WO2010086944A1 - 絶縁電線およびコイル - Google Patents
絶縁電線およびコイル Download PDFInfo
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- WO2010086944A1 WO2010086944A1 PCT/JP2009/006831 JP2009006831W WO2010086944A1 WO 2010086944 A1 WO2010086944 A1 WO 2010086944A1 JP 2009006831 W JP2009006831 W JP 2009006831W WO 2010086944 A1 WO2010086944 A1 WO 2010086944A1
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- insulated wire
- wire
- wires
- insulating
- insulating coating
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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
- H01B13/06—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
- 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
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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
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/1855—Sheaths comprising helical wrapped non-metallic layers
Definitions
- the present invention relates to an insulated wire and a coil, and more particularly to an insulated wire and a coil excellent in high-frequency characteristics and insulating characteristics.
- a litz wire has been known in which a self-bonding layer is provided on the outer periphery of a twisted wire made of a plurality of enameled wires, compressed into a circular shape from the outside and alternately attached to the enameled wires.
- a self-bonding layer is provided on the outer periphery of a twisted wire made of a plurality of enameled wires, compressed into a circular shape from the outside and alternately attached to the enameled wires.
- the conventional litz wire is excellent in high frequency characteristics.
- a twisted wire made of a plurality of enamel wires is passed through a circular die and compressed into a circle from the outside. Insulation characteristics deteriorate. That is, the conventional litz wire has a problem in insulation characteristics. For this reason, when it winds around a coil, it is easy to raise
- the self-fusion layer is provided on the outer peripheral surface, this does not guarantee the insulating characteristics. Then, the objective of this invention is providing the insulated wire and coil excellent in the high frequency characteristic and the insulation characteristic.
- the present invention provides a collective line in which a plurality of enamel lines having a non-circular cross-sectional outline are aggregated to form a circular cross-sectional outline, and an outer periphery of the collective line so as to bundle the collective lines.
- An insulated wire comprising a first insulating coating formed by winding an insulating tape is provided.
- a plurality of enameled wires having a non-circular cross-sectional outline are gathered, and an insulating tape is wound so as to bundle an aggregated wire having a circular overall cross-sectional outline.
- the enamel layer corresponding to the outer peripheral surface of the collective wire is damaged by friction with the circular die, and the outer peripheral surface of the collective wire
- the insulation characteristics of the are reduced.
- at least one layer of insulation coating is provided on the outer periphery of the assembly line, sufficient insulation characteristics can be obtained.
- the assembly wire can be prevented from being separated by tape winding, a uniform finished outer diameter can be obtained even when the coil is wound.
- the high frequency copper loss can be reduced as compared with a single wire, the high frequency characteristics are excellent.
- the total number of enamel wires constituting the assembly line is preferably 4 or more from the viewpoint of improving high-frequency characteristics. Moreover, when compressing using a circular die
- the present invention provides an insulated wire according to the first aspect, wherein the plurality of enamel wires are bundled in parallel without being twisted.
- the finished outer shape can be made smaller than when twisted.
- the line length can be shortened.
- the direct current resistance can be reduced.
- the twisting process has a slower processing line speed than the compression process and the tape winding process, which decreases productivity and increases manufacturing costs. Since a twisting process is not required, productivity can be improved and manufacturing cost can be reduced.
- the present invention provides an insulated wire according to the first or second aspect, wherein a soft magnetic layer is formed on the outer periphery of all or part of the plurality of enameled wires.
- a featured insulated wire is provided.
- the copper wire is covered with the soft magnetic layer, the magnetic flux that generates eddy current loss passes through the magnetic layer on the surface more easily than the copper wire portion. Since the magnetic layer has a higher specific resistance than copper, eddy current loss can be reduced. Therefore, high frequency copper loss can be further reduced, and high frequency characteristics can be further improved.
- the present invention relates to a collective line in which a plurality of enamel wires and bare copper wires having a non-circular cross-sectional outline are aggregated so that the overall cross-sectional outline is circular and the bare copper wires are not adjacent to each other. And a first insulating coating formed by winding an insulating tape around the outer periphery of the assembly wire so as to bundle the assembly wire.
