Assembled conductive wire

Abstract

To provide an assembled conductive wire in which generation of breakage due to bending is suppressed, and a space factor of a conductive wire is improved.SOLUTION: A cross section composed of multiple conductive wires is a rectangular assembled conductive wire, and includes: multiple first conductive wires 21 arranged in contact with a first side 11a in a cross section of a membrane 11 that forms the assembled conductive wire; multiple second conductive wires 23 arranged in contact with a second side 11b opposing the first side 11a in the cross section of the membrane 11; and multiple intermediate conductive wires 22 arranged between the multiple first conductive wires 21 and the multiple second conductive wires 23. The multiple second conductive wires 23 are formed to be larger in diameter than the multiple first conductive wires 21, and the multiple conductive wires 21, 22, 23 are arranged such that the diameters of the conductive wires constituting respective layers gradually increase from the layer constituted by the first conductive wires 21 in contact with the first side 11a to the layer constituted by the second conductive wires 23 in contact with the second side 11b.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present disclosure relates to a collection conductor. [Background technology]

[0002] In recent years, coils are arranged on a stator core to form stators used in motors. In such stators, there is a demand for the coils to be bent with a small radius so that they are in close contact with the electromagnetic steel sheet in order to improve the electric cost.

[0003] However, it is difficult to bend a coil with a small radius, and forcing it to bend with a small radius may result in breakage. Meanwhile, collective conductors are being considered that reduce eddy-current loss in the coil and improve power consumption by bundling multiple conductors together. JP 2014-032751 A (Patent Document 1) considers forming a collective conductor by placing a single copper-aluminum composite wire at the center and arranging and bundling copper-aluminum composite wires in a concentric pattern around the periphery of the central wire so as to be closely packed. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2014-032751 A Summary of the Invention [Problem to be solved by the invention]

[0005] In an assembled conductor as described in Patent Document 1, each copper-aluminum composite wire is made of thin wires of the same diameter bundled together, so while the inside of the bend can be easily bent with a small radius, the outside of the bend has a small diameter and may break. In addition, with an assembled conductor of the same diameter, there is a problem in that it is not possible to increase the space factor when bending in a way that does not break.

[0006] The present disclosure provides an assembly conductor that suppresses the occurrence of breakage due to bending and improves the space factor of the conductor wires. [Means for solving the problem]

[0007] The collective conductor according to the present disclosure is a collective conductor having a square cross section and composed of a plurality of conductors, comprising a plurality of first conductors arranged in contact with a first side in the cross section of a coating forming the collective conductor, a plurality of second conductors arranged in contact with a second side opposite to the first side in the cross section of the coating, and a plurality of intermediate conductors arranged between the plurality of first conductors and the plurality of second conductors, wherein the plurality of second conductors are formed with a diameter larger than that of the plurality of first conductors, and the first conductors, the second conductors and the intermediate conductors are arranged such that the diameters of the conductors constituting each layer gradually increase from a layer formed of first conductors in contact with the first side to a layer formed of second conductors in contact with the second side. This makes it possible to impart bending strength in a predetermined direction. Effect of the Invention

[0008] According to the present disclosure, it is possible to provide an assembly conductor that suppresses the occurrence of breakage due to bending and improves the space factor of the conductor wires. [Brief description of the drawings]

[0009] [Figure 1] FIG. 2 is a perspective view of a stator according to the first embodiment. [Diagram 2] 2 is a diagram showing thin wires constituting the assembly conducting wire according to the first embodiment. FIG. [Diagram 3] 1 is a cross-sectional view of a collective conductor in which each thin wire has a rectangular cross-section. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] First embodiment Hereinafter, the assembly conductor 2 according to this embodiment will be described with reference to the drawings. As shown in Fig. 1, the assembly conductor 2 is a conductor used as a coil for a stator core of a stator 1 used in a motor.

[0011] Fig. 2(a) is a further enlarged schematic diagram of a bent portion of the collective conducting wire 2 shown by a dashed rectangle in Fig. 1, and Fig. 2(b) is a cross-sectional view taken along line AA in Fig. 2(a). As shown in Fig. 2(b), the collective conducting wire 2 has a square cross section and includes a coating 11 and a plurality of thin wires 12 which are conductors. In the following, it is assumed that resin is used for the coating 11, and it will be described as a resin coating 11.

