A method for continuously manufacturing electric wire conductors in which aggregates of maghemite microparticles, magnetically attracted to each other by saturated magnetization, are stacked, and these aggregates cover the entire surface of the electric wire conductor, regardless of the shape of the conductor, thereby insulating it.

Abstract

This invention provides a method for continuously manufacturing electric wire conductors in which the surface is insulated by an aggregate of stacked Maghemite microparticles that are magnetically attracted to each other by saturated magnetization. [Solution] The method involves creating a suspension in which maghemite microparticles are dispersed in an organic compound and the viscosity can be changed, continuously adsorbing the suspension onto a conductor, continuously covering the surface of the conductor with an aggregate of maghemite microparticles using the suspension, continuously saturating the magnetization of the maghemite microparticles, continuously winding up the conductor of the wire insulated with the aggregate of maghemite microparticles, creating a suspension in which an aggregate of fine crystals of an organic iron compound that precipitates ferrous oxide by thermal decomposition is dispersed in an organic compound with a high boiling point, thermally decomposing the organic iron compound, oxidizing the ferrous oxide to ferric oxide, reducing the viscosity of the suspension with an organic solvent, continuously immersing the conductor in the low-viscosity suspension, continuously vaporizing the organic solvent and organic compound from the conductor, continuously passing the conductor through a magnetic field, and continuously winding the conductor onto a bobbin.

Description

[Technical Field]

[0001] The present invention Tired With the combined magnetization each other Magnetic adsorption A collection of mites in the magnesium Lamination So The magnesium is composed of a collection of fine particles. Regardless of the shape of the conductor of the electric wire, surface of the conductor Cover the whole thing, Insulation Let This relates to a method for continuously manufacturing conductors for electric wires. Prior to this invention, the inventor filed a Japanese Patent Application No. 2021-158547 (filed on September 28, 2021) for a method of insulating the conductor of an electric wire with an aggregate of magnetically adsorbed Magnamide fine particles. One method for insulating a conductor with an aggregate of maghemite microparticles involves thermally decomposing an organic iron compound adsorbed on the conductor, precipitating ferrous oxide from the organic iron compound, and then applying a heat treatment to oxidize the ferrous oxide into maghemite. However, only conductors that enter the heat treatment apparatus can be heat-treated. In contrast, since conductors have a certain length, only a small portion of the conductor can be heat-treated. Furthermore, the heat treatment of a conductor involves performing two types of heat treatments with different heat treatment conditions in succession. Therefore, to heat-treat a conductor, a conductor of a length that can be fed into the heat treatment apparatus must undergo two types of heat treatments in succession based on a predetermined temperature profile. Next, a new conductor of the same length is fed into the heat treatment apparatus and similarly subjected to two types of heat treatments based on a predetermined temperature profile. Based on this idea, the prior application involved feeding a conductor into a heat treatment device and then heat-treating the conductor, performing these two processes in conjunction as a pair. By continuously performing this pair of processes, heat treatment could be performed on all conductors, and the surface of the conductor was insulated by an aggregate of magnesiumite particles. In contrast, the present invention involves firstly heat-treating a first suspension in which fine crystals of an organic iron compound are dispersed in an organic compound to obtain a second suspension in which fine particles of ferrous oxide (FeO) are dispersed in the organic compound, then further heat-treating it to obtain a third suspension in which fine particles of maghemite (γ-Fe2O3) are dispersed in the organic compound, then continuously immersing a conductor in a fourth suspension obtained by adding an organic solvent to the third suspension to reduce its viscosity, then continuously passing the conductor through a third heat treatment device that vaporizes the organic solvent, and then continuously passing the conductor through a fourth heat treatment device that vaporizes the organic compound. As a result, fine particles of maghemite (γ-Fe2O3) appear on the surface of the conductor, and the surface of the conductor of the electric wire is continuously insulated by an aggregate of magnetically adsorbed maghemite particles. Thus, the present invention insulates the surface of the electric wire conductor with continuous heat treatment, eliminating the need for the complex heat treatment described in the prior art. [Background technology]

[0002] Insulated wires are wires in which a conductor is covered with an insulator, and they are used for a variety of purposes. Conductors consist of single or stranded wires. Furthermore, conductors can be round wires with a roughly circular cross-section or flat wires with a rectangular cross-section. In addition, most conductors are made of copper or aluminum, but if the advantages of alloys outweigh the disadvantages of increased costs for alloy materials, copper alloys or aluminum alloys with high conductivity are used. Wires in which multiple insulated wires are bundled together and covered with a sheath (protective outer covering) are called cables, and there are metal communication cables that transmit electrical signals and optical fiber cables that transmit optical signals.

[0003] Insulated wires, made of round wire, are classified into transmission, distribution, and wiring wires according to their allowable current. Wires used outdoors have a black insulating layer to protect against ultraviolet rays, and the Japan Electric Wire and Cable Manufacturers Association estimates their service life to be 15-20 years. Insulated power transmission wires include high-voltage distribution lines that carry voltages exceeding 700 volts DC, exceeding 600 volts AC, and up to 7kV. Therefore, depending on the magnitude of the current flowing through the conductor, the conductor consists of 7 to 19 strands twisted together. In addition, the insulation layer is mostly made of cross-linked polyethylene resin with a maximum continuous operating temperature of 90°C, or polyethylene resin with a maximum continuous operating temperature of 75°C. There are also high-voltage service drops that connect outdoor distribution lines of 3300-6600 volts to transformers on utility poles. The conductor consists of 7 strands twisted together, and the insulation layer is made of cross-linked polyethylene resin with a maximum continuous operating temperature of 90°C, or ethylene propylene rubber with a maximum continuous operating temperature of 80°C. Furthermore, there are low-voltage overhead power lines used in low-voltage distribution lines that use transformers to reduce the power received from high-voltage service drops to single-phase or three-phase power of 100 volts or 200 volts. The conductor consists of 7 to 19 strands of wire twisted together, and the insulating layer is made of vinyl resin with a maximum continuous operating temperature of 60°C. Insulated electrical wires for wiring vary widely depending on their final application, but a major use case is indoor wiring in buildings. Most indoor wiring is low-voltage wiring up to 600 volts, with a conductor made of seven strands twisted together and an insulation layer made of vinyl resin with a maximum continuous operating temperature of 60°C. The Japan Electric Wire and Cable Manufacturers Association estimates the service life for indoor wiring to be 20-30 years.

[0004] Furthermore, insulated wires made of round wire are used in coils, motors, plungers, relays, and automotive electrical components as windings (also called magnet wires). Windings include enameled wires, which are coated and baked with insulating material; transversely wound wires, which are wound with fibers, films, tapes, paper, threads, etc.; and wires that combine these. Enameled wires are classified by the heat resistance temperature of the insulating layer: polyvinyl formal copper wire at 105°C, polyurethane copper wire at 120°C, polyester copper wire at 155°C, polyesterimide copper wire at 180°C, polyamideimide copper wire at 200°C, and polyimide copper wire at 220°C. The insulating layer of windings requires various properties such as dielectric breakdown resistance, abrasion resistance, solvent / chemical / oil resistance, hydrolysis resistance, thermal shock resistance, and heat life. The environment in which round wires are used and the applied loads vary greatly depending on the equipment in which they are used, and consequently, the performance required of the insulating layer also varies greatly. In particular, windings used in various electrical components installed in automobiles require high performance.