- a plurality of enamel wires and bare copper wires having a non-circular cross-sectional outline are aggregated to form a circular overall cross-sectional outline and the bare copper wires are not adjacent to each other.
- An insulating tape is wound so as to be bundled to form a first insulating coating.
- a plurality of enameled wires and bare copper wires are passed through a circular die and compressed into a circular shape from the outside, the enamel layer corresponding to the outer peripheral surface of the collecting wire is damaged by friction with the circular die, The insulation properties of the outer peripheral surface of the wire are reduced.
- at least one layer of insulation coating is provided on the outer periphery of the assembly line, sufficient insulation characteristics can be obtained.
- the assembly wire can be prevented from being separated by tape winding, a uniform finished outer diameter can be obtained even when the coil is wound.
- high frequency copper loss can be reduced compared with a single wire, it is excellent in high frequency characteristics.
- some bare copper wires are used, the solderability can be improved and the cost can be reduced as compared with the case where all are enamel wires.
- the total number of enamel wires and bare copper wires constituting the assembly wire is preferably 4 or more from the viewpoint of improving high-frequency characteristics. Moreover, when compressing using a circular die
- the present invention provides an insulated wire according to the fourth aspect, wherein the plurality of enamel wires and bare copper wires are bundled in parallel without being twisted. To do.
- the finished outer shape can be made smaller than when twisted.
- the wire length can be shortened and the direct current resistance can be reduced.
- the twisting process is slower than the compression process and the tape winding process, which reduces productivity and increases manufacturing costs. However, since the twisting process is not required, productivity can be improved and manufacturing cost can be reduced.
- the present invention provides an insulated wire according to the fourth or fifth aspect, wherein at least a part of all or a part of the plurality of enameled wires and a part or all of the bare copper wires.
- an insulated wire characterized in that a soft magnetic layer is formed on one outer periphery.
- the magnetic flux that generates eddy current loss passes through the magnetic layer on the surface more easily than the copper wire portion. Since the magnetic layer has a higher specific resistance than copper, eddy current loss can be reduced. Therefore, high frequency copper loss can be further reduced, and high frequency characteristics can be further improved.
- the present invention provides the insulated wire according to any one of the fourth to sixth aspects, wherein a tin plating layer is formed on an outermost periphery of all or part of the bare copper wire.
- An insulated wire is provided.
- the tin plating layer is exposed at a part of the assembly line, the solderability can be improved.
- the present invention provides an insulated wire according to any one of the first to seventh aspects, wherein an insulating tape is wound around an outer periphery of the first insulating coating to form a second insulating coating, An insulated wire is provided, characterized in that an insulating tape is wound around the outer periphery of two insulating coatings to form a third insulating coating.
- the insulated wire according to the eighth aspect since three or more layers of insulating tape are wound, it is regarded as a reinforced insulated wire defined by safety standards, and when used in a high-frequency transformer used for a switching power supply, etc., between primary and secondary It is possible to contribute to miniaturization of the high-frequency transformer, such as eliminating the need to provide an insulating partition.
- the present invention provides an insulated wire according to any one of the first to seventh aspects, wherein a second insulating coating is formed by extruding resin on an outer periphery of the first insulating coating, and the second An insulated wire is provided in which a third insulating coating is formed by resin extrusion on the outer periphery of the insulating coating.
- the winding property can be improved.
- sufficient insulation characteristics can be obtained. Therefore, it can be used, for example, in a coil of a high-frequency transformer such as a switching power supply, and in this case, there is no need to provide an insulating partition between the primary and secondary, which can contribute to downsizing of the high-frequency transformer.
- the present invention provides an insulated wire according to any one of the first to ninth aspects, wherein a self-bonding layer is provided on the outermost periphery.
- a self-bonding layer is provided on the outermost periphery.
- the shape retention of the coil can be obtained. If the inner layer of the self-bonding layer is a resin extruded layer, the self-bonding layer can be easily formed.
- the present invention provides a coil in which an insulated wire according to any one of the first to tenth aspects is wound.
- the coil according to the eleventh aspect since an insulated wire excellent in high frequency characteristics and insulation characteristics is used, the coil is excellent in high frequency characteristics and insulation characteristics. Moreover, it becomes easy to reduce in size. For example, it can be used for a coil of a high-frequency transformer such as a switching power supply, and in this case, it is not necessary to provide an insulating partition between the primary and secondary, which can contribute to miniaturization of the high-frequency transformer.