[0012] The resin film 11 bonds and fixes the fine wires 12 together. As shown in Fig. 2(b), the resin film 11 has a rectangular cross section with sides extending in the X and Y directions, and is formed to have a length of 12x in the X direction and 7x in the Y direction. Here, x is any positive number, and the same applies to x used for the length of the fine wires 12 described later.

[0013] For the sake of explanation, the lower side of the surface of the resin film 11 in Fig. 2(b) is referred to as the first side 11a, and the upper side in Fig. 2(b) is referred to as the second side 11b. Note that the first side 11a may be referred to as one side, and the second side 11b may be referred to as the other side. The first side 11a and the second side 11b face each other.

[0014] The plurality of thin wires 12 include a plurality of small diameter thin wires 21, a plurality of medium diameter thin wires 22, and a plurality of large diameter thin wires 23.

[0015] The small diameter thin wires (first conductive wires) 21 are thin wires arranged along the first side 11a, each in contact with the first side 11a. Here, as shown in Fig. 2(b), the small diameter thin wires 21 have a circular cross section and a diameter of x. That is, since the length of the resin film 11 in the X direction is 12x, the 12 small diameter thin wires 21 are arranged side by side in the X direction, in contact with the first side 11a.

[0016] The small diameter thin wire 21 is composed of a conductor portion 21a through which current flows and a resin coating 21b of the thin wire arranged to surround the conductor portion. The resin coating 21b covers the conductor portion 21a, thereby ensuring insulation between the thin wires. The conductor portion and the resin coating of the thin wire are similarly configured for the multiple medium diameter thin wires 22 and the multiple large diameter thin wires 23. The portion formed only of the small diameter thin wires 21 in the X direction is considered to be one layer, and the same is true for the multiple medium diameter thin wires 22 and the multiple large diameter thin wires 23.

[0017] Each of the medium-diameter thin wires (intermediate conductive wires) 22 is disposed closer to the second side 11b than the small-diameter thin wires 21. In other words, the medium-diameter thin wires 22 are thin wires disposed between the small-diameter thin wires 21 disposed in contact with the first side 11a and the large-diameter thin wires 23 disposed in contact with the second side 11b (described later). Here, as shown in FIG. 2(b), the medium-diameter thin wires 22 have a circular cross section and a diameter of 2x. That is, since the length of the resin film 11 in the X direction is 12x, six medium-diameter thin wires 22 are disposed side by side in the X direction.

[0018] The multiple large diameter thin wires (second conductive wires) 23 are thin wires arranged along the second side 11b in a state where each of them is in contact with the second side 11b. Here, as shown in Fig. 2(b), the multiple large diameter thin wires 23 have a circular cross section and a diameter of 4x. That is, since the length of the resin film 11 in the X direction is 12x, three large diameter thin wires 23 are arranged side by side in the X direction in a state where they are in contact with the second side 11b.

[0019] In other words, in the collective conductor 2, the thin wires are arranged so that the diameters of the thin wires constituting each layer gradually increase from the layer composed of small diameter thin wires 21 in contact with the first side 11a to the layer composed of large diameter thin wires 23 in contact with the second side 11b.

[0020] Here, as shown in FIG. 2(a), when the collective conducting wire 2 is used as a coil, the multiple small diameter thin wires 21 are arranged on the inside of the bend and the multiple large diameter thin wires 23 are arranged on the outside of the bend.

[0021] This allows the assembly conductor 2 to be given bending strength in a predetermined direction, making it possible to prevent breakage even when bending with a small R and to improve the space factor. Therefore, when this assembly conductor 2 is used in a stator, the torque of a motor using this stator can be improved.

[0022] The material of the collective conductor 2 is optimally pure copper with low electrical resistance for the conductive part of each thin wire, and PI (polyimide) with low dielectric constant and high insulation for the resin coating, but is not limited thereto. For example, the conductor may be made of metals such as pure aluminum, aluminum alloy, tin, zinc, and iron, although the electrical resistance will increase and the power consumption will deteriorate. Furthermore, a superconducting coil (such as magnesium diboride) with zero electrical resistance may be used. Similarly, the resin coating is not limited to PI, and a wide range of resins, including PA (polyamide), phenol, acrylic, polyurethane, urea resin, and PPS (polyphenylene sulfide) resin, regardless of whether they are thermosetting resins or thermoplastic resins, can be used. In addition to resins, inorganic materials with high insulation such as enamel and glass can be used for the coating, and it is possible to change to various materials as long as they have heat resistance, insulation, and dielectric constant that can withstand the usage environment of the product.

