Self-adhesive silk-covered stranded wire with braided structure

Abstract

The utility model discloses to the self -adhesion silk package stranding wire difficultly sets up the stranding wire's package compactness degree reasonably, makes the self -adhesion silk package stranding wire existence stability bad, winding performance is poor, the problem of the coil outer diameter of partial big, provides the self -adhesion silk package stranding wire of weaving structure. The self -adhesion silk package stranding wire is by following part constitutes: the stranding wire body is by multiple first stranding enameled wire stranding again, and the first stranding enameled wire stranding is by multiple enameled single wire stranding, the terylene silk weaving layer, multiple terylene silk are wrapped in the outside of stranding wire body with the oblique staggered weaving mode, the hot melt nylon silk self -adhesion layer, multiple hot melt nylon silk are wrapped in the outside of terylene silk weaving layer with the mode of around package. The utility model discloses terylene silk weaving layer oblique staggered weaving mode, the stranding wire body's wrapping force degree can be controlled at reasonable level to make the self -adhesion silk package stranding wire under the premise of satisfying adhesion, the softness and winding property when winding coil are better, and the coil winding radius can reduce about 30%.

Description

Technical Field

[0001] This utility model relates to the technical field of wires and cables, specifically to a self-adhesive twisted wire with a braided structure. Background Technology

[0002] Self-adhesive stranded wire is a special type of electromagnetic wire that combines Litz wire (multi-strand insulated wire stranded together) with self-adhesive layer technology. After the coil is wound, the outer self-adhesive layer can be melted and bonded by heating (such as with hot air), thus fixing the coil in place without the need for additional glue or binding, and eliminating the need for a support frame. In particular, self-adhesive stranded wire significantly reduces the size of in-vehicle wireless chargers, achieving miniaturization for automotive applications. Therefore, self-adhesive stranded wire is currently widely used in wireless charger products for electric vehicles.

[0003] In the manufacturing of self-adhesive stranded wire, the outermost layer of the stranded wire is a self-adhesive layer, and an insulating layer is generally placed inside the self-adhesive layer. For example, the applicant's earlier application CN202320304231.6 provides a low-melting-point, high-adhesion self-adhesive film-wrapped stranded wire. This film-wrapped stranded wire consists of a first strand of enameled wire twisted together from multiple enameled single wires. The first strand of enameled wire is covered with a first insulating film layer. Multiple first strands of enameled wire are then twisted together to form a second strand of enameled wire. The twisting direction of the second strand of enameled wire is different from that of the first strand of enameled wire. The second strand of enameled wire is covered with a second insulating film layer (i.e., the aforementioned insulating layer, made of polyurethane, polyamide, or other materials). A self-adhesive layer is applied outside the second insulating film layer through an extrusion process. The self-adhesive layer is made of nylon film. When the self-adhesive layer is made of nylon filaments, and the nylon filaments are used to wrap the stranded wire using a wrapping process, a self-adhesive filament-wrapped stranded wire is formed.

[0004] In the aforementioned prior art, in order to accelerate the absorption of hot air by the self-adhesive layer and improve the production efficiency of coil self-adhesive operation, the outer self-adhesive layer of the self-adhesive wire is often wrapped relatively loosely to enhance its air permeability. As a result, the inner insulation layer (second insulation layer) needs to be set to wrap the wire more tightly to prevent the entire wire layer from detaching and failing to meet the adhesion requirements of the wire layer of the wire-covered wire.

[0005] To achieve a tighter wrapping of the stranded wire, Chinese patent CN202220434935.0 provides an easy-to-wind self-adhesive enameled Litz wire. This patent presents a solution involving a polyester composite filament braided layer, made of polyester and spandex fibers. This layer contacts the outer protective layer of multiple conductors (which together constitute the stranded wire). The high strength and elasticity of the polyester and spandex fibers effectively increase the tensile strength and abrasion resistance of the conductors, further enhancing their overall strength. However, since the self-adhesive layer in this patent is located on the outside of the conductors, not the entire stranded wire, which is covered by a high-density polyethylene outer sheath primarily for extending its lifespan, this patent does not represent the self-adhesive filament-wrapped stranded wire that this patent aims to improve.

[0006] The self-adhesive filament-wrapped stranded wire, with its tightly wrapped insulation layer, is a double-edged sword. Overly tight wrapping leads to stiffer strands and poorer winding performance. When winding coils with this, gaps between turns may become too large, resulting in insufficient and weak adhesion of the self-adhesive layer in some areas, thus reducing coil stability. Poor winding performance also affects the coil's shape, causing an excessively large outer diameter. In the aforementioned prior art, the polyester composite filament braiding layer employs a bidirectional braiding method, which enhances the tightness of the wrapping. Furthermore, the use of spandex fiber composite structures increases the elasticity of the spandex fibers, allowing them to automatically tighten and further strengthen the wrapping.

