JP2009245658A - Straight-angle electric wire and manufacturement method therefor - Google Patents

Straight-angle electric wire and manufacturement method therefor Download PDF

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JP2009245658A
JP2009245658A JP2008088635A JP2008088635A JP2009245658A JP 2009245658 A JP2009245658 A JP 2009245658A JP 2008088635 A JP2008088635 A JP 2008088635A JP 2008088635 A JP2008088635 A JP 2008088635A JP 2009245658 A JP2009245658 A JP 2009245658A
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flat
electric wire
oxide film
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JP5367291B2 (en
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Katsumi Osada
克己 長田
Hironobu Okuma
啓伸 大隈
Kanichiro Yamamoto
寛一郎 山本
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Furukawa Electric Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a straight-angle electric wire which is superior in usability, and capable of improving high frequency characteristics, and realizing shortening of a manufacturing period and reduction of a manufacturing cost, and to provide a manufacturing method for the wire. <P>SOLUTION: The straight-angle electric wire W has a rectangular twisted conductor part 3, formed by twisting together a plurality of conductors 2 in which an oxide film 1 is formed at the outer periphery, and by drawing-processing them in a rectangular shape, and an insulating layer 4 formed to be pushed out and covered in the surrounding of the rectangular twisted conductor part 3. Since the rectangular twisted conductor part 3 is formed and drawing processed, by twisting together the plurality of conductors 2, it is easily bent and deformed in any direction, and superior in the usability. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

本発明は、平角電線及びその製造方法に関し、特に、交流モータや高周波電気機器のコイル等に用いられる高周波用の平角電線及びその製造方法に関する。   The present invention relates to a flat electric wire and a method for manufacturing the same, and more particularly to a high-frequency flat electric wire for use in an AC motor, a coil of a high-frequency electric device, and the like and a method for manufacturing the same.

交流モータや高周波電気機器のコイル等に用いられる高周波用の電線は、従来から種々のものが提案されている。   Conventionally, various types of high-frequency electric wires used for coils of AC motors and high-frequency electric devices have been proposed.

例えば特許文献１には、外周に絶縁用のエナメル皮膜が形成された断面方形の平角導体を平積みに積層して構成されている平角電線が提案されている（以下、この技術を従来例１という）。   For example, Patent Document 1 proposes a rectangular electric wire that is formed by laminating flat rectangular conductors having a rectangular cross section with an enamel coating for insulation formed on the outer periphery (hereinafter, this technique is referred to as Conventional Example 1). Called).

また、特許文献２には、複数本のエナメル線からなる撚り線を、外側より円形に圧縮してエナメル線を相互に密着させたものの外周上に、自己融着層を設けてなる電線が提案されている（以下、この技術を従来例２という）。
特開平１１−１１１０６７号公報 特開平６−１１９８２５号公報 Patent Document 2 proposes an electric wire in which a self-bonding layer is provided on the outer periphery of a twisted wire composed of a plurality of enameled wires, compressed into a circular shape from the outside and closely adhered to each other. (Hereinafter, this technique is referred to as Conventional Example 2).
Japanese Patent Laid-Open No. 11-111067 Japanese Patent Laid-Open No. 6-191985

従来例１では、図２に示すように、平角導体１０を平積みに積層しているので、幅方向（矢印方向）への曲げ変形が困難であり、使い勝手が悪いという課題があった。   In Conventional Example 1, as shown in FIG. 2, since the rectangular conductors 10 are stacked in a flat manner, there is a problem that bending deformation in the width direction (arrow direction) is difficult and usability is poor.

従来例２では、図３（Ｂ）に示すように、撚り線１１からなる導体の表面を方形の絶縁皮膜１２で被覆した場合、導体の有効表面積率が６０％程度と低く、高周波損失が高くなるという課題があった。   In Conventional Example 2, as shown in FIG. 3B, when the surface of the conductor made of the stranded wire 11 is covered with a rectangular insulating film 12, the effective surface area ratio of the conductor is as low as about 60% and the high-frequency loss is high. There was a problem of becoming.

