Composite insulated wires and their manufacturing method

Abstract

This invention provides a composite insulated wire with improved electrical insulation properties and a method for manufacturing the composite insulated wire. The composite insulated wire (1) comprises: multiple insulated wire portions (2) having conductors (21) and wire sheathing portions (22) surrounding the conductors (21); and an insulating tape (3) that aggregates and surrounds the multiple insulated wire portions (2). The insulating tape (3) comprises: an insulating layer (31) with electrical insulation properties, and a weld layer (32) fused to the multiple insulated wire portions (2). The weld layer (32) is made of engineering plastic or super engineering plastic. The method for manufacturing the composite insulated wire (1) involves laterally winding the insulating tape (3) in a manner that aggregates and surrounds the multiple insulated wire portions (2), and then bonding the weld layer (32) of the insulating tape (3) to the multiple insulated wire portions (2) respectively by induction heating.

Description

Technical Field

[0001] This invention relates to insulated wires and a method for manufacturing insulated wires. Background Technology

[0002] Patent Document 1 discloses an insulated wire as a group of insulated wires constituting segmented coils of a vehicle motor. The insulated wire described in Patent Document 1 includes: a plurality of wire portions having wires and a covering portion formed on the outer periphery of the wires; and an insulating layer covering the plurality of wire portions.

[0003] Existing technical documents

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent Application Publication No. 2021-141011 Summary of the Invention

[0006] The problem that the invention aims to solve

[0007] In the insulated wire described in Patent Document 1, the insulation layer is formed by coating a resin material onto the surface of a laminate consisting of multiple wire sections and then heating it. Here, depressions exist at the overlapping portions of the multiple wire sections on the surface of the resin-coated laminate. Therefore, when forming the insulation layer covering the laminate, air may remain in the depressions or foam may form, resulting in defects in the insulation layer and potentially reducing the electrical insulation properties of the insulated wire.

[0008] The present invention was made in view of the above circumstances, and its object is to provide a composite insulated wire and a method for manufacturing a composite insulated wire that can improve electrical insulation.

[0009] Methods for solving problems

[0010] To achieve the above objectives, the present invention provides an insulated wire comprising: a plurality of insulated wire portions having conductors and wire sheathing portions surrounding the conductors; and an insulating tape that aggregates and surrounds the plurality of insulated wire portions. The insulating tape comprises: an insulating layer having electrical insulation properties, and a fusion layer fused to the plurality of insulated wire portions, the fusion layer being made of engineering plastic or super engineering plastic.

[0011] In addition, to achieve the above objectives, the present invention provides a method for manufacturing an insulated wire assembly, comprising preparing a plurality of insulated wire portions having conductors and wire sheathing portions surrounding the conductors, and an insulating tape having an insulating layer and a fusion layer, wherein the insulating layer has electrical insulation properties, the fusion layer is fused to the plurality of insulated wire portions and is made of engineering plastic or super engineering plastic, the insulating tape is laterally wound in a manner that assembles and surrounds the plurality of insulated wire portions, and the fusion layer of the insulating tape is respectively bonded to the plurality of insulated wire portions by induction heating.

[0012] Invention Effects

[0013] According to the present invention, a composite insulated wire and a method for manufacturing a composite insulated wire are provided that can improve electrical insulation. Attached Figure Description

[0014] Figure 1 This is a perspective view of the insulated wire assembly in the first embodiment.

[0015] Figure 2 This is a cross-sectional view of the insulated wire assembly in the first embodiment.

[0016] Figure 3 This is a cross-sectional view of the insulated wire assembly in the second embodiment.

[0017] Figure 4 This is a cross-sectional view of the insulated wire assembly in the third embodiment.

[0018] Figure 5 This is a cross-sectional view of the insulated wire assembly in the fourth embodiment.

[0019] Figure 6 This is a cross-sectional view of the insulated wire assembly in the fifth embodiment.

[0020] Figure 7 This is a cross-sectional view of the insulated wire assembly in the sixth embodiment.

[0021] Figure 8 This is a cross-sectional view of the insulated wire assembly in the seventh embodiment.

[0022] Figure 9 This is a cross-sectional view of the insulated wire assembly in the eighth embodiment.

[0023] Figure 10 This is a cross-sectional view of the insulated wire assembly in the ninth embodiment.

[0024] Figure 11 This is a schematic diagram illustrating the heating process in the ninth embodiment.

[0025] Figure 12This is the first figure used to illustrate the fit evaluation method in Experiment Example 2.

[0026] Figure 13 This is the second figure used to illustrate the fit evaluation method in Experiment Example 2.

[0027] Explanation of reference numerals in the attached figures

[0028] 1…Insulated wire, 2…Insulated wire section, 21…Conductor, 22…Wire sheath, 221…Wire insulation layer, 222…Outer wire fusion layer, 3…Insulation tape, 31…Insulation layer, 32…Fusing layer. Detailed Implementation

[0029] [First Implementation Method]

[0030] Reference Figure 1 and Figure 2 The first embodiment of the present invention will be described below. It should be noted that the embodiments described below are shown as preferred specific examples for carrying out the present invention, and there are also specific examples of various technically preferred aspects, but the technical scope of the present invention is not limited to these specific methods.

[0031] Figure 1 This is a three-dimensional view of the insulated wire 1 in this method. Figure 2 This is a cross-sectional view of the insulated wire 1 in this method. Figure 2 The cross-section of the insulated wire 1, orthogonal to the length direction, is shown. It should be noted that when referred to simply as the "length direction," it refers to the length direction of the insulated wire 1.

[0032] The insulated wire 1 of this embodiment comprises multiple insulated wire portions 2 and an insulating strip 3. Each insulated wire portion 2 has a conductor 21 and a wire sheath 22 surrounding the conductor 21. The insulating strip 3 aggregates and surrounds the multiple insulated wire portions 2. Furthermore, the insulating strip 3 has: an insulating layer 31 having electrical insulation properties; and a fusion layer 32 formed on the inner surface of the insulating layer 31 and fused to the multiple insulated wire portions 2. The fusion layer 32 is made of engineering plastic or super engineering plastic. The insulated wire 1 of this embodiment will now be described in detail.

[0033] In this embodiment, the insulated wire 1 comprises four or fewer, specifically two insulated wire portions 2. The more numerous the insulated wire portions 2 are in the insulated wire 1, the easier it is to reduce the proportion of the conductor 21 in the arrangement space of the insulated wire 1, i.e., the duty cycle. Therefore, from this viewpoint, the number of insulated wire portions 2 is preferably four or fewer, more preferably two or fewer. However, the number of insulated wire portions 2 in the insulated wire 1 may exceed four. Each insulated wire portion 2 is a flat wire. Two insulated wire portions 2 are stacked on top of each other in the same thickness direction. It should be noted that the insulated wire portion 2 is not limited to a flat wire; its cross-sectional shape may also be circular, etc., but from the viewpoint of increasing the duty cycle, a flat wire is preferred.