[0005] On the other hand, rectangular conductors are manufactured by drawing wire if they have a relatively small aspect ratio, and by rolling round wire or slitting rolled sheets if they have a large aspect ratio. Rectangular conductors have an insulating layer formed on their surface, and when used as windings for coils or as coils, the ratio of the conductor's cross-sectional area to the coil's cross-sectional area is higher than that of round wire. Therefore, they are used as windings or coils in various electrical and electronic components where miniaturization and high performance are required. In other words, flat rectangular conductors are used in consumer electronics as surface-mount coils in personal computers, televisions, and control circuits, and as small surface-mount coils in tablet devices and smartphones. In automobiles, they are used as windings in electrical components such as hybrid vehicle drive motors, electric compressor motors, electric power steering motors, wiper motors, alternators, starters, and ignition coils. They are also used as windings in various motors, including industrial motors, home appliance motors, and small motors. Furthermore, they are used as various coils such as relay coils and clutch coils, and as coils in various transformers such as power transformers, lighting equipment transformers, and small transformers. On the other hand, the insulating layer of a rectangular conductor requires various properties such as dielectric breakdown resistance, abrasion resistance, solvent / chemical / oil resistance, hydrolysis resistance, thermal shock resistance, and thermal life. However, the environment in which the rectangular conductor is used and the applied load vary greatly depending on the equipment in which it is used, and consequently, the performance required of the insulating layer also varies greatly. Similar to windings, windings used in various electrical components installed in automobiles require high performance. Furthermore, the thickness and width of rectangular conductors vary greatly depending on the equipment in which they are used. For example, ultra-fine rectangular conductors used in small surface-mount coils have a conductor thickness of 0.02 mm, a conductor width of 0.1-0.3 mm, and an insulation layer thickness of only 0.005 mm. In contrast, general rectangular conductors have a conductor thickness of 0.8-1.0 mm, a conductor width of 1.7-3.5 mm, and an insulation layer thickness of 0.05 mm. Thus, the thickness of the insulation layer changes by an order of magnitude depending on the conductor thickness. Also, the spacing between coils changes by an order of magnitude depending on the conductor thickness. Furthermore, coils using rectangular wire come in a variety of shapes. For example, edgewise coils, which are made by bending rectangular wire in the width direction where it is difficult to bend, come in shapes such as rectangular edgewise coils, circular edgewise coils, oval edgewise coils, and elliptical edgewise coils. There are also various other coil shapes, such as 2-winding coils, tortoise shell coils, and toroidal coils.

[0006] As explained above, insulated wires are used in a variety of applications and environments, and various loads are applied to the insulating layer. Therefore, the performance required of the insulating layer varies depending on the application. Consequently, there is no single insulating layer that satisfies all the performance requirements for all types of insulated wires. Furthermore, the conductor thickness and width of rectangular conductors vary greatly depending on the application. Therefore, there is no insulating layer that can accommodate all conductor thicknesses and widths.

[0007] For example, Patent Document 1 describes forming an insulating layer on a coil made of flat rectangular conductors by electrodeposition coating, in which the coil is maintained in an elongated state with gaps between multiple windings within the elastic deformation region of the coil, and the electrodeposition coating process and baking process are carried out in that elongated state to form the insulating layer. However, this requires a process to maintain the coil's windings in an elongated state with sufficient spacing between them, increasing the cost of forming the insulating layer. Furthermore, it is impossible to maintain coils with windings as small as 0.01 mm in an elongated state with sufficient spacing between them. Therefore, insulating layers can only be formed on a limited number of coils.

[0008] Patent Document 2 describes a method of extruding a composite material of spherical silica and polyphenylene sulfide resin to form an insulating film on a rectangular conductor, thereby bringing the thermal expansion coefficient of the insulating layer closer to that of copper and improving thermal shock resistance. However, because spherical silica with an average particle size of 0.5-10 μm is compounded into molten PPS resin at a volume ratio of 25-32%, the more spherical silica is added, that is, the closer the thermal expansion coefficient of the composite material is to that of copper, the lower the flexibility of the composite material becomes. When forming a coil using windings insulated with such a composite material, cracks appear in the insulating layer at the bends, making it impossible to process into a coil. Therefore, its use is limited to winding applications that do not require bending, and the range of winding applications for which it can be used is extremely narrow. The thermal expansion coefficient of spherical silica is 0.55 × 10⁻⁶. -6 At / K, the thermal expansion coefficient of PPS resin is 49-55 × 10⁻⁶. -6 At / K, the thermal expansion coefficient of copper is 16.8 × 10⁻⁶. -6 Because the thermal expansion coefficient of the composite material is 1 / K, the proportion of silica spheres must be increased to 2 / 3 by volume in order to match the thermal expansion coefficient of copper. However, as the proportion of silica spheres increases, the viscosity of the composite material increases, making extrusion molding difficult. Furthermore, wear on the extrusion molding machine becomes significant. Therefore, because there are constraints on the proportion of spherical silica, there are also constraints on the thermal expansion coefficient of the composite material. Consequently, there are limits to improving the thermal shock resistance of the insulating layer made of the composite material.

[0009] Patent Document 3 describes that, in order to make the thickness of the insulating layer in the portion corresponding to the short side of the cross-sectional shape of a rectangular conductor thicker than the thickness of the insulating layer in the portion corresponding to the long side, the varnish used for electrodeposition coating is composed of a coating resin, water, and a water-soluble solvent. However, insulating layers require various properties such as dielectric breakdown resistance, abrasion resistance, solvent / chemical / oil resistance, hydrolysis resistance, thermal shock resistance, and heat life. Since the materials of water-soluble synthetic resins are limited, even if the desired insulating layer can be formed with such varnish, the performance of the insulating layer is constrained by the water-soluble resin, limiting the applications for which flat rectangular conductors can be used.

