in the cross section thereof. For this reason, electric resistance of eddy current circuits in the bundled conductor is high and generation of eddy current is suppressed, so that increase of high frequency resistance accompanying an eddy current loss can be prevented. Also, as a surface area of a bundled conductor is far larger than that of a single wire conductor, increase of a loss due to the skin effect can largely be reduced.
  • a length of used conductor can be shortened by the difference of twisting lengths of the bundled conductor as compared to an ordinary twist line, so that also DC current in the coil can be reduced proportionately.
  • the multi-layered insulated wire at least three independent insulating layers, each comprising a heat-resistant extruded layer, are arranged, and insulating resistance (3.75 kV in case of IEC 950) required by the safety standards are provided and maintained by any two of the three layers, so that it is accepted as an insulated wire for a winding having appropriate insulating characteristics required by the safety standards and is free from many of the aforesaid regulations required by conventional types of transformer.
  • a wire manufactured by forming an insulating layer made of such a material as polyurethane resin or polyester resin on a single wire conductor such as a copper wire, a copper-alloy wire, and tin-or solder-plated copper wire is used. Construction of the conductor is selected flexibly according to a specification of a transformer, but generally a conductor generally a conductor comprising a plurality of magnet wires and having a cross-sectional area of 0.032 mm 2 (AWG 32) to 0.52 mm 2 (AWG 20) is used.
  • the bundled conductor according to this invention may be manufactured by bundling a plurality of the aforesaid magnet wires almost parallel to each other into a conductor having a round cross section, or by twisting a plurality of the aforesaid magnet wires by means of bundle-twisting, coaxial twisting, or litz twisting into a conductor having a round cross section.
  • an extruded layer manufactured by extruding a heat-resistant resin such as various types of fluorine resin or various types of engineering plastics several times over a conductor is available. If necessary, each layer may be colored differently by, for instance, using a resin having a different color for each insulating layer respectively, to clearly identify each insulating layer.
  • each layer of three insulating layers is independent can be separated from other layers means that each layer can be separated from other layers and exists as one independent layer.
  • a means for separating an insulating layer such a method as using a stripper, removing an insulating layer by giving a slit flaw to the insulating layer, or removing an insulating layer by removing an insulating layer by burning and cutting the insulating layer with a heated knife, is available.
  • a coating of a magnet wire is formed by applying insulating varnishes several times around a conductor and baking the varnishes, but a single insulating layer is formed, so that each layer can not be separated from other layers and the insulating wire is not recognised as a multi-layered insulated wire. Also in this invention, a magnet wire is used, but it is not used in a state of single wire as a multi-layered wire, but as an insulated element wire constituting a bundle conductor.
  • the bundled conductor according to this invention is manufactured by bundling a plurality of magnet wires almost in parallel to each other into one conductor having a round cross section or by twisting a plurality of magnet wire into a conductor having a round section, and generation of an eddy current can be suppressed to a low level because each element conductor of the magnet wire is insulated respectively, so that increase of high frequency resistance accompanying an eddy current loss can be prevented. Also in a bundled conductor, a surface area of conductor is larger than that of a single wire conductor, increase of a loss due to the skin effect can largely be suppressed.
  • a length of twisted conductors can be shortened, and also DC current in a coil can be reduced in proportion to the shortened length of the twisted conductors.
  • the multi-layered wire according to this invention at least three independent insulating layers, each made of heat-resistant resin, are arranged, and insulation resistance (3.75 kV in case of IEC 950) is provided and maintained by any two of the three layers above, so that the multi-layered insulated wire is accepted as an insulated wire for a winding having appropriate insulation characteristics required by the safety standards and is free from many of the restrictions to conventional types of transformer as described above.
  • Fig. 1 is a drawing showing a cross section of a multi-layered insulated wire according to the first embodiment of this invention.
  • a copper wire having a diameter of 0.12 mm was used as an element wire conductor 1, and nineteen lines of this copper wire were bundled almost in parallel to each other into a bundled conductor 2 having a diameter of 0.60 mm.
  • a multi-layered insulated wire 24 was manufactured by arranging an extruded layer formed by extruding red fluorinated ethylene propylene resin (FEP) (Teflon 100 J, product name of Mitsui Dupont FluoroChemical Corp.) with a thickness of about 0.06 mm around this bundled conductor 2 as a primary insulating layer 23a, arranging an extruded layer formed by extruding natural color FEP with a thickness of about 0.06 mm around the primary insulating layer 23a as a secondary insulating layer 23b, and furthermore arranging an extruded layer formed by extruding a blue FEP with a thickness of about 0.06 mm around the secondary insulating layer 23b as a tertiary insulating layer 23c.