[0034] The conductor 21 of the insulated wire section 2 is a flat wire with a rectangular cross-sectional shape orthogonal to the length direction. The conductor 21 is made of metallic materials such as pure copper, copper alloy, aluminum, or aluminum alloy. The conductor 21 may also be plated with a metal such as nickel.

[0035] The wire sheath 22 includes a wire insulation layer 221. In this embodiment, the wire sheath 22 is composed of a wire insulation layer 221 that is in contact with the conductor 21. The wire insulation layer 221 is, for example, an enameled film made of a thermosetting resin with electrical insulating properties, such as polyamide-imide (PAI) or polyimide (PI). It should be noted that in this embodiment, the wire insulation layer 221 can be any film other than an enameled film, as long as it is formed adjacent to the conductor 21 and has electrical insulating properties. For example, the wire insulation layer 221 can also be an oxide film made of an oxide formed on the surface of the conductor 21.

[0036] Corner 220 of the surface of the wire covering portion 22 (refer to) Figure 2 The terrain inevitably becomes curved. Consequently, in the state where two insulated wire sections 2 are stacked, recesses 20 inevitably form between the corners 220 on the surface of the stack of multiple insulated wire sections 2 (see reference). Figure 2 ).

[0037] Here, we examine the case where the outermost layer is formed by coating a resin material onto the surface of a laminate consisting of multiple insulated wire portions 2 and then heating it (for example, the invention described in Patent Document 1 above). In this case, air may remain in the depressions 20 during resin coating, or foaming may occur from the depressions 20 during heating, resulting in a decrease in the electrical insulation of the finished product. Therefore, in this embodiment, by employing a configuration in which multiple insulated wire portions 2 are covered with an insulating tape 3, the decrease in the electrical insulation of the assembled insulated wire 1 is suppressed.

[0038] like Figure 1As shown, the insulating tape 3 is spirally wound (transversely wound) onto multiple insulated wire portions 2. In this configuration, the insulating tape 3 is wound onto the multiple insulated wire portions 2 in a manner where its portions do not overlap. Specifically, the insulating tape 3 is wound in a so-called butt-wound manner, where the ends of the insulating tape 3 in the width direction are joined together. Therefore, compared to, for example, an overlapping winding method where the ends of the insulating tape 3 are overlapped while winding, the thickness of the insulating tape 3 is made more uniform in the length direction. This results in uniform electrical insulation of the insulating tape 3 in the length direction and allows for miniaturization. It should be noted that the winding method of the insulating tape 3 is not limited to butt-wound; it can also be overlapping winding or longitudinally added. When overlapping winding the insulating tape 3, it is preferable to set the overlap width to less than half the width of the insulating tape 3. Alternatively, multiple insulating tapes 3 can be used, and the insulating tape 3 can be overlapped several times to form the desired shape.

[0039] The insulating layer 31 of the insulating tape 3 is made of engineering plastics or super engineering plastics with heat resistance and electrical insulation properties, such as polyimide (PI), polyetheretherketone (PEEK), polyphenylene sulfide (PPS), polyetherimide (PEI), and thermoplastic polyimide (TPI). The insulating layer 31 is preferably a thermosetting resin such as polyimide, but it can also be a thermoplastic resin. When the insulating layer 31 is made of a thermoplastic resin, its melting point is preferably higher than that of the weld layer 32.

[0040] A weld layer 32 is formed on the inner surface of the insulation layer 31 and is welded to each of the plurality of insulated wire portions 2. This fixes the relative positions of the plurality of insulated wire portions 2. The weld layer 32 is made of an engineering plastic or a super engineering plastic that is a thermoplastic resin with heat resistance and electrical insulation properties. For example, the melting point of the weld layer 32 is preferably 250°C or higher. Furthermore, if the weld layer 32 is made of a material with no melting point, the melt-forming temperature is preferably 250°C or higher. Specifically, the weld layer 32 is made of a material including fluoropolymers, polyetheretherketone (PEEK), polyphenylene sulfide (PPS), thermoplastic polyimide (PI), and polyetherimide (PEI). Examples of fluoropolymers include perfluoroethylene-propylene copolymer (FEP), perfluoroalkoxyalkylene polymer (PFA), polytetrafluoroethylene (PTFE), and ethylene-tetrafluoroethylene copolymer (ETFE). Since the insulated wire 1 may be exposed to high temperatures due to heat generated during energization, it is desirable that the weld layer 32 does not melt at high temperatures. Furthermore, from the viewpoint of improving the electrical insulation of the insulating tape 3, the weld layer 32 can also be formed with a thickness of 10 μm or more. The overall thickness of the insulating tape 3 can be, for example, set to 10 μm or more and 200 μm or less. It should be noted that, in this embodiment, an example is shown where the insulating tape 3 has an insulating layer 31 and a weld layer 32 formed on the inner surface of the insulating layer 31 as a layer different from the insulating layer 31, i.e., an example composed of multiple layers, but it is not limited to this, and it can also be composed of a single layer that serves as both the insulating layer 31 and the weld layer 32.

[0041] The insulated wire 1 of this type is used, for example, as a component of a segmented coil mounted in a slot in the stator core of a vehicle motor. In this case, the insulated wire 1 is bent into the shape of the segmented coil (e.g., approximately U-shaped). Furthermore, when the insulated wire 1 is used in a segmented coil of a motor, heat generation during use becomes significant, requiring high heat resistance. As described above, the insulated wire 1 of this type improves the heat resistance of the insulation tape 3, making it suitable for use in a segmented coil of a motor.

[0042] In manufacturing the insulated wire 1 of this method, firstly, two insulated wire portions 2 and an insulating tape 3 are prepared. Then, the two insulated wire portions 2 are stacked in the same thickness direction to form a laminate. Then, the insulating tape 3 is wound around the laminate, and the whole assembly is heated, thereby fusing the fusion layer 32 to the two insulated wire portions 2. As described above, the insulated wire 1 of this method can be manufactured.