また、従来例１及び従来例２では、いずれもエナメル皮膜が形成された導体を用いているので、エナメルを焼き付けるための工程及び設備が必要であり、製造時間及び製造コストがかかるという課題があった。   Further, in both the conventional example 1 and the conventional example 2, since the conductor on which the enamel film is formed is used, a process and equipment for baking the enamel are necessary, and there is a problem that it takes manufacturing time and manufacturing cost. It was.

また通電される電流の周波数が高くなると表皮効果により交流抵抗が増加して損失が高くなる現象（以下単に、高周波損失と称する）が見られるが、従来は絶縁皮膜として最低でも厚さが３μｍ程度はあるエナメル皮膜を使用しているので、その分、導体面積を減少させざるを得ず、高周波損失を低減するのが困難であるという課題もあった。   In addition, when the frequency of the energized current increases, the phenomenon that the AC resistance increases due to the skin effect and the loss increases (hereinafter simply referred to as high-frequency loss) is conventionally known. Since a certain enamel film is used, the conductor area has to be reduced correspondingly, and it is difficult to reduce high-frequency loss.

本発明は、上記課題を解決するためになされたものであり、エナメルを焼き付けたり、エナメル皮膜同士を接着するための材料、工程及び設備が不要となり、それぞれの導体に極薄い絶縁皮膜を持つ電線を短時間かつ低コストで製造することができ、高周波損失を低減できる平角電線及びその製造方法を提供することを目的とする。   The present invention has been made in order to solve the above-described problems, and there is no need for materials, processes and equipment for baking enamel or bonding enamel films to each other, and an electric wire having an extremely thin insulating film on each conductor. An object of the present invention is to provide a flat electric wire that can be manufactured in a short time and at low cost, and that can reduce high-frequency loss, and a method for manufacturing the same.

本発明の平角電線は、外周に酸化皮膜が形成された断面丸形状の導体を複数撚り合わせて平角状に伸線加工して形成された平角撚り導体部と、前記平角撚り導体部の周囲に押出被覆形成された絶縁層とを有することを特徴とするものである。   The flat electric wire of the present invention has a flat twisted conductor portion formed by twisting a plurality of conductors having a round cross section with an oxide film formed on the outer periphery and drawing into a flat rectangular shape, and around the flat twisted conductor portion. And an insulating layer formed by extrusion coating.

本発明の平角電線の製造方法は、
（１）断面丸形状の導体の外周に酸化皮膜を形成する工程と、
（２）複数の前記導体を撚り合わせながら整列させる工程と、
（３）前記整列された導体を平角状に伸線加工して、平角撚り導体部を形成する工程と、
（４）前記平角撚り導体部の周囲に絶縁層を押出被覆形成する工程と、
を有することを特徴とするものである。 The manufacturing method of the flat electric wire of the present invention is as follows:
(1) forming an oxide film on the outer periphery of a conductor having a round cross section;
(2) aligning a plurality of the conductors while twisting together;
(3) a step of drawing the aligned conductors into a rectangular shape to form a rectangular twisted conductor portion;
(4) a step of extrusion-coating an insulating layer around the flat twisted conductor portion;
It is characterized by having.

請求項１に係る発明によれば、平角撚り導体部が複数の導体を撚り合わせて平角状に伸線加工して形成されているので、どの方向にも曲げ変形しやすく、使い勝手が良好である。   According to the first aspect of the present invention, since the flat twisted conductor portion is formed by twisting a plurality of conductors and drawing into a flat rectangular shape, it is easy to bend and deform in any direction and is easy to use. .