[0010] Patent Document 4 describes an insulated wire in which multiple insulating layers are formed using an insulating paint with a low dielectric constant. In other words, for example, due to the influence of inverter surge voltage, the higher the dielectric constant of the insulating layer, the more partial discharge due to dielectric polarization occurs on the surface of the insulating layer. This partial discharge causes deterioration, which erodes the insulating layer and ultimately leads to dielectric breakdown. For this reason, the first layer on the inside is baked with a low dielectric constant insulating paint mainly composed of one of the following: a low dielectric constant polyesterimide resin with a dielectric constant of less than 3.8, a low dielectric constant polyamideimide resin with a dielectric constant of less than 4.0, or a low dielectric constant polyimide resin with a dielectric constant of less than 3.2. The second layer is baked with a low dielectric constant insulating paint mainly composed of one of the following: polyesterimide resin, polyamideimide resin, or polyimide resin, with inorganic fine particles as a secondary component. On the other hand, the conventional insulating material with the best arc resistance and tracking resistance is silicone varnish with a dielectric constant of 3.1-3.2. However, even silicone varnish has limitations in arc resistance and tracking resistance. Therefore, even when using the low dielectric constant insulating paint described in Patent Document 4, there are limitations in arc resistance and tracking resistance. Furthermore, the first and second layers are baked on separately, and the interface between the different materials does not fuse due to the difference in melting points, forming a gap at the interface due to layer separation. When such a gap exists, partial discharge occurs at the gap. Repeated discharges gradually erode the insulator, eventually leading to dielectric breakdown. In addition, the manufacturing cost increases compared to conventional single-layer insulating layers. [Prior art documents] [Patent Documents]

[0011] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-115242 [Patent Document 2] Japanese Patent Application Laid-Open No. 2014-029779 [Patent Document 3] Japanese Patent Application Laid-Open No. 2017-016956 [Patent Document 4] Japanese Patent Application Laid-Open No. 2016-181344 [Summary of the Invention] [Problems to be Solved by the Invention]

[0012] As described in the patent documents explained above, the described technology is only effective for limited applications and lacks universality. Therefore, there is no insulating layer that can satisfy all the performance requirements related to all insulated wires with a single type of insulating layer. Therefore, regardless of the environment in which the insulated wire is used, whether the wire is a single wire, a stranded wire, a flat wire, or any other type of wire, and regardless of the conductor thickness and conductor width of the flat conductor, there is a need to realize a method for continuously manufacturing insulated wires with performance superior to conventional ones and at a lower cost for all wires. As such an insulated wire, there is a means of magnetically adsorbing magnetite fine particles with saturated magnetization to each other and laminating the magnetically adsorbed magnetite fine particles gathering to form an aggregate of the magnetite fine particles, and insulating the surface of the conductor of the wire. That is, magnetite has insulation properties and is an extremely stable metal oxide, so the insulation properties can be maintained over a long period. whole Maghemite (γ-Fe2O3) is produced by thermally decomposing an organic iron compound to precipitate ferrous oxide (FeO). When the temperature is raised to a level where ferrous oxide (FeO) is oxidized to ferric oxide (Fe2O3), an oxidation reaction occurs in which the divalent iron ions in ferrous oxide (FeO) are converted to trivalent iron ions. In the initial stages of this oxidation reaction, some of the divalent iron ions in ferrous oxide (FeO) become trivalent iron ions, forming ferric oxide (Fe2O3), which is then oxidized to magnetite with the chemical formula FeO·Fe2O3. Since magnetite is a conductive ferromagnetic material, magnetite nanoparticles magnetically attract each other. Furthermore, if the standing time is extended, the oxidation reaction in which divalent iron ions are converted to trivalent iron ions progresses, and the number of magnetite nanoparticles produced increases. Furthermore, if the standing time is extended, all of the divalent iron ions that make up magnetite (FeO·Fe2O3) become trivalent iron ions, forming ferric oxide (Fe2O3), and the oxidation reaction is completed. This ferric oxide (Fe2O3) is maghemite (γ-Fe2O3), the gamma phase of ferric oxide (Fe2O3), which has the same cubic crystal system as magnetite (FeO·Fe2O3). Note that the crystal structure of hematite (α-Fe2O3), the alpha phase of ferric oxide (Fe2O3), is trigonal, and since its crystal structure is different from that of magnetite, hematite (α-Fe2O3), the alpha phase of ferric oxide (Fe2O3), is not produced by the oxidation of ferrous oxide (FeO). Maghemite has the following six properties: Firstly, it is a ferromagnetic material with spontaneous magnetization. On the other hand, if the maghemite particles are nanoscale particles, then since the maghemite particles have almost no mass, they magnetically attract each other due to saturated magnetization, and in an insulating layer where aggregates of magnetically attracted maghemite particles are stacked, the maghemite particles are strongly magnetically attracted to each other. Note that the magnetically attracted maghemite particles come into contact with each other at the contact point due to magnetic attraction, but they are not bonded to each other at the contact point. Therefore, when stress is applied to the aggregate of maghemite particles, the magnetic attraction between the maghemite particles at the localized area where the stress is applied is torn apart, and the maghemite particles are pulled apart. However, since a magnetic attraction force due to spontaneous magnetization is constantly acting on the maghemite particles, when the stress is released, the maghemite particles become magnetically attracted again. As a result, the magnetically attracted maghemite particles do not detach from the aggregate of maghemite particles. However, when processing a conductor with an insulating layer into various shaped winding coils, the greatest stress acts as tensile stress on the cluster of maghemite microparticles on the outside of the bend, forming the surface layer on the outside of the bend. gathering The magnetic attraction is torn apart, and the Maghemite microparticles are pulled away. Therefore, the insulating layer of the conductor processed into a wound coil is affected by the Maghemite microparticles. gathering The number of layers stacked is set to a maximum of 20, and even if the magnetic adsorption of the surface layer of Maghemite microparticles is torn apart, the magnetic adsorption of the Maghemite microparticles inside the surface layer ensures the insulation of the conductor. Secondly, although the magnetic Curie point is 675°C, it gradually undergoes a phase transition to hematite, a paramagnetic material, at temperatures above 450°C in air. Therefore, the magnetic adsorption force of maghemite nanoparticles has heat resistance close to 450°C. Since this phase transition is reversible, when the temperature returns to below 450°C, maghemite reverts to its ferromagnetic properties. Consequently, it has superior heat resistance of over 300°C compared to conventional synthetic resin insulating layers. Thirdly, even if the temperature of the insulated wire changes, if the maghemite particles are at the nanoscale, the thermal expansion and contraction of the maghemite particles are extremely small, and the aggregate of maghemite particles hardly expands or contracts at all. For this reason, an insulating layer made up of aggregates of maghemite particles has superior thermal shock resistance compared to conventional synthetic resin insulating layers. Fourthly, from ferric oxide Naru It is an inorganic substance, has excellent heat resistance, and does not react with acids, alkalis, or water vapor. Therefore, the magnetic adsorption force of maghemite microparticles does not change over time. Fifth, the resistivity is 10 7 It is an insulator with a resistance of Ωcm, and its resistivity as an insulator is not large. Here, the electrical resistance of the maghemite microparticles is defined as resistivity × (circumference of the microparticle) ÷ (surface area of ​​the microparticle), and if the size of the maghemite microparticles is 13 nm, then the electrical resistance of the maghemite microparticles is 7.7 × 10⁻⁶. 12 It becomes Ω. Note that the resistivity of the synthetic resin that forms the conventional insulating layer is 10 14-16 The resistance is Ωcm. On the other hand, the insulation resistance of an insulating layer made up of a collection of maghemite microparticles is the sum of the insulation resistance of the maghemite microparticles connected in series in the length direction of the insulating layer, that is, in the direction in which the current flows through the conductor, and the insulation resistance of the series-connected maghemite microparticles connected in parallel, which are the number of maghemite microparticles that form the thickness of the insulating layer. Note that the magnitude of the series-connected insulation resistance is a multiple of the magnitude of the parallel-connected insulation resistance and the number of maghemite microparticles that form the thickness. Therefore, the insulation resistance of the insulating layer is dominated by the insulation resistance of the maghemite microparticles connected in series. For example, if the size of the maghemite microparticles is 13 nm, the insulation resistance of an insulating layer with a length of 1 m is 7.7 × 10⁻⁶. 7 A resistor consisting of 10⁻¹⁵ Mag-Hemite microparticles is connected in series. The resistance value formed by these series-connected Mag-Hemite microparticles is 5.9 × 10⁻¹⁵ 20This results in an ohm resistance. Therefore, it forms an insulation resistance that is significantly higher than that of conventional insulating layers. Note that the thickness of conventional insulating layers is 5 μm or more. In contrast, the thickness of the insulating layer made of aggregated maghemite microparticles is 65-130 nm for all conductors, regardless of whether the conductor is a single wire, stranded wire, or rectangular wire, and regardless of the conductor thickness and width of the rectangular wire, if the insulating layer is made of 5-10 microparticles stacked on top of each other and the size of the microparticles is 13 nm. In this way, because the insulating layer is formed from aggregated microparticles, the thickness of the insulating layer is significantly thinner than that of conventional insulating layers. On the other hand, as mentioned above, when processing a conductor with an insulating layer into a wound coil, the greatest stress acts as tensile stress on the cluster of Maghemite microparticles on the outside of the bend, forming the surface layer on the outside of the bend. gathering The magnetic attraction is torn apart, and the Maghemite microparticles are pulled away from magnetic attraction. For this reason, for conductors processed into wound coils, the number of layers of Maghemite microparticles is set to 20, the thickest possible layer, so that even if the magnetic attraction of the surface Maghemite microparticles is torn apart, the magnetic attraction between the Maghemite microparticles inside the surface ensures the insulation of the conductor. Incidentally, among the thicknesses of insulating layers provided on conventional conductors, the thinnest insulating layer is 5 μm when processed into a small surface-mount coil using ultra-fine flat wire. In contrast, the thickness of the insulating layer with 20 Maghemite microparticles stacked is 260 nm, which is close to 1 / 20th the thickness of the insulating layer of a small surface-mount coil. In other words, because the cluster of stacked Maghemite microparticles forms a large insulating resistance, a large insulating resistance can be formed even with a thin insulating layer. Sixth, its arc resistance and tracking resistance are significantly superior to conventional insulating layers. In other words, among the materials that form conventional insulating layers, silicone varnish is the most excellent in terms of arc resistance and tracking resistance. That is, when an arc occurs on the surface of an insulating layer, the insulating layer decomposes and carbonizes at the temperature of the arc. As this carbonization progresses, a conductive path is formed in the insulating layer, causing arc tracking. The property of being less susceptible to this arc tracking phenomenon is called arc resistance. Silicone varnish is a varnish made by diluting polysiloxane with an organic solvent such as toluene or xylene. Polysiloxane begins to decompose at 150°C, and carbonizes as thermal degradation progresses. The boiling point of xylene is 140°C. In contrast, maghemite is an inorganic substance made of ferric oxide and does not contain carbon atoms. Furthermore, maghemite gradually undergoes a phase transition to hematite (α-Fe2O3), which is made of ferric oxide, at temperatures of 450°C or higher in the atmosphere. Therefore, an insulating layer made of an aggregate of inorganic magnetite fine particles does not cause arc tracking. Furthermore, tracking is the loss of insulating properties due to the formation of conductive paths in the insulating layer. Therefore, an insulating layer made up of magnetite nanoparticles does not undergo arc tracking, and thus exhibits excellent tracking resistance. Seventh, it is an extremely stable, black, inorganic material consisting of metal oxides, with excellent resistance to solvents, chemicals, and oils. It does not hydrolyze, does not degrade under electrical conditions, and does not degrade under ultraviolet light. Therefore, the insulating properties of the insulating layer do not change over time, and the insulating properties of the wire are maintained over a long period of time. Eighth, it has a Mohs hardness of 6.5, which is significantly harder than electrical steel sheets. This means that even when the wire comes into contact with components and substrates of various materials, the insulating layer does not wear down, and the insulating properties of the wire are maintained. As explained above, an insulated wire in which the conductor of an electric wire is insulated by a stack of these magnesium nanoparticles that are magnetically attracted to each other by saturated magnetization, and by the stacked collection of these magnesium nanoparticles, becomes an insulated wire with various superior properties compared to conventional insulated wires.