[0043] (Function and effects of the first embodiment)

[0044] In the insulated wire 1 of this embodiment, the insulating tape 3, which gathers and surrounds multiple insulated wire portions 2, has: an insulating layer 31 that has electrical insulation properties; and a fusion layer 32 formed on the inner surface of the insulating layer 31 and fused to the multiple insulated wire portions 2. Here, when the outermost layer is formed by coating the surface of a laminate formed by stacking multiple insulated wire portions 2 with resin material and heating (for example, the invention described in Patent Document 1 above), air may remain in the depressions 20 during resin material coating, or foam may occur from the depressions 20 during heating, potentially leading to a decrease in the electrical insulation of the finished product. Therefore, in this embodiment, the multiple insulated wire portions 2 are covered with the insulating tape 3. This suppresses the decrease in the electrical insulation of the insulated wire 1. Furthermore, the fusion layer 32 of the insulating tape 3 is made of engineering plastic or super engineering plastic. Therefore, it is possible to suppress the deterioration or degradation of the fusion layer 32 due to heat during use of the insulated wire 1, thus preventing a decrease in the electrical insulation of the insulated wire 1.

[0045] Furthermore, the weld layer 32 is composed of a material containing fluoropolymer, PEEK, PPS, PI, or PEI. Therefore, the heat resistance of the weld layer 32 is further improved.

[0046] Furthermore, the insulating tape 3 is formed such that its parts do not overlap. Therefore, the thickness of the insulating tape 3 is uniform along its length. As a result, the electrical insulation of the insulating tape 3 is uniform along its length, and miniaturization of the entire insulated wire 1 can be achieved.

[0047] Furthermore, the number of multiple insulated wire sections 2 is four or less. The more the number of insulated wire sections 2 in the bundled insulated wire 1 increases, the easier it is to reduce the proportion of the conductor 21 in the arrangement space of the bundled insulated wire 1, i.e., the duty cycle. By setting the number of multiple insulated wire sections 2 to four or less, the duty cycle can be improved.

[0048] As described above, according to this method, it is possible to provide a composite insulated wire that can improve electrical insulation.

[0049] [Second Implementation]

[0050] Reference Figure 3 The second embodiment of the present invention will be described. Figure 3 This is a cross-sectional view of insulated wire 1.

[0051] This embodiment differs from the first embodiment in that it modifies the wire sheath 22. Specifically, the wire sheath 22 in this embodiment further includes an outer wire welding layer 222 formed on the outside of the wire insulation layer 221. It should be noted that the wire insulation layer 221 is the same as in the first embodiment.

[0052] The outer wire welding layer 222 is made of an engineering plastic or super engineering plastic that is a thermoplastic resin with heat resistance and electrical insulation. For example, the melting point of the welding layer 32 is preferably 250°C or higher. Furthermore, if the outer wire welding layer 222 is made of a material with no melting point, the melt-forming temperature is preferably 250°C or higher. Specifically, the outer wire welding layer 222 is made of a material including fluoropolymer, polyetheretherketone (PEEK), polyphenylene sulfide (PPS), thermoplastic polyimide (PI), and polyetherimide (PEI). For example, perfluoroethylene propylene copolymer (FEP), perfluoroalkoxyalkane polymer (PFA), polytetrafluoroethylene (PTFE), and ethylene tetrafluoroethylene copolymer (ETFE) can be used as fluoropolymers. Since the insulated wire 1 may be exposed to high temperatures due to heat generated by current flow, it is desirable that the outer wire welding layer 222 does not melt at high temperatures. It should be noted that the boundary of the outer wire welding layer 222 may not be clearly identifiable after welding, but... Figure 3 In the diagram, a double-dotted line indicates the outline position of the outer wire welding layer 222 before welding.

[0053] The outer wire weld layers 222 of the multiple insulating wire sections 2 are fixed to each other by welding. In addition, the outer wire weld layers 222 of the multiple insulating wire sections 2 are also welded to the weld layer 32 of the insulating tape 3.

[0054] In manufacturing the insulated wire 1 of this method, firstly, two insulated wire sections 2 and an insulating tape 3 are prepared. Each insulated wire section 2 is formed, for example, by coating a conductor 21 with a resin material that forms the basis of the wire insulation layer 221 and heating it to form a wire insulation layer 221. Then, an outer wire welding layer 222 is formed by coating the wire insulation layer 221 with a resin material that forms the basis of the outer wire welding layer 222 and heating it. The two insulated wire sections 2 are then stacked in their respective thickness directions to form a laminate. The laminate is then heated to fuse the outer wire welding layers 222 of the two insulated wire sections 2 together. This fixes the relative positions of the two insulated wire sections 2. Next, the insulating tape 3 is wound around the two insulated wire sections 2, and the entire assembly is heated to fuse the welding layer 32 to the outer wire welding layers 222 of the two insulated wire sections 2.

[0055] As described above, it is possible to manufacture the insulated wire 1 of this method.

[0056] The other configurations of this embodiment are the same as those of the first embodiment.

[0057] It should be noted that, unless otherwise specified, reference numerals in the drawings used in the second embodiment and thereafter that are the same as those used in the previously appeared embodiments indicate the same constituent elements as those in the previously appeared embodiments.

[0058] (Function and effects of the second embodiment)

[0059] In this method, the outer wire welding layers 222 of the plurality of insulated wire portions 2 are welded together. Therefore, it is possible to suppress the positional displacement of the plurality of insulated wire portions 2 relative to each other.

[0060] Furthermore, it has the same function and effect as the first embodiment.

[0061] [Third Implementation Method]

[0062] Reference Figure 4 The third embodiment of the present invention will be described. Figure 4 This is a cross-sectional view of insulated wire 1.

[0063] This embodiment modifies the wire sheath 22 compared to the first embodiment. Specifically, the wire sheath 22 in this embodiment is composed of a strip. The wire sheath 22 in this embodiment includes a wire insulation layer 221 and an inner wire welding layer 223 formed on the inner surface of the wire insulation layer 221 and fused to the conductor 21.

[0064] The wire sheath 22 is spirally wound (transversely wound) onto the conductor 21. In this configuration, the wire sheath 22 is wound onto the conductor 21 such that its portions do not overlap. Specifically, the wire sheath 22 is wound in a so-called butt-wound manner, where the ends of the wire sheath 22 in the width direction are joined together. Therefore, compared to, for example, overlapping winding where the ends of the wire sheath 22 in the width direction are overlapped while winding, the thickness of the wire sheath 22 is made more uniform in the length direction. This results in uniform electrical insulation of the wire sheath 22 in the length direction and enables miniaturization. It should be noted that the winding method of the wire sheath 22 is not limited to butt-wound; it can also be overlapping winding or longitudinally added. Furthermore, multiple wire sheaths 22 can be used, formed by overlapping several layers of the wire sheaths 22.