またそれぞれの導体にエナメル皮膜の代わりに導体の一部を酸化させて酸化皮膜を形成することで、エナメル皮膜を形成する必要がないので、エナメルを焼き付けたり、エナメル皮膜同士を接着するための材料、工程及び設備が不要となり、製造時間の短縮化及び製造コストの低減を図ることができる。   Also, it is not necessary to form an enamel film by oxidizing a part of the conductor on each conductor instead of enamel film, so it is not necessary to form an enamel film, so the material for baking enamel or bonding enamel films together This eliminates the need for processes and equipment, and shortens manufacturing time and manufacturing costs.

また酸化皮膜は、自然に形成される酸化膜ではなく、意図的に形成され、厚みがあり、剥げにくい酸化膜であるので、伸線加工等を行ってもつぶれにくく、導体同士の絶縁性を確保できる。   In addition, the oxide film is not a naturally formed oxide film, it is an intentionally formed, thick, and difficult-to-peel oxide film. It can be secured.

また、平角撚り導体部の外周に極薄い酸化皮膜を形成した場合、同一面積をもつ従来の電線に比べ、導体の有効表面積率が高くなり、高周波損失が低減され、高周波特性が向上する。   In addition, when an extremely thin oxide film is formed on the outer periphery of the flat twisted conductor portion, the effective surface area ratio of the conductor is increased, high frequency loss is reduced, and high frequency characteristics are improved as compared with a conventional electric wire having the same area.

さらに、平角形状をしているので、コイル等の占積率が良好になる。   Furthermore, since the rectangular shape is used, the space factor of the coil or the like is improved.

請求項２に係る発明によれば、上記効果を奏する平角導体を提供することができる。   According to the invention which concerns on Claim 2, the flat conductor which has the said effect can be provided.

以下、本発明の実施の形態について図面を参照して説明する。図１（Ａ）は本発明の実施形態例に係る平角電線を示す断面図、（Ｂ）〜（Ｄ）は本発明の実施形態例に係る平角電線の製造方法を説明するための断面図である。   Hereinafter, embodiments of the present invention will be described with reference to the drawings. 1A is a cross-sectional view showing a flat electric wire according to an embodiment of the present invention, and FIGS. 1B to 1D are cross-sectional views for explaining a method of manufacturing a flat electric wire according to an embodiment of the present invention. is there.

図１（Ａ）に示すように、本発明の実施形態例に係る平角電線Ｗは、外周に酸化皮膜１が形成された複数の導体２を撚り合わせて平角状に伸線加工して形成された平角撚り導体部３と、平角撚り導体部３の周囲に押出被覆形成された絶縁層４とを有する。   As shown in FIG. 1 (A), the flat electric wire W according to the embodiment of the present invention is formed by twisting a plurality of conductors 2 having an oxide film 1 formed on the outer periphery and drawing them into a flat rectangular shape. The flat twisted conductor portion 3 and the insulating layer 4 formed by extrusion coating around the flat twisted conductor portion 3.

導体２は、例えば、銅，銅合金，アルミニウム，アルミニウム合金又はそれら金属の組み合わせ等で作られており、酸化皮膜１を形成する段階までは断面丸形状であり、上記伸線加工される際につぶれて断面非円形に変形する。   The conductor 2 is made of, for example, copper, a copper alloy, aluminum, an aluminum alloy, or a combination of these metals, and has a round cross section until the oxide film 1 is formed. It collapses and deforms into a non-circular cross section.

酸化皮膜１は、単に自然に形成される酸化膜を意図するものではなく、それぞれの導体２の絶縁皮膜として該導体２の表面を酸化させて得たものである。例えば酸化皮膜１は、酸化雰囲気中の炉内で導体２に熱風を吹き掛けたり、アルミニウムであればアルマイト処理やアルマット処理（「メタルコア配線板におけるコア金属と絶縁樹脂の密着性向上」電子材料 Vol.44 No.10（工業調査会2005）参照）を行なうなどにより、導体２の外周にたとえば０．５〜２．５μｍの所定の厚さに形成されたものである。   The oxide film 1 is not intended to be a naturally formed oxide film, but is obtained by oxidizing the surface of the conductor 2 as an insulating film of each conductor 2. For example, the oxide film 1 is formed by spraying hot air on the conductor 2 in a furnace in an oxidizing atmosphere, or alumite treatment or alumt treatment for aluminum (“improvement of adhesion between core metal and insulating resin in metal core wiring board”) .44 No. 10 (Industrial Research Committee 2005)) is formed on the outer periphery of the conductor 2 to a predetermined thickness of, for example, 0.5 to 2.5 μm.

