An insulated electric wire for inductance, a coil

Abstract

The utility model discloses an insulating wire and coil for inductance relates to insulating wire technical field, this insulating wire for inductance includes conductor and the insulating layer of setting in the conductor outer periphery, the conductor is flat conductor, the width value of conductor is W, and the thickness value is T, wherein, W / T is not less than 2, the thickness value of insulating layer on the both sides of conductor is all delta 1, the thickness value of insulating layer on the both sides of conductor is all delta 2, wherein, delta 2 / delta 1=1.5~3. The insulating wire for inductance provided by the utility model can effectively improve the wear resistance of the whole insulating layer, avoid the problem of insulating layer rupture of the insulating wire for inductance in the magnetic powder filling process or subsequent use, and effectively guarantee the insulation performance.

Description

Technical Field

[0001] This utility model relates to the field of insulated wire technology, and more specifically, to an insulated wire and coil for inductance. Background Technology

[0002] The integral molding inductor is processed by compression molding. First, the insulated wire is wound into a coil, and the coil is placed into the mold cavity. The mold cavity is filled with magnetic powder (containing binder). Under high temperature (150-250℃) and high pressure (50-200MPa), the magnetic powder and the coil are die-cast into an integral structure in which "the coil is completely covered by magnetic powder".

[0003] Because magnetic powder is harder than the insulation layer, it is more likely to puncture the coil's insulation layer under high voltage, causing insulation failure. During coil winding, the narrow side of the insulated wire, due to its smaller contact area, will bear greater pressure. Therefore, the narrow side of the insulated wire is more prone to magnetic powder puncturing the insulation layer.

[0004] Therefore, it is necessary to provide a novel insulated wire structure to reduce damage to the narrow side of the insulated wire during magnetic powder die casting, reduce the short circuit rate, and improve the stability of the finished product voltage. Utility Model Content

[0005] In view of this, the purpose of this utility model is to provide an insulated wire for inductors to solve the problem that the insulation layer of insulated wires for inductors is prone to cracking at narrow edges during the magnetic powder die casting process in the prior art.

[0006] To achieve the above objectives, the technical solution of this utility model is as follows: An insulated wire for inductance includes a conductor and an insulating layer disposed on the outer periphery of the conductor. The conductor is a flat conductor with a width of W and a thickness of T, wherein W / T is not less than 2. The thickness of the insulating layer on the upper and lower sides of the conductor is δ1, and the thickness of the insulating layer on the left and right sides of the conductor is δ2, wherein δ2 / δ1 = 1.5~3.

[0007] Furthermore, the δ1 is 2~20μm.

[0008] Furthermore, the conductor's width and thickness directions are transitioned by circular arcs.

[0009] Furthermore, the radius of the arc is not less than 0.25T.

[0010] Furthermore, W is 0.1~2.0 mm and T is 0.02~0.4 mm.

[0011] Furthermore, the insulating layer also includes a wear-resistant layer, which is located on the outermost side of the insulating layer.

[0012] Furthermore, the thickness of the wear-resistant layer is 1~5μm.

[0013] Furthermore, the wear-resistant layer is made of modified polyamide-imide (modified PAI).

[0014] Furthermore, the insulating layer also includes a self-adhesive layer disposed on the outermost side.

[0015] Furthermore, the self-adhesive layer is a hot-melt self-adhesive layer or an alcohol-soluble self-adhesive layer.

[0016] Furthermore, the self-adhesive layer is made of any one of phenolic resin, epoxy resin, polyamide resin, polyethylene, polyacrylate, and polyurethane.

[0017] It should be noted that the modified PAI can be formed by adding wear-resistant fillers such as MoS2, silica, and alumina to the polyamide-imide paint to obtain the modified polyamide-imide paint, and then coating it on the outermost side of the insulation layer and baking it; or it can be formed by mixing polyamide-imide with epoxy resin and then coating it on the outermost side of the insulation layer and baking it; both can significantly enhance the wear resistance of the material.

[0018] This utility model also provides a coil made of the above-mentioned insulated wire.

[0019] The beneficial effects of this utility model are as follows: The insulated wire for inductors provided by this utility model is designed for conductors with a flat structure. By increasing the thickness of the insulation layer on both sides of the conductor, that is, by thickening the varnish film in the thickness direction, the voltage withstand capability on both sides of the insulated wire can be improved. This can reduce the damage to the narrow side of the insulated wire during the magnetic powder die casting process, reduce the short circuit rate, and improve the stability of the finished product voltage. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other embodiments can be obtained based on these drawings.

[0021] Figure 1 This is a structural diagram of the insulated wire of this utility model without a self-adhesive layer.

[0022] Figure 2 This is a schematic diagram of the cross-sectional structure of the insulated wire for inductors of this utility model after winding. Figure 1 .

[0023] Figure 3This is a schematic diagram of the structure of the insulated wire of this utility model when it has a self-adhesive layer.

[0024] Explanation of reference numerals in the attached figures: 1. Conductor; 2. Insulating layer; 21. Bottom layer; 22. Wear-resistant layer; 23. Self-adhesive layer. Detailed Implementation

[0025] The structure provided by this utility model will be explained and described in detail below with reference to the accompanying drawings.

[0026] refer to Figures 1 to 2 As shown, this embodiment specifically discloses an insulated wire for inductance, including a conductor 1 and an insulation layer 2 disposed on the outer periphery of the conductor 1. The conductor 1 is a flat conductor with a width of W and a thickness of T, wherein W / T is not less than 2; the thickness of the insulation layer on the upper and lower sides of the conductor is δ1, and the thickness of the insulation layer 2 on the left and right sides of the conductor 1 is δ2; wherein δ2 / δ1 = 1.5~3.