[0065] The wire insulation layer 221 is made of engineering plastics or super engineering plastics with heat resistance and electrical insulation properties, such as polyimide (PI), polyetheretherketone (PEEK), and polyphenylene sulfide (PPS). The wire insulation layer 221 is preferably a thermosetting resin such as polyimide, but it can also be a thermoplastic resin. When the wire insulation layer 221 is made of a thermoplastic resin, its melting point is preferably higher than that of the inner wire welding layer 223.

[0066] An inner wire weld layer 223 is formed on the inner surface of the wire insulation layer 221 and welded to the conductor 21. The inner wire weld layer 223 is made of an engineering plastic or super engineering plastic that is a thermoplastic resin with heat resistance and electrical insulation properties. For example, the melting point of the inner wire weld layer 223 is preferably 250°C or higher. Furthermore, if the inner wire weld layer 223 is made of a material with no melting point, the melt-forming temperature is preferably 250°C or higher. Specifically, the inner wire weld layer 223 is made of a material comprising fluoropolymer, polyetheretherketone (PEEK), polyphenylene sulfide (PPS), thermoplastic polyimide (PI), or polyetherimide (PEI). Examples of fluoropolymers include perfluoroethylene-propylene copolymer (FEP), perfluoroalkoxyalkylene polymer (PFA), polytetrafluoroethylene (PTFE), and ethylene tetrafluoroethylene copolymer (ETFE). Since the insulated wire 1 may be exposed to high temperatures due to heat generated by energizing, it is desirable that the inner wire fusion layer 223 does not melt at high temperatures.

[0067] In manufacturing the insulated wire 1 of this method, firstly, two insulated wire sections 2 and an insulating tape 3 are prepared. Each insulated wire section 2 is obtained by winding a wire covering section 22 around a conductor 21, and then heating it to fuse the inner wire welding layer 223 of the wire covering section 22 to the conductor 21. Then, the two insulated wire sections 2 are stacked in the same thickness direction to form a laminate. Then, the insulating tape 3 is wound around the laminate, and the whole is heated, thereby fusing the welding layer 32 to the two insulated wire sections 2.

[0068] As described above, the insulated wire 1 of this method can be manufactured. Everything else is the same as in the first embodiment.

[0069] (Function and effects of the third embodiment)

[0070] This method also has the same function and effect as the first embodiment.

[0071] [Fourth Implementation Method]

[0072] Reference Figure 5 The fourth embodiment of the present invention will be described. Figure 5 This is a cross-sectional view of insulated wire 1.

[0073] This embodiment modifies the wire sheath 22 compared to the third embodiment. Specifically, the wire sheath 22 in this embodiment further includes an outer wire welding layer 222 formed on the outside of the wire insulation layer 221. That is, the wire sheath 22 in this embodiment is a strip on both sides of the wire insulation layer 221 with welding layers (i.e., inner wire welding layer 223 and outer wire welding layer 222) formed.

[0074] The outer wire weld layer 222 is made of an engineering plastic or super engineering plastic that is a thermoplastic resin with heat resistance and electrical insulation. For example, the melting point of the outer wire weld layer 222 is preferably 250°C or higher. Furthermore, if the outer wire weld layer 222 is made of a material with no melting point, the melt-forming temperature is preferably 250°C or higher. Specifically, the outer wire weld layer 222 is made of a material including fluoropolymer, polyetheretherketone (PEEK), polyphenylene sulfide (PPS), thermoplastic polyimide (PI), and polyetherimide (PEI). Examples of fluoropolymers include perfluoroethylene propylene copolymer (FEP), perfluoroalkoxyalkylene polymer (PFA), polytetrafluoroethylene (PTFE), and ethylene tetrafluoroethylene copolymer (ETFE). Since the insulated wire 1 may be exposed to high temperatures due to heat generated during energization, it is desirable that the outer wire weld layer 222 does not melt at high temperatures. It should be noted that the boundary of the outer wire welding layer 222 may not be clearly identifiable after welding, but... Figure 5 In the diagram, a double-dotted line indicates the outline position of the outer wire welding layer 222 before welding.

[0075] The outer wire weld layers 222 of the multiple insulating wire sections 2 are fixed to each other by welding. In addition, the outer wire weld layers 222 of the multiple insulating wire sections 2 are also welded to the weld layer 32 of the insulating tape 3.

[0076] In manufacturing the insulated wire 1 of this method, firstly, two insulated wire sections 2 and an insulating tape 3 are prepared. Each insulated wire section 2 is obtained by winding a wire covering section 22 around a conductor 21, and then heating it to fuse the inner wire fusion layer 223 of the wire covering section 22 to the conductor 21. Then, the two insulated wire sections 2 are stacked in the same thickness direction to form a laminate. Then, the laminate is heated to fuse the outer wire fusion layers 222 of the two insulated wire sections 2 to each other. This fixes the relative position of the two insulated wire sections 2. Next, the insulating tape 3 is wound around the two insulated wire sections 2, and the whole is heated to fuse the fusion layer 32 to the outer wire fusion layers 222 of the two insulated wire sections 2.

[0077] As described above, it is possible to manufacture the insulated wire 1 of this method.

[0078] The rest is the same as in the third embodiment.

[0079] (Function and Effects of the Fourth Implementation)

[0080] This method also has the same function and effect as the third embodiment.

[0081] [Fifth Implementation]

[0082] Reference Figure 6 The fifth embodiment of the present invention will be described. Figure 6 This is a cross-sectional view of insulated wire 1.

[0083] This method has the same basic configuration as the first embodiment, but with four insulated wire sections 2. The four insulated wire sections 2 are arranged in two rows and two columns in both the thickness and width directions.

[0084] Everything else is the same as in the first embodiment.

[0085] (Function and Effects of the Fifth Embodiment)

[0086] This method also has the same function and effect as the first embodiment.

[0087] [Sixth Implementation Method]

[0088] Reference Figure 7 The sixth embodiment of the present invention will be described. Figure 7 This is a cross-sectional view of insulated wire 1.

[0089] This method has the same basic structure as the second embodiment, but with four insulated wire sections 2. The four insulated wire sections 2 are arranged in two rows and two columns in both the thickness and width directions.

[0090] The rest is the same as in the second embodiment.

[0091] (Function and Effects of the Sixth Implementation Method)

[0092] This method also has the same function and effect as the second embodiment.

[0093] [Seventh Implementation Method]

[0094] Reference Figure 8 The seventh embodiment of the present invention will be described. Figure 8 This is a cross-sectional view of insulated wire 1.