絶縁層４は、例えば、ポリイミド（ＰＩ）、ポリアミドイミド（ＰＡＩ）、ポリカーボネート（ＰＣ）、ポリサルホン（ＰＳＵ）、ポリエチレンテレフタレート（ＰＥＴ）、ポリエーテルエーテルケトン（ＰＥＥＫ）、ポリフェニレンサルファイド（ＰＰＳ）等で作られており、例えば３０μｍ程度の厚さを有する。   The insulating layer 4 is made of, for example, polyimide (PI), polyamideimide (PAI), polycarbonate (PC), polysulfone (PSU), polyethylene terephthalate (PET), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), or the like. For example, it has a thickness of about 30 μm.

次に、本発明の実施形態例に係る平角電線Ｗの製造方法について説明する。   Next, the manufacturing method of the flat electric wire W which concerns on the example of embodiment of this invention is demonstrated.

まず、例えば銅からなる半径約０．２ｍｍの断面丸形状の導体２を酸化雰囲気中の炉内に入れ、導体２の外周に厚さ０．５〜２．５μｍの酸化銅からなる酸化皮膜１を形成する（図１（Ｂ）参照）。   First, for example, a conductor 2 having a round shape with a radius of about 0.2 mm made of copper is placed in a furnace in an oxidizing atmosphere, and an oxide film 1 made of copper oxide having a thickness of 0.5 to 2.5 μm is formed on the outer periphery of the conductor 2. (See FIG. 1B).

次いで、上記酸化皮膜１が形成された複数本の導体２を撚り合わせながら整列させる撚り加工を行なう（図１（Ｃ）参照）。   Next, twisting is performed in which the plurality of conductors 2 on which the oxide film 1 is formed are aligned while being twisted (see FIG. 1C).

次いで、内部の酸化皮膜１が壊れない程度に、上記撚り合わせられた複数の導体２を全体の断面形状が略平角形状になるように伸線加工して、高さ１ｍｍ、幅１ｍｍの平角撚り導体部３を形成する（図１（Ｃ）参照）。   Next, the plurality of twisted conductors 2 are drawn so that the entire cross-sectional shape becomes a substantially rectangular shape so that the internal oxide film 1 is not broken, and a rectangular twist having a height of 1 mm and a width of 1 mm is obtained. The conductor portion 3 is formed (see FIG. 1C).

なお上記撚り加工や伸線加工により、平角撚り導体部３の外周に露出された酸化皮膜１はある程度剥離したり破損する可能性があるが、該平角撚り導体部３の外周には次の工程で絶縁層４を形成することで平角電線Ｗ外部との絶縁性は確保され、また導体２同士の絶縁性は、平角撚り導体部３内部に残っている酸化皮膜１により確保されるので平角電線Ｗの実用上全く問題ない。   Note that the oxide film 1 exposed on the outer periphery of the flat twisted conductor portion 3 may be peeled off or damaged to some extent by the above-described twisting process or wire drawing process. By forming the insulating layer 4 in this way, the insulation from the outside of the flat wire W is secured, and the insulation between the conductors 2 is secured by the oxide film 1 remaining inside the flat twisted conductor portion 3, so that the flat wire There is no problem in practical use of W.

次いで、押出機により、平角撚り導体部３の周囲を絶縁樹脂で押し出し被覆して、厚さ３０μｍの絶縁層４を形成する。これによって、本発明の実施形態例に係る平角電線Ｗが完成する（図１（Ａ）参照）。   Next, the periphery of the flat twisted conductor portion 3 is extruded and covered with an insulating resin by an extruder to form an insulating layer 4 having a thickness of 30 μm. Thereby, the flat electric wire W which concerns on the example of embodiment of this invention is completed (refer FIG. 1 (A)).