[0007] Therefore, in the existing technology, there has never been a good solution for how to reasonably set the tightness of the strand wrapping of self-adhesive wire-wrapped strands. Utility Model Content

[0008] This invention addresses the problem in the prior art where it is difficult to reasonably set the tightness of the strand wrapping in self-adhesive filament-wrapped wire, resulting in poor stability, poor winding performance, and excessively large outer diameter of the coil wound from the self-adhesive filament-wrapped wire. It provides a self-adhesive filament-wrapped wire with a braided structure.

[0009] The technical problem to be solved by this utility model can be achieved through the following technical solution:

[0010] A self-adhesive filament-covered stranded wire with a braided structure, characterized in that the self-adhesive filament-covered stranded wire is composed of the following parts:

[0011] The stranded wire body is made of multiple first strands of enameled stranded wires, and each first strand of enameled stranded wire is made of multiple single enameled wires.

[0012] Polyester filament braided layer, multiple polyester filaments are wrapped around the outside of the stranded wire body in a diagonally interwoven manner;

[0013] The hot-melt nylon filament self-adhesive layer consists of multiple hot-melt nylon filaments wrapped around the outside of the polyester filament braided layer.

[0014] In this invention, in order to further ensure that the polyester filament braided layer tightly wraps the stranded wire body within a reasonable range.

[0015] Preferably, the weave angle of the polyester filament braided layer is 25 to 50 degrees.

[0016] Preferably, the polyester filament braided layer has a mesh count of not less than 12 and a braiding density of not less than 90%; the thickness of the polyester filament braided layer is not greater than 10% of the diameter of the strand body; and the resilience coefficient of the polyester filament braided layer is 10% to 20%.

[0017] In this invention, the production efficiency of coils is improved by accelerating the hot melting and bonding speed and bonding strength of the self-adhesive layer.

[0018] Preferably, the melting temperature of the hot-melt nylon filament self-adhesive layer is not greater than 90°C; the diameter of the hot-melt nylon filament is not greater than 200D; the wrapping density of the hot-melt nylon filament is 1000 to 1100 revolutions per meter; and the bonding strength of the hot-melt nylon filament self-adhesive layer is greater than 0.40 MPa.

[0019] In this invention, in order to ensure that the stranded wire body is more compatible with the braided structure of the self-adhesive filament-covered stranded wire, the stranded wire body is made of 3 to 5 first strands of enameled wire, and the first strand of enameled wire is made of no more than 60 enameled single wires; the stranded wire body has a temperature rating of no higher than 155°C.

[0020] This invention presents a self-adhesive filament-wrapped stranded yarn with a braided structure, which abandons the complex structure of existing self-adhesive filament-wrapped yarns and innovatively proposes a simplified structure consisting of only three parts: the stranded yarn body, the polyester filament braided layer, and the hot-melt nylon filament self-adhesive layer. The polyester filament braided layer, achieved through a diagonal interlacing braiding process, presents a mesh structure. Compared to the parallel structure of the wrapping process, it has better overall integrity. The polyester filaments form intersecting nodes, and even with surface scratches, there will be no filament breakage or exposed copper.

[0021] More importantly, the diagonal interlacing weaving method provides a moderate level of tightness in the wrapping, allowing the wrapping force on the strand body to be controlled at a reasonable and relatively small level. This results in moderate overall tensile strength of the strand, thus improving the softness and winding properties of the self-adhesive filament-wrapped strand when winding coils, while still maintaining adhesion. The coil winding radius can be reduced by about 30%. In addition, the unwinding tension of the polyester filaments during the diagonal interlacing weaving process is lower than that during the wrapping process. This helps to reduce the friction between the polyester filaments and the varnish film on the surface of the strand body, reducing varnish film damage and reducing pinholes in the final product by more than 20%.

[0022] Furthermore, the self-adhesive layer of this invention uses a hot-melt nylon filament self-adhesive layer. The melting temperature of the nylon filament is no greater than 90℃, the thickness of the hot-melt nylon filament is no greater than 200D, and the wrapping density of the hot-melt nylon filament is controlled between 1000 and 1100 revolutions per meter, which is considered light wrapping. This light wrapping can greatly accelerate the hot melting and bonding speed of the self-adhesive layer, improving the coil production efficiency. Due to the flexibility and good winding properties of the wire, the coil turns are tightly bonded together. Although the wrapping density is light, the inter-turn adhesion is still very strong, thereby ensuring the structural strength and stability of the coil. Attached Figure Description

[0023] The present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0024] Figure 1 This is a schematic diagram of the structure of the self-adhesive wire-wrapped stranded wire of this utility model.