[0095] This method has the same basic configuration as the third embodiment, but with four insulated wire sections 2. The four insulated wire sections 2 are arranged in two rows and two columns in both the thickness and width directions.

[0096] The rest is the same as in the third embodiment.

[0097] (Function and Effects of the Seventh Embodiment)

[0098] This method also has the same function and effect as the third embodiment.

[0099] [Eighth Implementation Method]

[0100] Reference Figure 9 The eighth embodiment of the present invention will be described. Figure 9 This is a cross-sectional view of insulated wire 1.

[0101] This method has the same basic configuration as the fourth embodiment, but with four insulated wire sections 2. The four insulated wire sections 2 are arranged in two rows and two columns in both the thickness and width directions.

[0102] The rest is the same as in the fourth embodiment.

[0103] (Effects and benefits of the eighth embodiment)

[0104] This method also has the same function and effect as the fourth embodiment.

[0105] [Ninth Implementation Method]

[0106] Reference Figure 10 and Figure 11 The ninth embodiment of the present invention will be described. Figure 10 This is a cross-sectional view of insulated wire 1.

[0107] This method has the same basic structure as the first embodiment, and the wire covering portions 22 of the two insulated wire portions 2 are partially fused and bonded together. Figure 10 The image shows an example where the wire covering portions 22 of the two insulated wire portions 2 are partially melted and bonded together to form an adhesive portion 22b, but the opposing surfaces 22a can also be melted and bonded together as a whole.

[0108] In addition, in this method, the manufacturing method of the insulated wire 1, specifically the heating process for fusing the insulating tape 3 to the two insulated wire sections 2, was studied.

[0109] Figure 11 This is a schematic diagram illustrating the heating process. In the heating process, an assembly 10, which is formed by laterally winding an insulating tape 3 through a laminate of two insulated wire sections 2, is heated, causing the weld layer 32 of the insulating tape 3 to adhere to the object being bonded. The heating process is performed by moving the assembly 10 sequentially through a front heating roller 11, an induction coil 12, and a rear heating roller 13.

[0110] The front heating roller 11 clamps the traveling assembly 10. At least the outer peripheral surface of the front heating roller 11 is made of a heat-resistant and elastic material such as fluororubber. The front heating roller 11 is pressed towards the traveling assembly 10 and heats the assembly 10. The assembly 10 passes through the front heating roller 11, thereby temporarily bonding the insulating tape 3.

[0111] The induction coil 12 is used to heat the assembly 10 (directly, the conductor 21) by induction heating. By causing the assembly 10 to travel through the induction coil 12 through which a high-frequency alternating current flows, eddy currents are generated in the conductor 21 of the assembly 10, thus generating Joule heating. Through this Joule heating, the welded layer 32 of the insulating tape 3 is heated and melted.

[0112] The rear heating roller 13 clamps the traveling assembly 10 in the thickness direction. At least the portion constituting the outer peripheral surface of the rear heating roller 13 is made of a heat-resistant and elastic material such as fluororubber. The rear heating roller 13 is pressed towards the traveling assembly 10 and heats the assembly 10. As the assembly 10 passes through the rear heating roller 13, the formal bonding of the insulation tape 3 is performed while suppressing the temperature drop of the weld layer 32 of the insulation tape 3. At this time, the weld layer 32 of the insulation tape 3 enters at least a portion of the recess 20. After the assembly 10 passes through the rear heating roller 13, the weld layer 32 of the insulation tape 3 is cooled, and the weld layer 32 of the insulation tape 3 is fused to the two insulating wire portions 2.

[0113] Furthermore, during the heating process, the wire insulation layers 221 of the two insulated wire portions 2 are also heated, and a portion of the wire insulation layers 221 melts and mixes with each other, thereby forming the adhesive portion 22b. Here, as described above, the wire insulation layer 221 is composed of thermosetting resins such as polyamide-imide (PAI) and polyimide (PI), and its glass transition temperature is approximately 250~400°C. When this wire insulation layer 221 is heated in the aforementioned heating process, it softens and undergoes molecular motion when its glass transition temperature exceeds the temperature, resulting in a slight volume expansion of, for example, 5%. Subsequently, rapid cooling is performed, causing the fine unevenness at the interfaces between the wire insulation layers 221 to interlock, exhibiting an anchoring effect. This results in excellent adhesion.

[0114] Furthermore, from a chemical perspective, this can be understood as follows: In polyamide-imide (PAI), the molecule contains amide groups (-CONH-) and imide groups (-CO-N-CO-), which contribute to the formation of intermolecular hydrogen bonds. In particular, it is believed that a strong hydrogen bond is formed between the NH group in the amide group and the oxygen group in the carbonyl group, greatly contributing to the intermolecular adhesion. Additionally, polyamide-imide (PAI) contains an aromatic ring, and therefore sometimes exhibits π-electron interactions (π-π interactions), but the contribution of hydrogen bonds is considered dominant.

[0115] Furthermore, in polyimide (PI), hydrogen bonds may form if unreacted amine and carbonyl groups remain. Additionally, polyimide (PI) contains a large amount of aromatic backbone, thus π-π interactions readily occur between molecules. Furthermore, van der Waals forces are believed to play a role due to the large contact area between polymer chains. Stable adhesion is exhibited between the wire insulation layers 221 through these interactions. As described above, a composite insulated wire 1 of this type can be manufactured.

[0116] Everything else is the same as in the first embodiment.

[0117] (Function and effects of the ninth embodiment)

[0118] In the insulated wire 1 of this method, the wire sheaths 22 of adjacent insulated wire portions 2 are partially melted and bonded to each other. Therefore, it is easy to suppress the misalignment between the multiple insulated wire portions 2.

[0119] Furthermore, in the manufacturing method of the composite insulated wire 1 of this embodiment, the fusion layer 32 of the insulation tape 3 is bonded to multiple insulated wire portions 2 by induction heating. Induction heating offers advantages such as rapid heating speed, easy temperature control, and excellent localized heating, thereby increasing productivity. Additionally, it reduces the energy consumption required for manufacturing the composite insulated wire 1.

[0120] Furthermore, in the manufacturing method of the composite insulated wire 1 of this embodiment, the fusion layer 32 of the insulation tape 3 is bonded to multiple insulated wire portions 2 by induction heating. Simultaneously, the wire sheathing portions 22 of adjacent insulated wire portions 2 are partially melted together, thereby bonding adjacent insulated wire portions 2 to each other. Therefore, it is possible to manufacture the composite insulated wire 1 with high productivity, ensuring that the relative positions of the multiple insulated wire portions 2 do not easily shift.