- the insulated wire of the present invention high frequency characteristics and insulating characteristics can be improved.
- the finished outer diameter can be reduced.
- high frequency characteristics and insulation characteristics can be improved. Moreover, it becomes easy to reduce in size.
- FIG. 1 is a side view showing an insulated wire according to Example 1.
- FIG. FIG. 2 is a cross-sectional view taken along the line A-A ′ of FIG. 1.
- 6 is a cross-sectional view showing an insulated wire according to Example 2.
- FIG. 6 is a cross-sectional view showing an insulated wire according to Example 3.
- FIG. 6 is a cross-sectional view showing an insulated wire according to Example 4.
- FIG. 10 is a cross-sectional view showing an insulated wire according to Example 5.
- FIG. It is a side view which shows the insulated wire which concerns on Example 6.
- FIG. 1 is a side view illustrating an insulated wire 101 according to the first embodiment.
- FIG. 2 is a cross-sectional view taken along the line AA ′ of FIG.
- the insulated wire 101 includes an assembly line 11 in which seven enamel wires 4 having a non-circular cross-sectional outline are gathered in parallel to form a circular overall cross-sectional outline, and an outer periphery of the assembly line 11 so that the assembly line 11 is bundled.
- a first insulating coating 1 formed by winding an insulating tape around the first insulating coating 1, a second insulating coating 2 formed by winding the insulating tape around the first insulating coating 1, and a third insulating coating formed by winding the insulating tape around the second insulating coating 2.
- the enameled wire 4 is obtained by baking an enamel layer 4b on the outer periphery of the copper wire 4a.
- the insulated wire 101 has an outer diameter of 0.69 mm, a conductor cross-sectional area of 0.191 square mm, and the insulating tape is a polyester film.
- the insulated wire 101 is formed by, for example, gathering seven parallel enamel wires made by baking a heat-resistant urethane resin to a film thickness of 1.5 ⁇ m on a copper wire having an outer diameter of 0.21 mm and a circular cross section and passing through a circular die having a diameter of 0.51 mm.
- the assembly line 11 is manufactured by compression (compression process), and tape winding is performed on the outer periphery of the assembly line 11 in three stages (tape winding process), so that it can be continuously manufactured.
- the insulated wire 101 of Example 1 the following effect is acquired.
- High-frequency loss can be reduced compared to a single wire having the same conductor cross-sectional area.
- It has three layers of insulating coatings 1, 2, and 3 and has excellent insulating properties.
- the twisting process has a slower processing line speed than the compression process and the tape winding process, and thus the productivity is deteriorated and the manufacturing cost is increased. Since the twisting process is not required, productivity can be improved and manufacturing cost can be reduced.
- FIG. 3 is a cross-sectional view illustrating the insulated wire 102 according to the second embodiment.
- the insulated wire 102 includes a set line 12 in which seven enamel magnetic wires 5 having a non-circular cross-sectional outline gather in parallel to form a circular overall cross-sectional outline, and a set line 12 so that the set line 12 is bundled.
- a first insulating coating 1 formed by winding an insulating tape around the outer periphery
- a second insulating coating 2 formed by winding an insulating tape around the first insulating coating 1
- a second insulating coating 2 formed by winding an insulating tape around the second insulating coating 2.
- the enamel magnetic wire 5 is formed by forming a soft magnetic layer 5a on the outer periphery of the copper wire 4a and baking the enamel layer 4b on the outer periphery thereof.
- the soft magnetic layer 5a is nickel or a nickel alloy that easily follows compression deformation and expansion deformation in the compression process.
- the thickness of the soft magnetic layer 5a is, for example, 1.5 ⁇ m.
- the high frequency loss can be further reduced by the magnetic shield effect of the soft magnetic layer 5a.
- FIG. 4 is a cross-sectional view illustrating the insulated wire 103 according to the third embodiment.
- This insulated wire 103 is a set in which six enameled wires 4 having a non-circular cross-sectional outline are assembled in parallel around a single bare copper wire 6 having a non-circular cross-sectional outline, and the entire cross-sectional outline is circular.