本発明の実施形態例に係る平角電線Ｗによれば、平角撚り導体部３が複数の断面丸形状の導体２を撚り合わせて平角状に伸線加工して形成されているので、図２の平角電線に比べてどの方向にも曲げ変形しやすく、使い勝手が良好である。   According to the flat electric wire W according to the embodiment of the present invention, the flat twisted conductor portion 3 is formed by twisting a plurality of round conductors 2 and drawing them into a flat rectangular shape. Compared to flat electric wires, it is easy to bend and deform in any direction and is easy to use.

また、導体２の外周に酸化皮膜１が形成されていることで、導体２の周囲にエナメル皮膜を形成する必要がないので、エナメルワニス塗布や炉内でのエナメル焼付など、エナメルを焼き付け形成したり、さらにエナメル皮膜に絶縁層との接着を良好にする接着層を形成するなどエナメル皮膜同士を接着するための材料、工程及び設備が不要となり、製造時間の短縮化及び製造コストの低減を図ることができる。   Further, since the oxide film 1 is formed on the outer periphery of the conductor 2, it is not necessary to form an enamel film around the conductor 2. Therefore, enamel is baked and formed, such as enamel varnish coating or enamel baking in a furnace. In addition, materials, processes, and equipment for bonding enamel films to each other, such as forming an adhesive layer on the enamel film to improve the adhesion with the insulating layer, are no longer required, and the manufacturing time and manufacturing costs are reduced. be able to.

酸化皮膜１は、自然に形成される酸化膜ではなく、意図的に形成され、例えば０．５〜２．５ミクロンの厚さがあることで剥げにくい酸化膜であるので、伸線加工等を行っても導体同士の絶縁性をある程度、確保できる。   The oxide film 1 is not an oxide film that is naturally formed, but is intentionally formed. For example, the oxide film 1 is an oxide film that is difficult to peel off due to the thickness of 0.5 to 2.5 microns. Even if the operation is performed, a certain degree of insulation between the conductors can be secured.

また、図３（Ａ）に示すように、平角撚り導体部３の外周に極薄い酸化皮膜１を形成した場合、導体の有効表面積率が約８０％と、同一面積をもつ従来の電線（図３（Ｂ）参照）に比べ２０％程度高くなり、その分高周波損失が低減され、高周波特性が向上する。   In addition, as shown in FIG. 3A, when an extremely thin oxide film 1 is formed on the outer periphery of the flat twisted conductor portion 3, a conventional electric wire (Fig. 3) has an effective surface area ratio of about 80%. 3 (B)), the high frequency loss is reduced by that amount, and the high frequency characteristics are improved.

本実施形態では銅からなる導体２を炉内に入れて酸化皮膜１を形成したが、酸化皮膜１を形成する方法はこれに限定されるものではない。例えば導体２の材質としてアルミニウムを選定する場合は、酸化アルミニウムからなる酸化皮膜１を形成するためにアルマイト処理やアルマット処理（「メタルコア配線板におけるコア金属と絶縁樹脂の密着性向上」電子材料 Vol.44 No.10（工業調査会2005）参照）を用いることも可能であり、とくに導体2をアルミニウムで構成し、アルマット処理により酸化アルミニウムからなる酸化皮膜１を形成した場合には、アルマット処理がアルミニウム材の表面粗化処理であるために絶縁層４のアンカー効果も得ることができるので好ましい。   In this embodiment, the conductor 2 made of copper is placed in the furnace to form the oxide film 1, but the method of forming the oxide film 1 is not limited to this. For example, when aluminum is selected as the material of the conductor 2, anodizing or alumting treatment ("Improvement of adhesion between core metal and insulating resin in metal core wiring board" electronic material Vol. 44 No. 10 (Industry Research Committee 2005)) can also be used. In particular, when the conductor 2 is made of aluminum and the oxide film 1 made of aluminum oxide is formed by the almat treatment, the almat treatment is aluminum. Since the surface roughening treatment of the material, the anchor effect of the insulating layer 4 can also be obtained, which is preferable.