[0121] Furthermore, it has the same function and effect as the first embodiment.

[0122] [Experimental Example 1]

[0123] Example 1 of this experiment is an example of evaluating the heat resistance of eight resins. Among these resins, those with high heat resistance ratings are suitable for use as insulating tapes 3 or wire sheathing parts 22.

[0124] The first resin is a single-layer PEI-based resin that serves as both an insulating layer and a welding layer; specifically, it is ULTEM (a registered trademark) manufactured by SABIC Innovative Plastics.

[0125] The second resin is a single-layer TPI resin that serves as both an insulating layer and a welding layer, specifically Aurum (a registered trademark) manufactured by Mitsui Chemicals Co., Ltd.

[0126] The third resin is a single-layer aromatic polyamide resin that serves as both an insulating layer and a welding layer.

[0127] The fourth resin is composed of a single layer of PI-based resin that serves as both an insulating layer and a welding layer, specifically Kapton 300H manufactured by Toray DuPont.

[0128] The fifth resin is a laminated film formed by stacking an insulating layer made of PI-based resin and a welding layer made of FEP-based resin. Specifically, it is Kapton 150F manufactured by Toray DuPont.

[0129] The sixth resin is a single-layer PEEK-based resin that serves as both an insulating layer and a welding layer.

[0130] The seventh resin is a laminated film formed by laminating a TPI-based resin fusion layer on both sides of an insulating layer composed of PI-based resin. Specifically, it is UPILEX (registered trademark) VT manufactured by Toray DuPont.

[0131] The eighth resin is a single-layer PI-based resin that serves as both an insulating layer and a welding layer. Specifically, it is PIXEO (a registered trademark) manufactured by Kaneka Corporation.

[0132] Furthermore, in the evaluation of the heat resistance of each resin, 10 mg of each resin was collected for thermogravimetric analysis (TGA), and the temperature at which the weight decreased by 5% was set as the T5 temperature [°C], which is used as the evaluation index for heat resistance. As for the TGA conditions, the heating rate was set to 10°C / min, and air was supplied to the device at a rate of 100 ml / min.

[0133] The evaluation results of the heat resistance of each resin are shown in Table 1. In Table 1, those with a T5 temperature below 500℃ are indicated by ×, those with a T5 temperature above 500℃ and below 550℃ are indicated by ○, and those with a T5 temperature above 550℃ are indicated by ◎.

[0134] [Table 1]

[0135]

[0136] Table 1 shows that single-layer PEI-based resins, TPI-based resins, PI-based resins, and PEEK-based resins, as well as laminated films formed by stacking an insulating layer made of PI-based resin and a fusion layer made of FEP-based resin, and laminated films formed by stacking fusion layers made of TPI-based resin on both sides of an insulating layer made of PI-based resin, exhibit high heat resistance. However, for PI-based resins, product differences should be considered. From the viewpoint of heat resistance, single-layer TPI-based resins and PEEK-based resins are preferred. Furthermore, laminated films formed by stacking an insulating layer made of PI-based resin and a fusion layer made of FEP-based resin, and laminated films formed by stacking fusion layers made of TPI-based resin on both sides of an insulating layer made of PI-based resin, also exhibit high heat resistance.

[0137] [Experimental Example 2]

[0138] This experimental example 2 is an example of evaluating the fit between the insulated wire part 2 and the insulated tape 3 when using various tapes as the insulated tape 3.

[0139] Figure 12 This is the first diagram used to illustrate the evaluation method for tightness. Figure 13 This is the second figure used to illustrate the evaluation method for tightness.

[0140] The following details the evaluation method for tightness.

[0141] First, such as Figure 12 As shown, the bending tendency of the insulated wire section 2 is obtained, and after being cut to a length of 80 mm, it is bent vertically at a position P 20 mm from the front end using tools such as pliers. Then, the base end sides of the two bent portions of the insulated wire section 2 are arranged parallel to each other, and a 40 mm long strip of tape 30 is added longitudinally between them. The two predetermined portions closer to the base end side than the bent portions are then tied with wire W. At this time, the base end positions of the two insulated wire sections 2 and the strip 30 ( Figure 12 Align the left end of the wire section with the wire section 2. Additionally, the two insulated wire sections 2 are arranged in a trumpet-shaped configuration, with their respective curved portions moving further apart towards the front end. Then, the tape 30 is bonded to the insulated wire section 2 using induction heating, and the wire W is removed.

[0142] Then, as Figure 13 As shown, the front ends of the two insulated wire sections 2 are held by clamp J and stretched to the side where they are separated at a speed of 25 mm / min. The fit is evaluated using the evaluation criteria described later (refer to the explanation of the ◎, 〇, and × symbols described later).

[0143] In this Experimental Example 2, the type of the tape 30 was changed in various ways, and the sealing performance was evaluated when the wire covering part 22 of the insulated wire part 2 was set as an enameled film (specifically, a PAI enameled film) and when the wire covering part 22 of the insulated wire part 2 was set as a tape (hereinafter referred to as a wire tape).

[0144] In the example where the wire sheath 22 in the insulated wire section 2 is an enameled film, the conductor 21 has a thickness of 1.15 mm and a width of 6.50 mm, and the wire sheath 22 has a thickness of 10 μm. Furthermore, in the example where the wire sheath 22 is an enameled film, examples are prepared where induction heating is used to bond the tape 30 to the two insulated wire sections 2, and the induction heating temperature is set to 365°C and 385°C, respectively. The welding heating temperature refers to the temperature of the insulated wire section 2 heated by the passage of the induction coil 12.

[0145] In the example where the wire-covering portion 22 of the insulated wire portion 2 is a wire strip, the conductor 21 has a thickness of 1.15 mm and a width of 6.50 mm. The wire strip is made of Kapton 150F with a thickness of 37.5 μm and a width of 12 mm, and is wound onto the conductor 21 by a 1 / 2 overlap transverse winding. Furthermore, the induction heating temperature for bonding the wire strip to the conductor 21 and the induction heating temperature for bonding the strip 30 to the two insulated wire portions 2 are both set to 365°C.

[0146] The tape 30 used is of the same type as the tapes used in Example 1. Here, two types of tapes 30, one made of ULTEM and the other of aromatic polyamide, with different thicknesses, are prepared. In addition, all tapes 30 are 6.5 mm wide.