[0025] Figure 2 This is a schematic diagram of the unfolded structure of the polyester filament braided layer of this utility model. Detailed Implementation

[0026] To make the technical means, creative features, objectives and effects of this utility model easier to understand, the following description, in conjunction with specific illustrations, further elaborates on this utility model.

[0027] The main purpose of this invention is to address the problem that existing self-adhesive filament-covered stranded yarns have difficulty in properly setting the tightness of the strand wrapping, resulting in coils with poor stability, poor winding performance, and excessively large outer diameters. This invention analyzes the key factors leading to poor winding performance and the technical objectives that the filament layers of self-adhesive filament-covered stranded yarns need to achieve. Combining the characteristics of various existing covering processes, a filament layer covering scheme of braiding + wrapping is proposed.

[0028] See Figure 1 and Figure 2 This utility model presents a self-adhesive filament-covered stranded yarn with a braided structure. It innovatively proposes that the self-adhesive filament-covered stranded yarn consists of three parts: a stranded yarn body 1, a polyester filament braided layer 2, and a hot-melt nylon filament self-adhesive layer 3. Specifically, the stranded yarn body 1 is formed by twisting multiple first-strand enameled strands 11, each first-strand enameled strand being formed by twisting multiple enameled single wires 12; the polyester filament braided layer 2 is formed by wrapping multiple polyester filaments diagonally and interlaced on the outside of the stranded yarn body 1; and the hot-melt nylon filament self-adhesive layer 3 is formed by wrapping multiple hot-melt nylon filaments around the outside of the polyester filament covering layer 2.

[0029] Specifically, for the stranded wire body 1, in order to ensure that the stranded wire body is more suitable for the braided structure of the self-adhesive filament-covered stranded wire, the stranded wire body 1 is preferably made of 3 to 5 first strands of enameled stranded wire 11, and the first strands of enameled stranded wire 11 are preferably made of no more than 60 enameled single wires 12. The enameled single wires 12 are generally provided with an insulating varnish film 13 on the outside, and the stranded wire body is set to a temperature rating of no more than 155°C. In specific implementation, when multiple first-strand enameled strands 11 are twisted into strand body 1, the twisting direction of strand body 1 and the twisting direction of first-strand enameled strands 11 can be set to be different. For preferred purposes, the first-strand enameled strands 11 are twisted in the Z direction, and the strand body 1 is twisted in the S direction. In this way, the strand structure is optimized and a twisting structure with two twists and opposite twists is adopted. This twisting structure can keep the internal self-torsion of the strand in a balanced state. When the internal forces of the strand are balanced, its structure is more stable and its shape is more rounded. Its non-roundness can be controlled within 5%.

[0030] Combination Figure 1 For more details, please refer to Figure 2 ( Figure 2 In the middle (the vertical direction is the length direction of the stranded wire), the polyester filament braided layer 2 is made of multiple polyester filaments wrapped around the outside of the stranded wire body 1 in a diagonally interwoven manner. Based on the insulation properties of polyester filaments themselves, the polyester filament braided layer 2 forms an insulation layer for the stranded wire body 1 in a relatively simple way, achieving insulation protection for the stranded wire. More importantly, compared with the overly tight wrapping force of the insulation layer on the stranded wire body 1 in the prior art, the polyester filament braided layer 2, with its multiple polyester filaments diagonally interwoven, provides a moderate wrapping tightness in structure. This method allows for reasonable and relatively low wrapping force on the stranded wire, resulting in moderate overall tensile strength. This ensures better flexibility and winding properties of the self-adhesive filament-wrapped stranded wire while maintaining adhesion, reducing the coil winding radius by approximately 30%. Furthermore, the unwinding tension of the polyester filaments during the diagonal cross-weaving process is lower than that during wrapping, reducing friction between the polyester filaments and the enamel film on the stranded wire surface, minimizing enamel film damage, and reducing pinholes in the final product by more than 20%. Additionally, the polyester filament braided layer achieved using the diagonal cross-weaving process exhibits a mesh structure, offering better overall integrity compared to the parallel structure of the wrapping process. The intersecting nodes between the polyester filaments prevent copper exposure and fraying even with surface scratches.

[0031] To further ensure that the polyester filament braid layer tightly wraps around the stranded wire, the braiding angle α of the polyester filament braid layer is between 25 and 50 degrees. For example... Figure 2 As shown, the braiding angle α is determined by the braiding width b formed by multiple polyester filaments and the axial (length direction of strand body 1) component b' formed by the braiding width, i.e., cosα=b / b'.