[0013] However, when insulating the surface of a wire conductor with an aggregate of Magmite microparticles, it is necessary to continuously cover the surface of the conductor of all wires with an aggregate of Magmite microparticles, regardless of whether the wire is solid, stranded, or rectangular, and regardless of the thickness or width of the conductor of the rectangular conductor. Therefore, the challenge is to concretize the following processing method to continuously insulate the surface of a wire conductor with an aggregate of Magmite microparticles. Firstly, we will develop a method for dispersing magnesiumite microparticles in an organic compound and creating a suspension with adjustable viscosity. In other words, the viscosity of the suspension can be varied according to the thickness of the single or stranded wire, and the conductor thickness and width of the rectangular conductor. Furthermore, for conductors that will be processed into wound coils, the viscosity of the suspension will be maximized. Secondly, a method for continuously adsorbing the suspension onto the surface of the conductor of an electric wire is provided. Thirdly, the method for continuously covering the surface of the electric wire conductor with an aggregate of Magmite microparticles by processing the suspension is provided. Fourthly, we will provide a method for continuously saturating the magnetization of maghemite nanoparticles covering the surface of the conductor of an electric wire. Fifth, we will provide a method for continuously extracting conductors from electric wires insulated on the surface of the conductor by an aggregate of magnetized maghemite nanoparticles. The problem that this invention must solve is the five problems described above. [Means for solving the problem]