[0147] The results of the seal evaluation are shown in Table 2 below. In the seal column of Table 2, an "×" mark indicates that the two insulated wire parts 2 can be peeled off manually, and an "〇" or "◎" mark indicates that the two insulated wire parts 2 cannot be peeled off manually. Here, after the test, when the clamp J is removed from the two insulated wire parts 2, the shape of the two insulated wire parts 2 is elastically restored to the shape before the test (i.e., Figure 12 Examples of the shapes shown are marked with ○, and examples where the shapes of the two insulated wire parts 2 have undergone plastic deformation before and after the test are marked with ◎. Examples marked with ◎ are those requiring stronger force to peel off the two insulated wire parts 2, and represent the best adhesion. In addition, in Table 2, the reference numeral "-" indicates that no test was performed.

[0148] [Table 2]

[0149]

[0150] As shown in Table 2, regardless of whether the wire covering portion 22 is an enameled film or a wire strip, high adhesion can be achieved by using a strip 30 composed of a single layer of PEI-based resin. In particular, it can be seen that in the example where the wire covering portion 22 is an enameled film, very high adhesion is obtained. Furthermore, according to the results of Experimental Example 1 above, a single layer of PEI-based resin can also ensure heat resistance. In other words, it can be said that the strip 30 composed of a single layer of PEI-based resin is excellent from both the viewpoints of heat resistance and adhesion.

[0151] As shown in Table 2, in the example where the wire sheath 22 is a coated film, the adhesion is easily ensured by constructing the tape 30 from a single layer of TPI-based resin. Furthermore, as shown in the results of Experimental Example 1 above, the single layer of TPI-based resin also ensures heat resistance. In other words, it can be said that the tape 30 constructed from a single layer of TPI-based resin is excellent from both the viewpoints of heat resistance and adhesion.

[0152] As shown in Table 2, in the example where the wire covering portion 22 is a wire strip, it is easy to ensure a tight seal by using a strip 30 made of a single layer of aromatic polyamide resin. However, based on the results of Example 1 above, the single layer of aromatic polyamide resin has low heat resistance, so attention needs to be paid to the operating environment (temperature environment).

[0153] As shown in Table 2, in the example where the wire sheath 22 is a varnish film, it is easy to ensure adhesion by using a single layer of PI-based resin for the tape 30. When using a single layer of PI-based resin for the tape 30, it is preferable that the thickness of the tape 30 exceeds 50 μm. However, adhesion may vary depending on the heating temperature at which the tape 30 is bonded to the two insulated wire portions 2, so this needs to be considered. Furthermore, as described in Example 1 above, the heat resistance of a single layer of PI-based resin varies depending on its type, so this needs to be considered from both the viewpoint of heat resistance and adhesion.

[0154] As shown in Table 2, in the example where the wire sheath 22 is an enameled film, it is easy to ensure adhesion by making the tape 30 a laminated film formed by stacking an insulating layer made of PI-based resin and a fusion layer made of FEP-based resin. However, the adhesion may vary depending on the heating temperature when the tape 30 is bonded to the two insulated wire portions 2, so this needs to be considered. In addition, as shown in the results of Example 1 above, it is also possible to ensure heat resistance by stacking an insulating layer made of PI-based resin and a fusion layer made of FEP-based resin. That is, it can be said that in the example where the wire sheath 22 is an enameled film, it is preferable from the viewpoint of both heat resistance and adhesion by making the tape 30 a laminated film formed by stacking an insulating layer made of PI-based resin and a fusion layer made of FEP-based resin.

[0155] As shown in Table 2, in the example where the wire sheath 22 is a coated film, and the tape 30 is a single layer of PEEK resin, it is easy to ensure a tight seal when the heating temperature for bonding with the two insulated wire portions 2 is set to 385°C. Furthermore, as shown in the results of Example 1 above, a single layer of PEEK resin can also ensure heat resistance. That is, while the tape 30 made of a single layer of PEEK resin requires attention to the heating temperature when bonding with the two insulated wire portions 2, it can be said to be excellent from both the viewpoint of heat resistance and sealing performance.

[0156] As shown in Table 2, in the example where the wire sheath 22 is an enameled film, and when the tape 30 is a laminated film formed by laminating a fusion layer made of TPI-based resin on both sides of an insulating layer made of PI-based resin (especially when the heating temperature for bonding the two insulated wire portions 2 is set to 365°C), it is easy to ensure a tight seal. Furthermore, according to the results of Example 1 above, heat resistance can also be ensured for a laminated film formed by laminating a fusion layer made of TPI-based resin on both sides of an insulating layer made of PI-based resin. In other words, it can be said that in the example where the wire sheath 22 is an enameled film, making the tape 30 a laminated film formed by laminating a fusion layer made of TPI-based resin on both sides of an insulating layer made of PI-based resin is excellent from both the viewpoints of heat resistance and tight seal.

[0157] [Experiment Example 3]

[0158] This experimental example 3 is an example of evaluating the fit of the two insulated wire portions 2 of the combined insulated wire 1 in the ninth embodiment.

[0159] The assessment of the fit was conducted using the method described in Experiment Example 2. This will be explained in detail below.

[0160] In this Experimental Example 3, similar to Experimental Example 2, firstly, the bending tendency of the insulated wire portion 2 was determined, and after being cut to a length of 80 mm, it was bent vertically at a position 20 mm from the front end using tools such as pliers. Then, the base-end positions of the two insulated wire portions 2 were arranged parallel to each other from the bent portions, and two predetermined positions closer to the base end than the bent portions were bound together using wire W. At this point, the base ends of the two insulated wire portions 2 were aligned. Here, there is no clamping tape between the two insulated wire portions 2. Figure 12 The reference numeral 30 in the accompanying drawings differs from that in Embodiment 2. Furthermore, the two insulated wire portions 2 are arranged in a trumpet-shaped configuration, with their respective curved portions moving further apart towards the front end. Then, the wire-covered portions 22 of the two insulated wire portions 2 are bonded together from the curved portion at the base end side (i.e., the parallel portion) using an induction heating method at an induction heating temperature of 385°C, and the wire W is removed.

[0161] Then, using clamp J, the front ends of the two insulated wire sections 2 are stretched to the sides at a speed of 25 mm / min, and the fit is evaluated using the evaluation criteria described in Example 2 (refer to the explanation of the ◎, 〇, × symbols above).

[0162] In this example, the insulated wire portion 2 is made by forming a wire sheath 22 of 10 μm thickness made of polyamide-imide around a conductor 21 with a thickness of 1.15 mm and a width of 6.50 mm.

[0163] As a result of the test, the seal performance was rated as "○". That is, it was confirmed that in the configuration where the wire sheathing portions 22 are partially fused and bonded together as in the ninth embodiment, the seal performance of the insulated wire portions 2 is good.