[0032] Preferably, the polyester filament braided layer 2 has a mesh count of not less than 12 and a braiding density of not less than 90%; the thickness of the polyester filament braided layer 2 is preferably not greater than 10% of the diameter of the strand body 1, and the resilience coefficient of the polyester filament braided layer 2 is preferably set to 10% to 20%. Thus, by rationally allocating the number of strands and the density of individual filaments per spindle, this invention makes the polyester filament braided layer 2 smoother with less unevenness, thereby improving the uniformity of the self-adhesive filament layer and enhancing the bonding effect of the self-adhesive filament. In actual manufacturing, by controlling the resilience coefficient of the polyester filament braided layer 2 between 10% and 20%, the unwinding tension of the spindle can be reasonably controlled by the specifications of the wire springs. The polyester filament braided layer 2 can adhere well to the surface of the strand body 1 without wrapping it too tightly, achieving the best balance between adhesion and winding properties.

[0033] For the hot-melt nylon filament self-adhesive layer 3, to accelerate its hot-melt melting and bonding speed and increase its bonding strength, thereby improving coil production efficiency, the preferred melting temperature of the hot-melt nylon filament self-adhesive layer 3 is no greater than 90℃; the thickness of the hot-melt nylon filament is no greater than 200D; the wrapping density of the hot-melt nylon filament is 1000 to 1100 revolutions per meter; and the bonding strength of the hot-melt nylon filament self-adhesive layer 3 is greater than 0.40 MPa. The above method forms the hot-melt nylon filament self-adhesive layer 3, which is a light wrapping. This light wrapping can greatly accelerate the hot-melt melting and bonding speed of the self-adhesive layer, improving coil production efficiency. Due to the good flexibility and winding properties of the wire, the coil turns are tightly bonded together. Although the wrapping density is light, the inter-turn adhesion is still very strong, thus ensuring the structural strength and stability of the coil.

[0034] The foregoing has shown and described the basic principles, main features, and advantages of this utility model. Those skilled in the art should understand that this utility model is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of this utility model. Various changes and modifications can be made to this utility model without departing from its spirit and scope, and all such changes and modifications fall within the scope of the claimed utility model. The scope of protection of this utility model is defined by the appended claims and their equivalents.

Claims

1. A self-adhesive twisted yarn with a braided structure, characterized in that, The self-adhesive twisted yarn consists of the following parts: The stranded wire body is made of multiple first strands of enameled stranded wires, and each first strand of enameled stranded wire is made of multiple single enameled wires. Polyester filament braided layer, multiple polyester filaments are wrapped around the outside of the stranded wire body in a diagonally interwoven manner; The hot-melt nylon filament self-adhesive layer consists of multiple hot-melt nylon filaments wrapped around the outside of the polyester filament braided layer.

2. The self-adhesive twisted wire with a braided structure according to claim 1, characterized in that: The weaving angle of the polyester filament braided layer is 25 to 50 degrees.

3. The self-adhesive wire-wrapped stranded yarn with a braided structure according to claim 1, characterized in that: The mesh count of the polyester filament braided layer is not less than 12, and the braiding density is not less than 90%.

4. The self-adhesive twisted wire with a braided structure according to claim 3, characterized in that: The thickness of the polyester filament braided layer is no more than 10% of the diameter of the stranded wire body.

5. The self-adhesive twisted wire with a braided structure according to claim 3, characterized in that: The resilience coefficient of the polyester filament braided layer is 10% to 20%.

6. The self-adhesive twisted wire with a braided structure according to claim 1, characterized in that: The melting temperature of the hot-melt nylon filament self-adhesive layer is no greater than 90°C.

7. The self-adhesive wire-wrapped yarn with a braided structure according to claim 1, characterized in that: The thickness of the hot-melt nylon filament is no greater than 200D, and the wrapping density of the hot-melt nylon filament is 1000 to 1100 revolutions per meter.

8. The self-adhesive wire-wrapped stranded yarn with a braided structure according to claim 1, characterized in that: The bonding strength of the hot-melt nylon filament self-adhesive layer is greater than 0.40 MPa.

9. The self-adhesive twisted wire with a braided structure according to claim 1, characterized in that: The stranded wire body is composed of 3 to 5 first strands of enameled wire, and each first strand of enameled wire is composed of no more than 60 enameled single wires.

10. The self-adhesive twisted wire with a braided structure according to claim 1, characterized in that: The stranded wire body has a temperature rating of no higher than 155℃.

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