[0014] Tired With the combined magnetization each other Magnetic adsorption A collection of mites in the magnesium Lamination The said A collection of magnesiumite microparticles Regardless of the shape of the conductor of the electric wire, surface of the conductor whole of Cover, Insulation Let A method for continuously manufacturing electric wire conductors is, The first step involves dispersing an organic iron compound that precipitates ferrous oxide (FeO) upon thermal decomposition in methanol in its molecular state to create a methanol dispersion of the organic iron compound, then vaporizing the methanol from the methanol dispersion of the organic iron compound to precipitate an aggregate of crystals of the organic iron compound, and finally filling a container with the aggregate of crystals of the organic iron compound. A plate material is placed over the entire surface of the collection of organic iron compound crystals in the container, and then a compressive load is applied to the entire surface of the plate material. equally In addition, the crystals of the organic iron compound in the container are crushed, and then impact accelerations in three directions (front / back, left / right, and up / down) are repeatedly applied to the sides and bottom of the container to rearrange the aggregate of crushed organic iron compound crystals within the container, and after this, the compressive load is applied again to the entire surface of the plate material. equally In addition, the crushing of the crystals of the organoiron compound is further advanced, and the impact acceleration in the three directions is repeatedly applied again to the sides and bottom of the container, and this pair of processes consisting of applying the compressive load and applying the impact acceleration is repeated, thereby applying the compressive load to the plate material. equally When added, the movement of the plate material They've completely disappeared. At this point, it is determined that the pulverization of the crystals of the organoiron compound is complete, and the pair of processes is stopped, thereby pulverizing the crystals of the organoiron compound into fine crystals of 1 / 5 of their original size. After this, the second step is to remove the plate material from the container, A third step is to weigh an organic compound having the following properties: firstly, that the crystals of the organic iron compound do not dissolve or disperse; secondly, that its boiling point is higher than the temperature at which ferrous oxide (FeO) is oxidized to ferric oxide (Fe2O3); thirdly, that it does not chemically react with both the fine particles of ferrous oxide (FeO) and the fine particles of ferric oxide (Fe2O3); and fourthly, that its viscosity at 25°C is 11-18 mPa·s, in a weight greater than the aggregate of fine crystals of the organic iron compound in the container; thirdly, to mix the weighed organic compound into the container filled with the aggregate of fine crystals of the organic iron compound; and thirdly, to stir with a stirrer, thereby creating a first suspension in which the aggregate of fine crystals of the organic iron compound is dispersed in the organic compound. A first heat treatment apparatus is prepared to thermally decompose the fine crystals of the organic iron compound into fine ferrous oxide (FeO) particles, the container is moved into the first heat treatment apparatus, the first heat treatment apparatus is heated to a temperature at which the fine crystals of the organic iron compound thermally decompose into fine ferrous oxide (FeO) particles, and the temperature is maintained at this decomposition temperature for a predetermined time, thereby causing fine ferrous oxide (FeO) particles, approximately 10 nm in size, to precipitate surrounded by the organic compound, and a second suspension consisting of a collection of these ferrous oxide (FeO) particles surrounded by the organic compound is created in the container, the first heat treatment apparatus is heated to a temperature at which the ferrous oxide (FeO) particles oxidize into fine ferric oxide (Fe2O3) particles, and the warm The mixture is held for a predetermined time, thereby oxidizing all of the ferrous oxide (FeO) particles to maghemite (γ-Fe2O3) particles, and a third suspension is created in the container in which maghemite (γ-Fe2O3) particles, approximately 13 nm in size, are dispersed in the organic compound. After this, the container is removed from the first heat treatment apparatus, and a fourth step is taken in which a large amount of an organic solvent possessing both the first property of dissolving or mixing with the organic compound and the second property of having a viscosity of 0.3-0.6 mPa·s at 20°C is added to the third suspension to create a fourth suspension with a viscosity of 1-4 mPa·s at 25°C. A fifth step is to continuously pull out the conductor of the electric wire from a first bobbin on which the conductor of the electric wire is wound at a pulling speed of 0.5 cm per second, continuously immerse the pulled-out conductor of the electric wire in a fourth suspension in the container, continuously move it through the fourth suspension at a movement speed of 0.5 cm per second, and then continuously pull it out of the fourth suspension at a pulling speed of 0.5 cm per second. A second heat treatment apparatus is prepared in advance, which is heated to the boiling point of the organic solvent and is equipped with a suction device for sucking up gas. The conductor of the electric wire, which has been lifted out of the fourth suspension, is moved continuously through the second heat treatment apparatus at a speed of 0.5 cm per second, vaporizing the organic solvent, and the vaporized organic solvent is sucked up by the suction device. This causes the conductor of the electric wire, covered with the third suspension, to move continuously outside the third heat treatment apparatus. A third heat treatment apparatus is prepared in advance, heated to the boiling point of the organic compound. The conductor of the electric wire that has come out of the second heat treatment is moved continuously through the third heat treatment apparatus at a speed of 0.5 cm per second. As a result, an aggregate of fine particles of maghemite (γ-Fe2O3) is deposited on the surface of the conductor of the electric wire, and these fine particles of maghemite (γ-Fe2O3) are magnetically attracted to each other. Furthermore, the magnetically attracted fine particles of maghemite (γ-Fe2O3) gathering A seventh step is in which the conductor of the electric wire, which is covered with an aggregate of fine particles of the stacked maghemite (γ-Fe2O3), moves continuously outside the third heat treatment apparatus, The process consists of: first, preparing a magnetic field generator that generates a magnetic field that saturates the magnetization of the maghemite (γ-Fe2O3) fine particles; second, continuously moving the conductor of the electric wire, which has been moved outside the third heat treatment apparatus in the seventh step, through the magnetic field generator at a speed of 0.5 cm per second to saturate the magnetization of the maghemite fine particles; and third, continuously winding the conductor of the electric wire, which has been moved outside the magnetic field generator, onto a second bobbin at a peripheral speed of 0.5 cm per second in the eighth step. A method for performing all eight of the aforementioned processes in sequence is: Tired With the combined magnetization each other Magnetic adsorption A collection of mites in the magnesium Lamination The said A collection of magnesiumite microparticles Regardless of the shape of the conductor of the electric wire, surface of the conductor Cover the whole thing, Insulation Let A method for continuously manufacturing conductors for electric wires.