[0027] For the insulated wire for inductors provided in this embodiment, the left and right sides are subjected to greater pressure due to their smaller area. At this time, the left and right sides of the insulated wire are prone to deformation and breakage. Damage to the insulation layer will cause a short circuit in the coil. Therefore, in this embodiment, by setting the thickness of the insulation layer on the left and right sides to 1.5 to 3 times the thickness of the insulation layer on the top and bottom sides, it is possible to effectively prevent the sides of the insulated wire from being punctured by magnetic powder and avoid short circuit problems.

[0028] In other words, thickening the enamel film in the thickness direction can improve the voltage withstand capability on both sides of the insulated wire, thereby reducing the damage to the narrow side of the insulated wire during magnetic powder die casting, reducing the short circuit rate, and improving the stability of the finished product voltage.

[0029] In some embodiments, δ1 is 2~20μm, W is 0.1~2.0 mm, and T is 0.02~0.4 mm; these settings can be adjusted according to different specifications.

[0030] Continue to refer to Figure 1 As shown, in some embodiments, the width and thickness directions of the conductor are transitioned by a circular arc, with a radius of not less than 0.25T. In this embodiment, by setting a circular arc transition, mechanical stress can be dispersed, enhancing the insulation layer's resistance to breakage; at the same time, it can also prevent damage to the insulation layers of adjacent insulated wires during winding.

[0031] In some preferred embodiments, the insulating layer 2 further includes a wear-resistant layer 22, as shown in the reference. Figure 1As shown, the insulation layer 2 includes a bottom layer 21 directly coated on the conductor 1, and a wear-resistant layer 22 coated on the outer periphery of the bottom layer 21, that is, the bottom layer 21 is located between the conductor and the wear-resistant layer 22. At this time, the wear-resistant layer 22 is located on the outside of the bottom layer 21. By setting a wear-resistant layer on the outside of the bottom layer 21, the wear resistance of the insulated wire can be further improved.

[0032] In some embodiments, the thickness of the wear-resistant layer is 1~5μm, and its material is modified polyamide-imide; the modified polyamide-imide is a material that can be purchased in the prior art, namely wear-resistant polyamide-imide, or it can be formed by adding wear-resistant fillers such as MoS2, silica, and alumina to the polyamide-imide paint to obtain the modified polyamide-imide paint, and then coating it on the outermost side of the insulating layer and baking it; or it can be formed by mixing polyamide-imide with epoxy resin and then coating it on the outermost side of the insulating layer and baking it; all of these can significantly enhance the wear resistance of the material.

[0033] Continue to refer to Figure 3 As shown, in some embodiments, the insulation layer 2 further includes a self-adhesive layer 23. It should be noted that when both the wear-resistant layer 22 and the self-adhesive layer 23 are provided, the self-adhesive layer 23 is located on the outermost side of the insulation layer 2. The self-adhesive layer is a hot-melt self-adhesive layer or an alcohol-soluble self-adhesive layer; its material is any one of phenolic resin, epoxy resin, polyamide resin, polyethylene, polyacrylate, and polyurethane. By providing a self-adhesive layer 23 on the outermost side, the material of the self-adhesive layer softens and becomes sticky when appropriately heated during winding, thus achieving mutual adhesion and fixation between the wires. This is beneficial for dense wiring and can improve installation efficiency and long-term stability.

[0034] In summary, the insulated wire for inductors provided by this utility model can effectively improve the overall wear resistance of the insulation layer, avoid the problem of insulation layer cracking during the magnetic powder filling process or subsequent use, effectively ensure its insulation performance, and also improve its space utilization.

[0035] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and simple improvements made on the substantive content of the present utility model should be included within the protection scope of the present utility model.

Claims

1. An insulated wire for inductance, characterized in that, It includes a conductor and an insulating layer disposed on the outer periphery of the conductor. The conductor is a flat conductor with a width of W and a thickness of T, wherein W / T is not less than 2. The thickness of the insulating layer on the upper and lower sides of the conductor is δ1, and the thickness of the insulating layer on the left and right sides of the conductor is δ2, wherein δ2 / δ1 = 1.5~3.

2. The insulated wire for inductance according to claim 1, characterized in that, The value of δ1 is 2~20μm.

3. The insulated wire for inductance according to claim 1, characterized in that, The conductor's width and thickness directions are transitioned by circular arcs.

4. The insulated wire for inductance according to claim 3, characterized in that, The radius of the arc is not less than 0.25T.

5. The insulated wire for inductance according to claim 1, characterized in that, The W is 0.1~2.0 mm and the T is 0.02~0.4 mm.

6. The insulated wire for inductance according to claim 1, characterized in that, The insulating layer also includes a wear-resistant layer, which is located on the outermost side of the insulating layer.

7. The insulated wire for inductance according to claim 6, characterized in that, The thickness of the wear-resistant layer is 1~5μm.

8. The insulated wire for inductance according to claim 6, characterized in that, The wear-resistant layer is made of modified polyamide-imide.

9. The insulated wire for inductance according to claim 1, characterized in that, The insulating layer also includes a self-adhesive layer disposed on the outermost side.

10. A coil, characterized in that, It is composed of an insulated wire as described in any one of claims 1 to 9.

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