- a first insulating coating 1 formed by winding an insulating tape around the outer circumference of the collecting wire 13 so that the collecting wire 13 is bundled, and a second insulating coating 2 formed by winding the insulating tape around the first insulating coating 1
- a third insulating coating 3 formed by winding an insulating tape around the second insulating coating 2.
- the cost can be reduced as compared with the case where all are enameled wires 4.
- FIG. 5 is a cross-sectional view illustrating the insulated wire 104 according to the fourth embodiment.
- the insulated wire 104 includes three enamel magnetic wires 5 having a non-circular cross-sectional profile and three tin-plated copper wires 7 having a non-circular cross-sectional profile around one enamel magnetic wire 5 having a non-circular cross-sectional profile.
- FIG. 6 is a side view illustrating the insulated wire 105 according to the fifth embodiment.
- the insulated wire 105 includes an assembly line 11 in which seven enamel wires 4 having a non-circular cross-sectional outline are gathered in parallel to form a circular overall cross-sectional outline, and an outer periphery of the assembly line 11 so that the assembly line 11 is bundled.
- a first insulating coating 1 formed by winding an insulating tape, a second insulating coating 2 'obtained by coating the outer periphery of the first insulating coating 1 by resin extrusion, and an outer periphery of the second insulating coating 2' by resin extrusion. It is provided with a third insulating coating 3 ′.
- the winding property can be improved.
- FIG. 7 is a cross-sectional view illustrating the insulated wire 106 according to the sixth embodiment.
- This insulated wire 106 is obtained by forming the self-bonding layer 9 on the outermost periphery of the insulated wire 105 of Example 5.
- Example 7 The elements in Examples 1 to 6 may be appropriately combined.
- the self-bonding layer 9 may be provided on the outer periphery of the third insulating coating 3 of Example 1.
- a tin-plated copper wire may be used instead of the bare copper wire 6 of the third embodiment.
- Example 8 The insulated wire 101 (conductor cross-sectional area 0.191 square mm, outer diameter 0.69 mm) according to Example 1 was wound to produce an air-core coil having 52 turns, a coil length of 5 mm, and a coil inner diameter of 20 mm.
- the number of coil layers of this air-core coil was 7, the outer diameter of the coil was 30 mm, the direct current resistance of the coil was 0.360 ⁇ , the effective resistance at 100 kHz was 0.82 ⁇ , and the effective resistance at 200 kHz was 2.17 ⁇ .
- Example 1 A single wire (conductor cross-sectional area 0.196 square mm, outer diameter 0.68 mm) was manufactured by winding the tape around the outer periphery of a copper wire having an outer diameter of 0.5 mm and a circular cross section. This single wire was wound to produce an air-core coil having 52 turns, a coil length of 5 mm, and a coil inner diameter of 20 mm. The number of coil layers of this air-core coil was 7, the outer diameter of the coil was 30 mm, the coil DC resistance was 0.355 ⁇ , the effective resistance at 100 kHz was 2.76 ⁇ , and the effective resistance at 200 kHz was 5.70 ⁇ .
- the coil of Example 8 is excellent in high frequency characteristics while having the same outer diameter as the coil of Comparative Example 1.
- -Comparative Example 2- Twist seven enameled wires that are baked with heat-resistant urethane resin to a film thickness of 1.5 ⁇ m on a copper wire with an outer diameter of 0.2mm and a circular cross-sectional outline to produce an assembly wire (twisting process), and the outer circumference of the assembly wire
- a litz wire (conductor cross-sectional area 0.220 square mm, outer diameter 0.84 mm) was manufactured by winding the tape in three stages.
- the litz wire was wound to produce an air-core coil having 52 turns, a coil length of 5 mm, and a coil inner diameter of 20 mm.
- This air-core coil had nine coil layers, a coil outer diameter of 35 mm, a coil DC resistance of 0.341 ⁇ , an effective resistance at 100 kHz of 0.78 ⁇ , and an effective resistance of 200 kHz at 2.02 ⁇ .
- the coil of Example 8 is excellent in miniaturization while having substantially the same high frequency loss as the coil of Comparative Example 2.