[0015] The present invention provides an aggregate of magnetically adsorbed Maghemite microparticles on the surface of the conductor of an electric wire. wholeThe method for continuous insulation is to perform all eight steps described in paragraph 14 in sequence. Each processing method and the effects it produces will be explained below. In the first step, a crystalline aggregate of an organic iron compound that precipitates ferrous oxide (FeO) by thermal decomposition is precipitated. To achieve this, the organic iron compound is dispersed in methanol in a molecular state, and then the methanol is vaporized to precipitate the crystalline aggregate of the organic iron compound. In other words, when an organic iron compound that precipitates ferrous oxide by thermal decomposition is mixed with methanol, the most common organic solvent, and stirred, the organic iron compound disperses in methanol in a molecular state. In contrast, when an organic iron compound dissolves in methanol, the iron that constitutes the organic iron compound dissolves into the methanol as iron ions, and the dissolved organic iron compound cannot return to its original state. Therefore, even if methanol is vaporized from the methanol solution of the organic iron compound, the crystals of the organic iron compound that were dissolved before dissolution will not precipitate. Accordingly, an organic iron compound that does not dissolve in methanol and disperses in a molecular state is used. As a result, when methanol is vaporized from the methanol dispersion of the organic iron compound, the organic iron compound precipitates as crystals of the organic iron compound with a size of approximately 100 nm. These crystals are formed when organoiron compounds dispersed in methanol in a molecular state precipitate as crystals. Therefore, they are aggregates of crystals formed by single molecules of the organoiron compounds. Consequently, applying stress to the crystals easily pulverizes them into fine crystals. However, the finer the crystals, the more difficult it becomes to apply stress, limiting the degree of crystal refinement. The vaporized methanol is recovered using a recovery machine and reused. Furthermore, the organic solvent used to disperse the organoiron compounds in a molecular state is limited to lower alcohols consisting of straight-chain saturated hydrocarbons (called alkanes) with five or fewer carbon atoms. In the second step, the crystals of the organoiron compound are uniformly pulverized to about 1 / 5 of their original size. In other words, the thermal decomposition of the organoiron compound involves the decomposition of the organoiron compound into organic acids and ferrous oxide. After the organic acids vaporize, the ferrous oxide molecules gather to form fine particles of ferrous oxide. As a result, the size of the ferrous oxide particles becomes about half the size of the crystals of the organoiron compound. Therefore, the size of the crystals of the organoiron compound is uniformly refined, and the fine particles of ferrous oxide precipitated by thermal decomposition are also uniformly refined. On the other hand, maghemite particles are generated by oxidizing the ferrous oxide particles, so by uniformly refining the crystals of the organoiron compound, the size of the maghemite particles becomes uniform. Therefore, the entire collection of organic iron compound crystals inside the container is covered with a plate material, confining the collection of organic iron compound crystals within the container, and the collection of organic iron compound crystals is compressed through the plate material. At this time, crystals that are relatively larger are more easily crushed. Therefore, relatively larger crystals are crushed preferentially, and the crushing of crystals progresses as long as the compressive load is applied. Meanwhile, in the collection of crystals inside the container, new voids are formed by the crushing of the crystals, and while the compressive load is applied, the crystals move to fill the voids. After this, the applied compressive load is stopped, and impact acceleration is repeatedly applied to the container in three directions: front and back, left and right, and up and down. At this time, the crystals do not scatter because they are confined inside the container by the plate material, and the crystals move to fill the voids, and the collection of crushed crystals rearranges within the container. Furthermore, after stopping the applied impact acceleration, a compressive load is applied again to the collection of crushed crystals through the plate material. At this time, the crushing of the previously crushed crystals progresses towards the collection of crystals that have become even finer. Next, the container is repeatedly subjected to impact acceleration in three directions to further rearrange the finer crystal aggregate. This pair of processes, consisting of applying compressive load and applying impact acceleration in three directions, is repeated. However, as the crystals become finer, it becomes more difficult to apply compressive stress to them even when applying compressive load, and there is a limit to crystal refinement. When the limit of crystal refinement is reached, applying compressive load to the plate material does not further crush the crystals, and no movement is observed in the plate material under compressive load. At this point, it is determined that the crushing of the organoiron compound crystals is complete, and the pair of processes is stopped. As a result, the size of the crystals is uniformly refined to a size of approximately 20 nm, which is close to 1 / 5 of the size at the time of precipitation. The size of ferrous oxide FeO precipitated by the thermal decomposition of the organoiron compound is approximately 1 / 2 the size of the refined organoiron compound crystals. The compressive load applied to the plate material is equivalent to 10-50 kgf, depending on the size of the container. Furthermore, the impact acceleration applied to the container will be 0.2-0.5G, depending on the size of the container. In the third step, a first suspension is prepared in which fine crystals of the organoiron compound are dispersed in the organic compound. To achieve this, an organic compound possessing the following properties is weighed in excess of the aggregate of organoiron compound fine crystals in the container: firstly, the organoiron compound fine crystals do not dissolve or disperse; secondly, the organic compound has a boiling point higher than the temperature at which ferrous oxide (FeO) is oxidized to ferric oxide (Fe2O3); thirdly, the organic compound does not chemically react with both ferrous oxide (FeO) and ferric oxide (Fe2O3) fine particles; and fourthly, the organic compound has a viscosity of 11-18 mPa·s at 25°C. The weighed organic compound is then mixed into the container filled with the aggregate of organoiron compound fine crystals, and further stirred with a stirrer to create a first suspension in which the aggregate of organoiron compound fine crystals is dispersed in the organic compound. In the fourth step, a second suspension is prepared in a container in which fine particles of ferrous oxide (FeO) are dispersed in an organic compound, and then a third suspension is prepared in which fine particles of maghemite (γ-Fe2O3) are dispersed in an organic compound. Note that, as mentioned above, the organic compound does not chemically react with the fine particles of ferrous oxide (FeO) and ferric oxide (Fe2O3). For this reason, a first heat treatment apparatus is prepared in advance to thermally decompose the fine crystals of the organic iron compound into fine particles of ferrous oxide (FeO). The container containing the first suspension is moved into the first heat treatment apparatus, and the temperature of the first heat treatment apparatus is raised to a temperature at which the fine crystals of the organic iron compound thermally decompose into fine particles of ferrous oxide (FeO), and then the temperature is maintained at the thermal decomposition temperature for a predetermined time. As a result, the microcrystalline organic iron compound decomposes into organic acid and ferrous oxide (FeO). After the organic acid vaporizes, the ferrous oxide (FeO) molecules gather together, and fine particles of ferrous oxide (FeO), approximately 10 nm in size (half the size of the microcrystalline organic iron compound), precipitate surrounded by the organic compound. This creates a second suspension in the container, consisting of aggregates of ferrous oxide (FeO) particles surrounded by the organic compound. Next, a fourth suspension is prepared in which maghemite (γ-Fe2O3) fine particles are dispersed in a liquid having a viscosity of 1-4 mPa·seconds at 25°C. For this purpose, the first heat treatment apparatus is heated to a temperature at which ferrous oxide (FeO) fine particles oxidize to ferric oxide (Fe2O3) fine particles, and further, warm Maintain for a predetermined time at each degree. That is, when