さらに、本実施形態例に係る平角電線Ｗは断面平角形状をしているので、コイル等における電線の占積率を高くすることができるので好ましい。   Furthermore, since the flat electric wire W which concerns on the example of this embodiment has the cross-sectional rectangular shape, since the space factor of the electric wire in a coil etc. can be made high, it is preferable.

本発明の実施形態例に係る平角電線Ｗの製造方法によれば、上記効果を奏する平角導体を提供することができる。   According to the manufacturing method of the flat electric wire W which concerns on the example of embodiment of this invention, the flat conductor which has the said effect can be provided.

本発明は、上記実施の形態に限定されることはなく、特許請求の範囲に記載された技術的事項の範囲内において、種々の変更が可能である。   The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the technical matters described in the claims.

本発明は、例えば交流モータや高周波電気機器のコイル等の高周波用の電線に利用される。   The present invention is used for high-frequency electric wires such as coils of AC motors and high-frequency electric devices, for example.

（Ａ）は本発明の実施形態例に係る平角電線を示す断面図、（Ｂ）〜（Ｄ）は本発明の実施形態例に係る平角電線の製造方法を説明するための断面図である。(A) is sectional drawing which shows the flat electric wire which concerns on the embodiment of this invention, (B)-(D) is sectional drawing for demonstrating the manufacturing method of the flat electric wire which concerns on the embodiment of this invention. 従来例１の電線を示す断面図である。It is sectional drawing which shows the electric wire of the prior art example 1. 複数の導体の周囲に絶縁皮膜を被覆した場合における導体の有効表面積率を比較するための説明図であり、（Ａ）は本発明の電線の場合、（Ｂ）は従来例２の電線の場合を示す。It is explanatory drawing for comparing the effective surface area rate of the conductor at the time of coat | covering the insulation film around the several conductor, (A) is the case of the electric wire of this invention, (B) is the case of the electric wire of the prior art example 2. Indicates.

符号の説明Explanation of symbols

Ｗ：平角電線
１：酸化皮膜
２：導体
３：平角撚り導体部
４：絶縁層
W: Flat wire 1: Oxide film 2: Conductor 3: Flat twisted conductor part 4: Insulating layer

Claims (2)

外周に酸化皮膜が形成された断面丸形状の導体を複数撚り合わせて平角状に伸線加工して形成された平角撚り導体部と、
前記平角撚り導体部の周囲に押出被覆形成された絶縁層と
を有することを特徴とする平角電線。 A flat twisted conductor portion formed by twisting a plurality of conductors having a round cross section with an oxide film formed on the outer periphery and drawing into a flat rectangular shape,
A flat electric wire comprising: an insulating layer formed by extrusion coating around the flat twisted conductor portion. （１）断面丸形状の導体の外周に酸化皮膜を形成する工程と、
（２）複数の前記導体を撚り合わせながら整列させる工程と、
（３）前記整列された導体を平角状に伸線加工して、平角撚り導体部を形成する工程と、
（４）前記平角撚り導体部の周囲に絶縁層を押出被覆形成する工程と、
を有することを特徴とする平角電線の製造方法。 (1) forming an oxide film on the outer periphery of a conductor having a round cross section;
(2) aligning a plurality of the conductors while twisting together;
(3) a step of drawing the aligned conductors into a rectangular shape to form a rectangular twisted conductor portion;
(4) a step of extrusion-coating an insulating layer around the flat twisted conductor portion;
A method for producing a flat electric wire, comprising:
JP2008088635A 2008-03-28 2008-03-28 Flat wire and method for manufacturing the same Active JP5367291B2 (en)

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