- the insulated wire and coil of the present invention can be used for a transformer for a switching power source, a coil for a non-contact power feeding device, a motor, and the like.
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Abstract
Description
しかし、製造時に、複数本のエナメル線より成る撚線を円形ダイスに通して外側より円形に圧縮するが、このとき外周面に相当するエナメル層が円形ダイスとの摩擦で損傷し、外周面の絶縁特性が低下する。すなわち、上記従来のリッツ線は、絶縁特性に問題がある。このため、コイルに巻回した場合、巻線間でのショート即ちレアーショートを起こしやすく信頼性に問題がある。なお、外周面に自己融着層を設けているが、これは絶縁特性を保障するものではない。
そこで、本発明の目的は、高周波特性および絶縁特性に優れた絶縁電線およびコイルを提供することにある。
上記第1の観点による絶縁電線では、断面輪郭が非円形のエナメル線が複数本集合して全体の断面輪郭が円形になった集合線を束ねるように絶縁テープを巻回して第1絶縁被覆とする。複数本のエナメル線を円形ダイスに通して外側より円形に圧縮して集合線を製造する場合、集合線の外周面に相当するエナメル層が円形ダイスとの摩擦で損傷し、集合線の外周面の絶縁特性が低下する。しかし、集合線の外周に少なくとも1層の絶縁被覆を設けるため、十分な絶縁特性が得られる。また、テープ巻きにより集合線のバラケを防止することが出来るため、コイルに巻線した際にも均一な仕上がり外径が得られる。さらに、単線に比べて高周波銅損を低減できるため、高周波特性に優れている。
上記第2の観点による絶縁電線では、複数本のエナメル線を撚らずに平行に束ねるため、撚った場合よりも仕上がり外形を小さく出来る。また、線長を短縮できる。さらに、直流抵抗を低減できる。また、複数本のエナメル線を撚る場合、その撚り加工工程は、圧縮工程やテープ巻工程と比べて加工線速が遅いため、生産性が悪くなり、製造コストを押し上げる要因となるが、その撚り加工工程を必要としないので、生産性を向上でき、製造コストを低減することが出来る。
上記第3の観点による絶縁電線では、銅線を軟磁性層で被覆するため、渦電流損を発生させる磁束は、銅線部分よりも表面の磁性層を通り易い。磁性層は銅よりも固有抵抗が高いため、渦電流損を低減することが出来る。従って、高周波銅損をさらに低減でき、高周波特性をさらに向上できる。
上記第4の観点による絶縁電線では、断面輪郭が非円形のエナメル線および裸銅線が複数本集合して全体の断面輪郭が円形になり且つ裸銅線同士が隣接しない配置になった集合線を束ねるように絶縁テープを巻回して第1絶縁被覆とする。複数本のエナメル線および裸銅線を円形ダイスに通して外側より円形に圧縮して集合線を製造する場合、集合線の外周面に相当するエナメル層が円形ダイスとの摩擦で損傷し、集合線の外周面の絶縁特性が低下する。しかし、集合線の外周に少なくとも1層の絶縁被覆を設けるため、十分な絶縁特性が得られる。また、テープ巻きにより集合線のバラケを防止することが出来るため、コイルに巻線した際にも均一な仕上がり外径が得られる。また、単線に比べて高周波銅損を低減できるため、高周波特性に優れている。さらに、一部に裸銅線を使用するため、全てをエナメル線にするよりも半田付け性を向上できると共にコストを低減できる。
上記第5の観点による絶縁電線では、複数本のエナメル線および裸銅線を撚らずに平行に束ねるため、撚った場合よりも仕上がり外形を小さく出来る。また、線長を短縮でき、直流抵抗を低減できる。また、複数本のエナメル線および裸銅線を撚る場合、その撚り加工工程は、圧縮工程やテープ巻工程と比べて加工線速が遅いため、生産性が悪くなり、製造コストを押し上げる要因となるが、その撚り加工工程を必要としないので、生産性を向上でき、製造コストを低減することが出来る。
上記第6の観点による絶縁電線では、銅線を軟磁性層で被覆するため、渦電流損を発生させる磁束は、銅線部分よりも表面の磁性層を通り易い。磁性層は銅よりも固有抵抗が高いため、渦電流損を低減することが出来る。従って、高周波銅損をさらに低減でき、高周波特性をさらに向上できる。