the temperature is raised to the temperature at which ferrous oxide (FeO) is oxidized to ferric oxide (Fe₂O₃), the oxidation reaction in which divalent iron ions in ferrous oxide (FeO) become trivalent iron ions proceeds. At the initial stage of this oxidation reaction, a part of the divalent iron ions in ferrous oxide (FeO) becomes trivalent iron ions and turns into ferric oxide (Fe₂O₃), and it is oxidized to magnetite having a composition formula of FeO·Fe₂O₃. Magnetite is a conductive ferromagnetic substance. Furthermore, when the standing time is extended, the oxidation reaction in which divalent iron ions become trivalent iron ions proceeds, and the generated magnetite fine particles increase. Furthermore, when the standing time is extended, all of the divalent iron ions constituting magnetite (FeO·Fe₂O₃) become trivalent iron ions, turn into ferric oxide (Fe₂O₃), and the oxidation reaction is completed. This ferric oxide (Fe₂O₃) has the same cubic crystal system as magnetite (FeO·Fe₂O₃) and is maghemite (γ-Fe₂O₃) which is the gamma phase of ferric oxide (Fe₂O₃). This maghemite is an insulating ferromagnetic substance. On the other hand, the crystal structure of hematite (α-Fe₂O₃) which is the alpha phase of ferric oxide (Fe₂O₃) is a trigonal crystal system and has a different crystal structure from magnetite. Therefore, hematite (α-Fe₂O₃) which is the alpha phase of ferric oxide (Fe₂O₃) is not generated by the oxidation of ferrous oxide (FeO). Note that ferrous oxide has a molar mass of 71.84 g / mol and a density of 5.7 g / cm 3 It is. In contrast, maghemite has a molar mass of 159.7 g / mol and a density of 5.24 g / cm 3 It is. Therefore, the volume per mole is 2.4 times larger for maghemite than for ferrous oxide. For this reason, the size of the maghemite fine particles generated by the oxidation of the ferrous oxide fine particles becomes around 13 nm, which is 1.3 times the size of the ferrous oxide fine particles. As a result, fine particles of maghemite (γ-Fe₂O₃) having a size of around 13 nm are dispersed in an organic compound to form a third suspension in the container. Furthermore, as mentioned above, the boiling point of organic compounds is higher than the temperature at which ferrous oxide (FeO) is oxidized to ferric oxide (Fe2O3). Also, as mentioned above, organic compounds do not chemically react with fine particles of ferric oxide (Fe2O3). Next, a large amount of an organic solvent possessing both the first property of dissolving or miscible with the organic compound and the second property of having a viscosity of 0.3-0.6 mPa·s at 20°C is added to the third suspension to create a fourth suspension with a viscosity of 1-4 mPa·s at 25°C. In other words, when a large amount of organic solvent is added to the third suspension, a large amount of the organic solvent with a viscosity of 0.3-0.6 mPa·s dissolves or mixes with the organic compound with a viscosity of 11-18 mPa·s, thus creating a fourth suspension with a viscosity of 1-4 mPa·s, and in the fifth step, the surface of the conductor of the electric wire... whole A fourth suspension is adsorbed onto it. For example, if an organic solvent with a viscosity of 0.3 mPa·s is added to an organic compound with a viscosity of 11 mPa·s, in order to make the viscosity of the liquid in which the organic compound is dissolved or mixed with the organic solvent 1 mPa·s, it is necessary to add organic solvent that accounts for 94% of the volume of the liquid. In the fifth step, the surface of the wire conductor whole The fourth suspension is then continuously adsorbed onto it. To this end, a first bobbin on which the electric wire conductor is wound is prepared, and the electric wire conductor is continuously drawn out from the bobbin at a pulling speed of 0.5 cm per second, while the drawn-out electric wire conductor is continuously immersed in the fourth suspension in the container, and then continuously moved through the fourth suspension at a moving speed of 0.5 cm per second, and then continuously pulled out from the fourth suspension at a pulling speed of 0.5 cm per second. As a result, the surface of the electric wire conductor is adsorbed to a thickness corresponding to the viscosity of the fourth suspension. whole The fourth suspension is adsorbed onto the wire. The wire conductor continues to move through the fourth suspension at a slow speed of 0.5 cm per second. Therefore, once the fourth suspension is adsorbed, it is less likely to fall off, and because it spends a long time moving through the fourth suspension, the thickness of the fourth suspension adsorbed onto the wire conductor is uniform. In the sixth step, the surface of the wire conductor wholeThe third suspension is continuously covered with it. For this purpose, a second heat treatment apparatus is prepared in advance, which is heated to the boiling point of the organic solvent and is equipped with a suction device for sucking up the gas. The conductor of the electric wire, which has been pulled up from the fourth suspension, is continuously moved through the second heat treatment apparatus at a speed of 0.5 cm per second to vaporize the organic solvent, and the vaporized organic solvent is sucked up by the suction device. In other words, the flash point of the low viscosity organic solvent is -18 From ℃ The temperature is low at 11°C, and to prevent the vaporized organic solvent from igniting due to the heat of the fourth heat treatment device, the vaporized organic solvent is sucked up with a vacuum. Furthermore, the ignition point of the organic solvent is high, at 464-505°C, which is higher than the boiling point of the organic compound, so it will not ignite due to the heat of the fourth heat treatment device. As a result, the conductor of the wire covered with the third suspension moves continuously outside the second heat treatment device. The organic solvent sucked up with the vacuum is also reused. In the seventh step, the surface of the wire conductor is formed by an aggregate of magnetically adsorbed maghemite (γ-Fe2O3) fine particles. whole The wire is continuously covered with the fourth suspension. For this purpose, a third heat treatment device heated to the boiling point of the organic compound is prepared in advance. The conductor of the wire coming out of the second heat treatment is continuously moved through the third heat treatment device at a speed of 0.5 cm per second. As a result, first, the organic compound vaporizes from the fourth suspension covering the surface of the wire conductor, and an aggregate of maghemite (γ-Fe2O3) particles precipitates on the surface of the wire conductor, then the maghemite (γ-Fe2O3) particles magnetically adhere to each other, and furthermore, the magnetically adhered maghemite (γ-Fe2O3) particles gathering These are layered, and the aggregate of layered magnesium microparticles forms the surface of the conductor of the wire. whole The layer is covered. The number of layers of stacked maghemite (γ-Fe2O3) microparticles varies from 5 to 20 layers, depending on the viscosity of the fourth suspension. The vaporized organic compounds are recovered using a recovery machine and reused. In the eighth step, the surface of the conductor of the electric wire wholeThe magnetization of the mag-Fe2O3 (γ-Fe2O3) microparticles covering the wire is saturated, and then the wire conductor is continuously wound onto a second bobbin. For this purpose, a magnetic field generator is prepared in advance to generate a magnetic field that saturates the magnetization of the mag-Fe2O3 (γ-Fe2O3) microparticles. Next, the wire conductor that was continuously moved outside the third heat treatment apparatus in the seventh step is continuously moved inside the magnetic field generator to saturate the magnetization of the mag-Fe2O3 (γ-Fe2O3) microparticles. Furthermore, the wire conductor that was moved outside the magnetic field generator is continuously wound onto a second bobbin at a peripheral speed of 0.5 cm per second. Furthermore, in the fifth step, the speed at which the wire conductor is drawn out of the first bobbin, the speed at which the drawn wire conductor moves through the fourth suspension, and the speed at which the wire conductor is pulled out of the fourth suspension; in the sixth step, the speed at which the wire conductor pulled out of the fourth suspension moves through the second heat treatment device that vaporizes the organic solvent; in the seventh step, the speed at which the wire conductor coming out of the second heat treatment device moves continuously through the third heat treatment device that vaporizes the organic compound; and in the eighth step, the speed at which the wire conductor moves through the magnetic field generator and the speed at which the wire conductor that has moved outside the magnetic field generator is continuously wound onto the second bobbin. Since the speed of the wire conductor in these eight processes is the same, the eight processes in the four steps become a continuous process. As a result, by performing all eight processes in