[0023] In the above description, the diameter of the small diameter thin wire 21 is x, the diameter of the medium diameter thin wire 22 is 2x, and the diameter of the large diameter thin wire 23 is 4x, and the diameters of the smallest diameter thin wires are doubled in each layer, but this is not limited to the above. In other words, when the diameter of the smallest diameter thin wire is x, the diameter of the next thin wire does not need to be 2x, and it is sufficient that the small diameter thin wire is arranged on the inside of the bend of the assembly conductor and the large diameter thin wire is arranged on the outside of the bend.

[0024] Furthermore, in the above description, the collective conductor 2 is described as being made up of three layers of small diameter thin wires 21, medium diameter thin wires 22, and large diameter thin wires 23, but the number of layers is not limited to this. That is, it is also possible to form an collective conductor in five layers using five types of thin wires with different diameters, or to form an collective conductor in ten layers using ten types of thin wires.

[0025] For example, when five types of fine wires are used in five layers, the fine wires arranged adjacent to the first side 11a have the smallest diameter, and the fine wires arranged adjacent to the second side 11b have the largest diameter. The fine wires arranged between them have smaller diameters closer to the first side 11a and larger diameters closer to the second side 11b, and are arranged in order of diameter with layers formed for each fine wire diameter.

[0026] In addition, although each thin wire has been described above as having a circular cross section, this is not limited thereto. For example, as shown in Fig. 3, each thin wire used in the collective conductor 2 can be changed to a thin wire with a square cross section. In this case, similar to the above, the thin wires can be arranged so that the side length of the thin wire arranged on the outside of the bend is longer for each layer than the side length of the smallest thin wire arranged on the inside of the bend. Typically, the thin wires can be arranged so that the side length of the thin wire arranged on the inside of the bend is doubled for each layer from the thin wire arranged on the outside of the bend.

[0027] That is, it is possible to arrange thin wires 31 with a small cross section on the inside of the bend, thin wires 32 with a medium cross section in the middle, and thin wires 33 with a large cross section on the outside of the bend. Also in this case, as with the thin wires with circular cross sections, the number of layers is not limited to three and can be changed as desired.

[0028] Although not shown, the cross section of each thin wire arranged in the collective conductor wire can have various shapes, such as a star shape.

[0029] The present invention is not limited to the above-described embodiment, and can be modified as appropriate without departing from the spirit of the present invention. In other words, the above description has been omitted or simplified as appropriate for the purpose of clarity, and a person skilled in the art can easily modify, add, or convert each element of the embodiment within the scope of the present invention.

[0030] For example, although the above description has been given of a collective conductor formed by bundling together a number of thin wires of different diameters, it is also possible to wind the conductor in the same manner without forming it into a collective conductor before winding it around the laminated steel plates that form the stator core.

[0031] For example, when this stator core is wound with a conductor in a coil to be used as a motor, it is fixed with a resin mold to suppress vibration and ensure insulation between the coils. Therefore, by winding a thin wire with the smallest diameter around the laminated steel plate, and then winding thin wires with gradually larger diameters, and finally integrating them with a resin mold, it is possible to obtain the same effect as when using an assembled conductor in which thin wires with multiple different diameters are provided for each layer, as described above. [Explanation of symbols]

[0032] 1 Stator 2 Collective conductor 11 Resin film 11a First Side 11b Second Side 12 Thin line 21 Small diameter thin wire 21a Conductor part 21b Resin film 22 Medium diameter thin wire 23 Large diameter thin wire 31 Fine wire with small cross section 32 Fine wire with medium cross section 33 Fine wire with large cross section

Claims

[Claim 1] A collective conductor having a rectangular cross section and composed of a plurality of conductors, a plurality of first conductive wires arranged in contact with a first side in a cross section of the coating forming the collective conductive wire; a plurality of second conductive wires arranged in contact with a second side of the cross section of the coating, the second side being opposed to the first side; a plurality of intermediate conductors disposed between the plurality of first conductors and the plurality of second conductors; The plurality of second conducting wires are formed to have a larger diameter than the plurality of first conducting wires, The first conductor, the second conductor, and the intermediate conductor are the diameters of the conductors constituting each layer are arranged so as to gradually increase from a layer constituted by the first conductor in contact with the first side to a layer constituted by the second conductor in contact with the second side; collective conductor.

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