  • FEP red fluorinated ethylene propylene resin
  • a tin-plated copper wire having a conductor diameter of 0.12 mm was used as an element wire conductor 1, and nineteen lines of this tin-plated copper wire were formed into a bundled conductor 2 having an outer diameter of 0.60 mm and also having a round cross section by giving a twisting pitch of 24 mm to the bundled conductor. Then, a multi-layered insulated wire 24 was manufactured by arranging an insulating layer 23 comprising three extruded layers 23a, 23b and 23c around this bundled conductor 2 according to the same procedure as that in embodiment 1-1.
  • the insulated wire having the construction as described above could satisfy the voltage resistance characteristics required by IEC 950, namely 3.75 kV for 1 minute.
  • a switching transformer in which a three-layered insulated wire according to the embodiment 1.1 of this invention was used as a secondary winding and a switching transformer in which 0.038 mm polyurethane coated copper wire with a diameter of 0.60 mm was used as a secondary winding were manufactured, using the completely same parts and components in other sections.
  • a switching transformer with an oscillation frequency of 50 kHz using in a switching power source with an output of 136 W these switching transformers were run under the conditions of output voltage of 161 V and output current of 0.5 A, and surface temperature of the winding in each transformer was measured using a thermistor thermometer. The results are as shown in Table 2.
  • a bundled conductor manufactured by bundling a plurality of small diameter conductors almost in parallel to each other into a conductor having a round cross section, or by giving a twisting pitch, which is twenty times or more larger than an outer diameter of said bundled conductor is used, so that heat emission due to an eddy current loss or the outer skin effect in the conductor can largely by suppressed, and because of this effect it is possible to suppress heat emission from a switching transformer even when the switching frequency is high, which contributes to improvement of efficiency of a switching power source.
  • Fig. 2 is a drawing showing a cross section of a multi-layered wire according to a second embodiment of this invention.
  • a class 2 polyurethane copper wire having a diameter of 0.10 mm and a finished diameter of 0.120 mm as a magnet wire 51 was used, and a bundled conductor 52 having a diameter of 0.60 mm was formed by bundling 19 lines of this polyurethane copper wire almost in parallel to each other.
  • a multi-layered insulated wire 54 was manufactured by arranging an extruded layer formed by extruding red fluorinated ethylene propylene resin (FEP) (Teflon 100 J, product name of Mitsui Dupont FluoroChemical Corp.) with a thickness of about 0.06 mm around this bundled conductor 52 as a primary insulating layer 23a, arranging an extruded layer formed by extruding natural color FEP with as thickness of about 0.06 mm around the primary insulating layer as a secondary insulating layer 23b, and furthermore arranging an extruded layer formed by extruding a blue FEP with a thickness of about 0.06 mm around the secondary insulating layer 23b as a tertiary insulating layer 23c.
  • FEP red fluorinated ethylene propylene resin
  • a class 2 polyester copper wire having a diameter of 0.10 mm and a finished outer diameter of 0.120 mm was used as a magnet wire 51, and a bundled conductor with a bundled outer diameter of 0.60 mm was manufactured by bundling 19 lines of this polyester copper wires into a conductor having a round cross section with a twisting pitch of 24 mm.
  • a multi-layered insulated wire 54 was manufactured by arranging an insulated layer 23 comprising 3 FEP extruded layers 23a, 23b and 23c around this bundled conductor like in embodiment 2-1. Each insulating layer in this multi-layered insulated wire 54 could be separated according to the same procedure as that in embodiment 2-1.
  • the insulated wire having the construction as described above could satisfy the voltage resistance characteristics required by IEC 950, namely 3.75 kV for 1 minute.
  • a switching transformer in which a three-layered insulated wire according to the embodiment 2-1 of this invention was used as a secondary winding and switching transformer in which 0.038 mm polyurethane coated copper wire with a diameter of 0.60 mm was used as a secondary winding were manufactured, using the completely same parts and components in other sections.
  • these switching transformers were run under the conditions of output voltage of 161 V and output current of 0.5 A, an surface temperature of the winding in each transformer was measured using a thermistor thermometer. The results are as shown in Table 4.
  • a bundled conductor having a round cross section prepared by bundling a plurality of magnet wires, or by twisting a plurality of magnet wires is used, so that heat emission due to an eddy current loss and the skin effect in the conductor can largely be reduced, and because of this effect also it is possible to suppress heat emission in a high frequency switching transformer, which can contribute to improvement of the switching efficiency.