上記第7の観点による絶縁電線では、集合線の一部に錫めっき層が露出しているため、半田付け性を向上することが出来る。
上記第8の観点による絶縁電線では、絶縁テープを3層以上巻くため、安全規格で定める強化絶縁電線とみなされ、スイッチング電源等に使用される高周波トランスに使用した場合、一次・二次間に絶縁隔壁を設ける必要がなくなるなど、高周波トランスの小型化などにも寄与しうる。
上記第9の観点による絶縁電線では、巻線性を向上することが出来る。また、十分な絶縁特性が得られる。そこで、例えばスイッチング電源等の高周波トランスのコイルに使用でき、この場合に一次・二次間に絶縁隔壁を設ける必要がなくなるなど、高周波トランスの小型化などにも寄与しうる。
上記第10の観点による絶縁電線では、コイルの形状保持性を得ることが出来る。なお、自己融着層の内側の層を樹脂押出層とすれば、自己融着層の形成が容易になる。
上記第11の観点によるコイルでは、高周波特性および絶縁特性に優れた絶縁電線を用いるため、高周波特性および絶縁特性に優れたコイルとなる。また、小型化することが容易になる。例えばスイッチング電源等の高周波トランスのコイルに使用でき、この場合に一次・二次間に絶縁隔壁を設ける必要がなくなるなど、高周波トランスの小型化などに寄与しうる。
本発明のコイルによれば、高周波特性および絶縁特性を向上できる。また、小型化することが容易になる。
図1は、実施例1に係る絶縁電線101を示す側面図である。図2は、図1のA-A’断面図である。
この絶縁電線101は、断面輪郭が非円形の7本のエナメル線4が平行に集合して全体の断面輪郭が円形になった集合線11と、集合線11を束ねるように集合線11の外周に絶縁テープを巻回してなる第1絶縁被覆1と、第1絶縁被覆1に絶縁テープを巻回してなる第2絶縁被覆2と、第2絶縁被覆2に絶縁テープを巻回してなる第3絶縁被覆3とを具備してなる。
エナメル線4は、銅線4aの外周にエナメル層4bを焼き付けたものである。
(1)同一の導体断面積をもつ単線に比べて高周波損失を低減できる。
(2)3層の絶縁被覆1,2,3を有し、絶縁特性に優れている。
(3)絶縁テープを巻くことにより圧縮された集合線11のバラケを防止できる。
(4)エナメル線4を撚らずに平行に束ねるため、撚った場合よりも外形を小さく出来る。また、線長を短縮できる。さらに、直流抵抗を低減できる。
(5)複数本のエナメル線4を撚る場合、その撚り加工工程は、圧縮工程やテープ巻工程と比べて加工線速が遅いため、生産性が悪くなり、製造コストを押し上げる要因となるが、その撚り加工工程を必要としないので、生産性を向上でき、製造コストを低減することが出来る。
図3は、実施例2に係る絶縁電線102を示す断面図である。
この絶縁電線102は、断面輪郭が非円形の7本のエナメル磁性線5が平行に集合して全体の断面輪郭が円形になった集合線12と、集合線12を束ねるように集合線12の外周に絶縁テープを巻回してなる第1絶縁被覆1と、第1絶縁被覆1に絶縁テープを巻回してなる第2絶縁被覆2と、第2絶縁被覆2に絶縁テープを巻回してなる第3絶縁被覆3とを具備してなる。
エナメル磁性線5は、銅線4aの外周に軟磁性層5aを形成し、その外周にエナメル層4bを焼き付けたものである。
図4は、実施例3に係る絶縁電線103を示す断面図である。
この絶縁電線103は、断面輪郭が非円形の1本の裸銅線6の周りに断面輪郭が非円形の6本のエナメル線4を平行に集合して全体の断面輪郭が円形になった集合線13と、集合線13を束ねるように集合線13の外周に絶縁テープを巻回してなる第1絶縁被覆1と、第1絶縁被覆1に絶縁テープを巻回してなる第2絶縁被覆2と、第2絶縁被覆2に絶縁テープを巻回してなる第3絶縁被覆3とを具備してなる。
図5は、実施例4に係る絶縁電線104を示す断面図である。
この絶縁電線104は、断面輪郭が非円形の1本のエナメル磁性線5の周りに断面輪郭が非円形の3本のエナメル磁性線5および断面輪郭が非円形の3本の錫メッキ銅線7を平行に集合して全体の断面輪郭が円形になり且つ錫めっき銅線7同士が隣接しない配置になった集合線14と、集合線14を束ねるように集合線14の外周に絶縁テープを巻回してなる第1絶縁被覆1と、第1絶縁被覆1に絶縁テープを巻回してなる第2絶縁被覆2と、第2絶縁被覆2に絶縁テープを巻回してなる第3絶縁被覆3とを具備してなる。