[0164] (Summary of Implementation Methods)

[0165] Next, the technical ideas learned from the embodiments described above will be described by reference to the accompanying reference numerals and the like. However, the reference numerals and the like described below do not limit the constituent elements in the claims to the components specifically shown in the embodiments.

[0166] [1] An insulated wire 1 comprising: a plurality of insulated wire portions 2 having conductors 21 and wire covering portions 22 surrounding the conductors 21; and an insulating strip 3 comprising and surrounding the plurality of insulated wire portions 2; wherein the insulating strip 3 comprises: an insulating layer 31 having electrical insulation properties and a fusion layer 32 fused to the plurality of insulated wire portions 2, wherein the fusion layer 32 is made of engineering plastic or super engineering plastic.

[0167] [2] According to the insulated wire 1 of [1], wherein the above-mentioned fusion layer 32 is composed of a material containing fluororesin, PEEK, PPS, PI or PEI.

[0168] [3] According to [1] or [2], the bundled insulated wire 1, wherein the wire covering portion 22 has a wire insulation layer 221 and an outer wire welding layer 222 formed on the outside of the wire insulation layer 221, and the outer wire welding layers 222 of the plurality of insulated wire portions 2 are welded to each other.

[0169] [4] The insulated wire 1 according to any one of [1] to [3], wherein the insulating strip 3 is formed such that its parts do not overlap.

[0170] [5] The bundled insulated wire 1 according to any one of [1] to [4], wherein the plurality of insulated wire portions 2 are four or less.

[0171] [6] According to the insulated wire 1 described in [1], the wire covering part 22 is made of an enameled film, the enameled film is made of PAI or PI, the insulating tape 3 is made of a single layer that serves as both the insulating layer 31 and the fusion layer 32, and is made of PEEK resin, PEI resin or TPI resin.

[0172] [7] According to the insulated wire 1 of [1], the wire sheath 22 is made of an enameled film, the enameled film is made of PAI or PI, the insulating tape 3 is made of multiple layers including the insulating layer 31 and the fusion layer 32 formed on the inner surface of the insulating layer 31 as different layers, the insulating layer 31 is made of PI resin, and the fusion layer 32 is made of TPI resin or FEP resin.

[0173] [8] The bundled insulated wire 1 according to any one of [1] to [7], wherein adjacent insulated wire portions 2 of the plurality of insulated wire portions 2 are partially fused together and bonded to each other by the wire covering portions 22.

[0174] [9] According to the insulated wire 1 of [1], wherein the fusion layer 32 is formed on the inner surface of the insulation layer 31.

[0175]

[10] A method for manufacturing an insulated wire 1 includes preparing a plurality of insulated wire portions 2 having a conductor 21 and a wire covering portion 22 surrounding the conductor 21, and an insulating tape 3 having an insulating layer 31 and a fusion layer 32. The insulating layer 31 has electrical insulation properties, and the fusion layer 32 is fused to the plurality of insulated wire portions 2 and is made of engineering plastic or super engineering plastic. The insulating tape 3 is laterally wound in a manner that gathers and surrounds the plurality of insulated wire portions 2, and the fusion layer 32 of the insulating tape 3 is bonded to the plurality of insulated wire portions 2 by induction heating.

[0176]

[11] According to the manufacturing method of the composite insulated wire 1 described in

[10] , the fusion layer 32 of the insulating tape 3 is bonded to the plurality of insulating wire portions 2 by induction heating, and the wire covering portions 22 of adjacent insulating wire portions 2 in the plurality of insulating wire portions 2 are partially melted to each other, thereby bonding the adjacent insulating wire portions 2 to each other.

[0177] (Postscript)

[0178] The embodiments of the present invention have been described above, but these embodiments do not limit the invention as defined in the claims. Furthermore, it should be noted that not all combinations of features described in the embodiments are necessary for solving the inventive problem. Additionally, the present invention can be implemented with appropriate modifications without departing from its spirit.

Claims

1. A type of insulated wire, comprising: Multiple insulated wire sections, each having a conductor and a wire sheath surrounding the conductor, and An insulating tape that gathers and surrounds the plurality of insulated wire sections; The insulating tape has: an insulating layer with electrical insulation properties, and a fusion layer fused to the plurality of insulating wire portions. The weld layer is made of engineering plastics or super engineering plastics.

2. The insulated wire according to claim 1, wherein, The weld layer is composed of a material containing fluoropolymer, PEEK, PPS, PI, or PEI.

3. The insulated wire according to claim 1, wherein, The wire sheath includes a wire insulation layer and an outer wire fusion layer formed on the outside of the wire insulation layer. The outer wire weld layers of the plurality of insulated wire sections are welded together with each other.

4. The insulated wire according to claim 1, wherein, The insulating tape is formed in such a way that its parts do not overlap.

5. The insulated wire according to claim 1, wherein, The number of insulated wire sections is four or less.

6. The insulated wire according to claim 1, wherein, The wire sheath is composed of an enameled film containing PAI or PI, and the insulating tape is composed of a single layer that serves as both the insulating layer and the fusion layer, and is composed of PEEK-based resin, PEI-based resin or TPI-based resin.

7. The insulated wire according to claim 1, wherein, The wire coating is composed of an enameled film containing PAI or PI. The insulating tape is composed of multiple layers, each comprising an insulating layer and a welded layer formed on the inner surface of the insulating layer. The insulating layer comprises a PI-based resin. The weld layer comprises TPI-based resin or FEP-based resin.

8. The insulated wire according to claim 1, wherein, In adjacent insulating wire portions of the plurality of insulating wire portions, the wire covering portions are partially fused together and bonded to each other.

9. The insulated wire according to claim 1, wherein, The weld layer is formed on the inner surface of the insulating layer.

10. A method for manufacturing insulated wires, Prepare multiple insulated wire portions having conductors and wire sheaths surrounding the conductors, and an insulating tape having an insulating layer and a fusion layer, wherein the insulating layer is electrically insulating, and the fusion layer is fused to the multiple insulated wire portions and is made of engineering plastic or super engineering plastic. The insulating tape is wound laterally in a manner that gathers and surrounds the plurality of insulated wire sections. The welding layer of the insulating tape is bonded to the plurality of insulating wire sections by induction heating.

11. The method for manufacturing a bundled insulated wire according to claim 10, wherein, By using induction heating, the fusion layer of the insulating tape is bonded to the plurality of insulating wire portions respectively, and the wire covering portions of adjacent insulating wire portions are partially melted to each other, thereby bonding the adjacent insulating wire portions to each other.

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