Landscapes

  • Engineering & Computer Science (AREA)
  • Power Engineering (AREA)
  • Coils Of Transformers For General Uses (AREA)
  • Insulated Conductors (AREA)
  • Insulating Of Coils (AREA)

Claims (6)

  1. Mehrlagig isolierter elektrischer Draht (24, 54) für eine Wicklung, die in einem Hochfrequenztransformator verwendet werden soll, umfassend:
    zumindest drei Isolierschichten (23) um einen Leiter, wobei beliebige zwei der zumindest drei Isolierschichten (23) eine Minute lang eine Isolationsfestigkeit von 3,75 kV bieten;
    dadurch gekennzeichnet, daß:
    jede Schicht der zumindest drei Isolierschichten (23) eine extrudierte Schicht umfaßt, die durch Extrudieren von wärmebeständigem Material gebildet wird;
    der Leiter ein Bündelleiter ist, der durch Bündeln einer Vielzahl Leiter (1, 51) hergestellt wird;
    und jede der zumindest drei Isolierschichten (23) jeweils unabhängig und trennbar von den anderen Schichten ist.
  2. Mehrlagig isolierter elektrischer Draht nach Anspruch 1, worin der Bündelleiter durch Bündeln der Vielzahl Leiter (1, 51) fast parallel zueinander zu einem Leiter mit rundem Querschnitt gebildet wird.
  3. Mehrlagig isolierter elektrischer Draht nach Anspruch 1, worin der gebündelte Leiter durch Verdrillen und Bündeln der Vielzahl an Leitern (1, 51) zu einem Leiter mit rundem Querschnitt gebildet wird.
  4. Mehrlagig isolierter elektrischer Draht nach Anspruch 1, 2 oder 3, worin die Isolierschichten ein wärmebeständiges Harz umfassen.
  5. Mehrlagig isolierter elektrischer Draht nach einem der vorhergehenden Ansprüche, worin die Leiter (51) Magnetdrähte sind.
  6. Mehrlagig isolierter elektrischer Draht nach einem der vorhergehenden Ansprüche, worin jeder Leiter (51) von einer Isolierschicht umgeben ist.
EP95108611A 1992-08-19 1992-08-19 Mehrlagig isolierter Draht für Hochfrequenz Transformatorwindung Expired - Lifetime EP0673044B1 (de)

Priority Applications (2)

Application Number Priority Date Filing Date Title
EP95108611A EP0673044B1 (de) 1992-08-19 1992-08-19 Mehrlagig isolierter Draht für Hochfrequenz Transformatorwindung
DE1992617089 DE69217089T2 (de) 1992-08-19 1992-08-19 Mehrlagig isolierter Draht für Hochfrequenz Transformatorwindung

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
EP95108611A EP0673044B1 (de) 1992-08-19 1992-08-19 Mehrlagig isolierter Draht für Hochfrequenz Transformatorwindung
EP92307575A EP0583521B2 (de) 1992-08-12 1992-08-19 Mehrlagig isolierter Draht für Hochfrequenztransformatorwindung

Related Parent Applications (2)

Application Number Title Priority Date Filing Date
EP92307575.8 Division 1992-08-19
EP92307575A Division EP0583521B2 (de) 1992-08-12 1992-08-19 Mehrlagig isolierter Draht für Hochfrequenztransformatorwindung

Publications (3)

Publication Number Publication Date
EP0673044A2 EP0673044A2 (de) 1995-09-20
EP0673044A3 EP0673044A3 (de) 1995-10-18
EP0673044B1 true EP0673044B1 (de) 1997-01-22

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ID=8211469

Family Applications (2)

Application Number Title Priority Date Filing Date
EP95113100A Expired - Lifetime EP0684617B1 (de) 1992-08-19 1992-08-19 Mehrlagig isolierter Draht für Hochfrequenz Transformatorwindung
EP95108611A Expired - Lifetime EP0673044B1 (de) 1992-08-19 1992-08-19 Mehrlagig isolierter Draht für Hochfrequenz Transformatorwindung

Family Applications Before (1)

Application Number Title Priority Date Filing Date
EP95113100A Expired - Lifetime EP0684617B1 (de) 1992-08-19 1992-08-19 Mehrlagig isolierter Draht für Hochfrequenz Transformatorwindung

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DE (1) DE69210398T3 (de)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
IL136301A (en) 2000-05-22 2005-09-25 Payton Planar Magnetics Ltd Method of insulating a planar transformer printed circuit and lead frame windings forms

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
NL6903660A (de) * 1968-03-26 1969-09-30
JPS6358709A (ja) * 1986-08-28 1988-03-14 カ−リスル　コ−ポレ−シヨン 多層耐高温絶縁体で絶縁された導体
JPH0249801U (de) 1988-09-29 1990-04-06
JPH0249802U (de) 1988-10-04 1990-04-06
JP2557965B2 (ja) 1988-12-01 1996-11-27 日本電信電話株式会社 画像の符号化方式
JPH0325219U (de) * 1989-03-01 1991-03-15
JP2593101B2 (ja) * 1990-06-08 1997-03-26 サンケン電気株式会社 コイル装置

Also Published As

Publication number Publication date
EP0684617A2 (de) 1995-11-29
EP0673044A3 (de) 1995-10-18
DE69210398D1 (de) 1996-06-05
DE69210398T3 (de) 2003-06-05
EP0684617B1 (de) 1998-11-11
EP0673044A2 (de) 1995-09-20
EP0684617A3 (de) 1996-09-25
DE69210398T2 (de) 1996-10-24

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