図6は、実施例5に係る絶縁電線105を示す側面図である。
この絶縁電線105は、断面輪郭が非円形の7本のエナメル線4が平行に集合して全体の断面輪郭が円形になった集合線11と、集合線11を束ねるように集合線11の外周に絶縁テープを巻回してなる第1絶縁被覆1と、第1絶縁被覆1の外周を樹脂押出しにより被覆してなる第2絶縁被覆2’と、第2絶縁被覆2’の外周を樹脂押出しにより被覆してなるに第3絶縁被覆3’とを具備してなる。
図7は、実施例6に係る絶縁電線106を示す断面図である。
この絶縁電線106は、実施例5の絶縁電線105の最外周に自己融着層9を形成したものである。
実施例1~実施例6の各要素を適宜組み合わせてもよい。例えば、実施例1の第3絶縁被覆3の外周に自己融着層9を設けてもよい。また、実施例3の裸銅線6の代わりに錫めっき銅線を用いてもよい。
実施例1に係る絶縁電線101(導体断面積0.191平方mm、外径0.69mm)を巻回し、巻数52ターン、コイル長5mm、コイル内径20mmの空芯コイルを製作した。
この空芯コイルのコイル層数は7層、コイル外径は30mm、コイル直流抵抗は0.360Ω、100kHzでの実効抵抗は0.82Ω、200kHzでの実効抵抗は2.17Ωであった。
外径0.5mmの断面輪郭が円形の銅線の外周にテープ巻きを3段階に行って単線(導体断面積0.196平方mm、外径0.68mm)を製作した。この単線を巻回し、巻数52ターン、コイル長5mm、コイル内径20mmの空芯コイルを製作した。
この空芯コイルのコイル層数は7層、コイル外径は30mm、コイル直流抵抗は0.355Ω、100kHzでの実効抵抗は2.76Ω、200kHzでの実効抵抗は5.70Ωであった。
実施例8のコイルは、比較例1のコイルと外径寸法は同一ながら高周波特性に優れている。
外径0.2mmの断面輪郭が円形の銅線に耐熱ウレタン樹脂を膜厚1.5μmに焼き付けたエナメル線を7本撚って集合線を製作し(撚り加工工程)、その集合線の外周にテープ巻きを3段階に行ってリッツ線(導体断面積0.220平方mm、外径0.84mm)を製作した。このリッツ線を巻回し、巻数52ターン、コイル長5mm、コイル内径20mmの空芯コイルを製作した。
この空芯コイルのコイル層数は9層、コイル外径は35mm、コイル直流抵抗は0.341Ω、100kHzでの実効抵抗は0.78Ω、200kHzでの実効抵抗は2.02Ωであった。
実施例8のコイルは、比較例2のコイルと高周波損失は略同等ながら小型化に優れている。
2,2’ 第2絶縁被覆
3,3’ 第3絶縁被覆
4 エナメル線
4a 銅線
4b エナメル層
5 エナメル磁性線
5a 軟磁性層
6 裸銅線
7 錫めっき銅線
7a 錫めっき層
9 自己融着層
11~14 集合線
101~106 絶縁電線
Claims (11)
- 断面輪郭が非円形のエナメル線が複数本集合して全体の断面輪郭が円形になった集合線と、前記集合線を束ねるように前記集合線の外周に絶縁テープを巻回してなる第1絶縁被覆とを具備したことを特徴とする絶縁電線。
- 請求項1に記載の絶縁電線であって、前記複数本のエナメル線を撚らずに平行に束ねたことを特徴とする絶縁電線。
- 請求項1または請求項2に記載の絶縁電線であって、前記複数本のエナメル線の全部または一部の銅線の外周に軟磁性層を形成したことを特徴とする絶縁電線。
- 断面輪郭が非円形のエナメル線および裸銅線が複数本集合して全体の断面輪郭が円形になり且つ裸銅線同士が隣接しない配置になった集合線と、前記集合線を束ねるように前記集合線の外周に絶縁テープを巻回してなる第1絶縁被覆とを具備したことを特徴とする絶縁電線。
- 請求項4に記載の絶縁電線であって、前記複数本のエナメル線および裸銅線を撚らずに平行に束ねたことを特徴とする絶縁電線。
- 請求項4または請求項5に記載の絶縁電線であって、前記複数本のエナメル線の全部または一部の銅線および裸銅線の全部または一部の少なくとも一方の外周に軟磁性層を形成したことを特徴とする絶縁電線。
- 請求項4から請求項6のいずれかに記載の絶縁電線であって、前記裸銅線の全部または一部の最外周に錫めっき層を形成したことを特徴とする絶縁電線。
- 請求項1から請求項7のいずれかに記載の絶縁電線であって、前記第1絶縁被覆の外周に絶縁テープを巻回して第2絶縁被覆とし、前記第2絶縁被覆の外周に絶縁テープを巻回して第3絶縁被覆としたことを特徴とする絶縁電線。
- 請求項1から請求項7のいずれかに記載の絶縁電線であって、前記第1絶縁被覆の外周に樹脂押出して第2絶縁被覆を形成し、前記第2絶縁被覆の外周に樹脂押出して第3絶縁被覆を形成したことを特徴とする絶縁電線。
- 請求項1から請求項9のいずれかに記載の絶縁電線であって、最外周に自己融着層を設けたことを特徴とする絶縁電線。
- 請求項1から請求項10のいずれかに記載の絶縁電線を巻回したことを特徴とするコイル。
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Cited By (2)
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CN103460305A (zh) * | 2011-03-30 | 2013-12-18 | 东京特殊电线株式会社 | 绝缘电线和线圈 |
CN109074946A (zh) * | 2016-04-22 | 2018-12-21 | 古河电气工业株式会社 | 绕线、线圈和变压器 |
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JP2013171700A (ja) * | 2012-02-21 | 2013-09-02 | Furukawa Electric Co Ltd:The | コイル用線材、コイル構造 |
CN102708952A (zh) * | 2012-06-27 | 2012-10-03 | 苏州科宝光电科技有限公司 | 励磁线 |
JP5621826B2 (ja) | 2012-10-05 | 2014-11-12 | トヨタ自動車株式会社 | 集合導線及びその製造方法 |
US9330815B2 (en) * | 2013-08-14 | 2016-05-03 | Apple Inc. | Cable structures with insulating tape and systems and methods for making the same |
JP5957428B2 (ja) * | 2013-09-25 | 2016-07-27 | 株式会社フジクラ | 高周波電線およびその製造方法 |
DE102015213616A1 (de) * | 2015-07-20 | 2017-01-26 | Schaeffler Technologies AG & Co. KG | Spulenwicklung aus HF-Litze, elektrische Maschine mit einer derartigen Spulenwicklung und Verfahren zu deren Herstellung |
JP6568133B2 (ja) * | 2017-03-30 | 2019-08-28 | パナソニック株式会社 | 伝送コイル及び送電装置 |
JP6817487B1 (ja) * | 2020-03-03 | 2021-01-20 | 東京特殊電線株式会社 | 絶縁電線及びコイル |
WO2020164645A2 (zh) * | 2020-04-21 | 2020-08-20 | 深圳顺络电子股份有限公司 | 一种电感元器件及制造方法 |
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CN109074946A (zh) * | 2016-04-22 | 2018-12-21 | 古河电气工业株式会社 | 绕线、线圈和变压器 |
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JP2010177075A (ja) | 2010-08-12 |
CN102171771A (zh) | 2011-08-31 |
CN102171771B (zh) | 2013-03-06 |
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