succession, the magnetization of the Magmite microparticles becomes saturated. each other Magnetic adsorption The mite particles then gathered in the magnet. Lamination So The magnesium is composed of a collection of fine particles. Regardless of the shape of the conductor of the electric wire, surface of the conductor Cover the whole thing, Insulation Let The conductors of the electric wire are manufactured in a continuous process. Furthermore, all processes in the eight steps are extremely simple and do not require any special equipment. In addition, since the raw materials used are general-purpose industrial chemicals, the conductors of the electric wire can be insulated with aggregates of magnesiumite particles at a low cost. By the way, the five problems that the present invention needed to solve were those described in paragraph 13. The first challenge was to develop a method for dispersing magnesiumite microparticles in an organic compound and creating a suspension with adjustable viscosity. This challenge was solved in the sixth step. Specifically, in the sixth step, the container was moved into the second heat treatment apparatus, and the second heat treatment apparatus was heated to a temperature at which ferrous oxide (FeO) microparticles oxidize to ferric oxide (Fe2O3) microparticles, and further, Applicable The mixture is held at a predetermined temperature for a set time. This oxidizes all the ferrous oxide (FeO) particles into maghemite (γ-Fe2O3) particles, creating a third suspension in the container where maghemite (γ-Fe2O3) particles, approximately 13 nm in size, are surrounded by an organic compound. Therefore, in the fourth step, a second suspension is created in the container, consisting of a collection of ferrous oxide (FeO) particles, approximately 10 nm in size, surrounded by an organic compound. Furthermore, to achieve a viscosity of 1-4 mPa·s in the third suspension, an organic solvent with a remarkably low viscosity of 0.3-0.6 mPa·s at 20°C is added to the third suspension, creating a fourth suspension. Therefore, the viscosity of the fourth suspension varies depending on the amount of organic solvent added to the third suspension. Consequently, the viscosity of the suspension is adjusted to 1-2 mPa·s depending on the thickness of the single or stranded wire, and the conductor thickness and width of the rectangular conductor. Furthermore, for conductors processed into wound coils, the viscosity of the suspension is set to 4 mPa·s, maximizing its viscosity. Since the viscosity of the fourth suspension is low (1-4 mPa·s), it can be adsorbed onto all types of wires, regardless of whether they are solid, stranded, or rectangular, and regardless of the conductor thickness or width of the rectangular conductor. The second challenge is the surface of the conductor in the electric wire. whole The objective is to provide a method for continuously adsorbing the fourth suspension onto the surface. This problem was solved in the fifth step. Specifically, in the fifth step, the conductor of the electric wire was continuously drawn out from the first bobbin on which the electric wire conductor was wound, and the drawn-out conductor was continuously immersed in the fourth suspension in a container, then continuously moved through the fourth suspension, and then continuously pulled out from the fourth suspension. This allowed the surface of the electric wire conductor to be continuously adsorbed. whole The suspension is adsorbed onto it. Furthermore, in the fifth step, the four speeds—the speed at which the wire conductor is drawn from the first bobbin, the speed at which the drawn wire conductor moves through the fourth suspension, the speed at which the wire conductor is pulled up from the fourth suspension, and in the sixth step, the speed at which the wire conductor pulled up from the fourth suspension moves through the second heat treatment apparatus that vaporizes the organic solvent—are the same, resulting in four processes being performed consecutively. This allows for continuous surface treatment of the wire conductor. whole The fourth suspension is adsorbed onto it. The third challenge was to concretize a method for continuously covering the surface of the wire conductor with an aggregate of magnetically adsorbed Maghemite microparticles. This challenge was solved in the seventh step. Specifically, in the seventh step, the wire conductor, which had been lifted out of the fourth suspension, was continuously moved through the third heat treatment apparatus, which was heated to the boiling point of the organic compound. This allowed the third suspension to adsorb onto the surface of the wire conductor. whole Organic compounds vaporize from the surface of the conductor of the electric wire. whole As aggregates of maghemite (γ-Fe2O3) particles precipitate, these maghemite (γ-Fe2O3) particles magnetically attract each other, and the conductor of the wire, covered with these aggregates of magnetically attracted maghemite (γ-Fe2O3) particles, moves continuously outside the third heat treatment apparatus. As a result, the surface of the conductor of the wire is covered with aggregates of magnetically attracted maghemite particles. whole The wire conductor, covered with an aggregate of maghemite (γ-Fe2O3) fine particles, is continuously moved outside the third heat treatment device. Therefore, the speed at which the wire conductor moves inside the third heat treatment device in the seventh step, the speed at which the wire conductor moves inside the magnetic field generator in the eighth step, and the speed at which the wire conductor that has moved outside the magnetic field generator is continuously wound onto the second bobbin are all the same. whole It is covered in a continuous pattern. The fourth challenge is the surface of the conductor of the electric wire. wholeThe objective was to provide a method for continuously saturating the magnetization of maghemite nanoparticles covering the material. This problem was solved in the eighth step. Specifically, in the eighth step, the conductor of the electric wire that had moved outside the third heat treatment apparatus in the seventh step was continuously moved through a magnetic field generator that generates a magnetic field that saturates the magnetization of the maghemite (γ-Fe2O3) nanoparticles, thereby saturating the magnetization of the maghemite nanoparticles. In order to move the electric wire conductor continuously within the magnetic field generator, the speed at which the electric wire conductor moved within the magnetic field generator and the speed at which the electric wire conductor that had moved outside the magnetic field generator was continuously wound onto the second bobbin were set to be the same. The fifth challenge is to create an aggregate of magnetically adsorbed Maghemite particles on the surface of the conductor of an electric wire. whole The objective is to provide a method for continuously extracting the conductor of an insulated electric wire. This problem was solved in the eighth step. Specifically, in the eighth step, the conductor of the electric wire that has moved outside the magnetic field generator is continuously wound onto a second bobbin, making it possible to continuously extract the conductor of the electric wire insulated by an aggregate of Maghemite microparticles from the bobbin. When winding the conductor of the electric wire onto the second bobbin, the conductors come into contact with each other. The Maghemite microparticles covering the surface of the conductors are strongly magnetically attracted to each other by saturated magnetization, as they have almost no mass. Therefore, even when the conductors come into contact with each other, the Maghemite microparticles do not detach from the surface of the conductors. Similarly, when pulling the conductors out of the second bobbin, the conductors come into contact with each other, but the Maghemite microparticles do not detach from the surface of the conductors. As explained above, all five problems described in paragraph 13 have been solved. Therefore, the present invention, consisting of the eight steps described in paragraph 14, allows the Maghemite fine particles to magnetically attract each other with saturated magnetization, and 、 The stacked magnesium microparticles form an aggregate on the surface of the conductor of the electric wire. whole of Cover, Insulation Let Ta electric This is a method for continuously manufacturing wire conductors. Furthermore, as described in paragraph 12, it is an aggregate of stacked magnesiumite microparticles, and the surface of the conductor of the electric wire. wholeThe insulation resistance of the insulating layer is mainly determined by the resistance value formed by the magnesium microparticles connected in series along the length of the conductor, and the insulation resistance of the insulating layer, which is 1m long, is 5.9 × 10⁻⁶. 20 It reaches Ω. Therefore, it forms an insulation resistance that is extremely large compared to the insulation resistance of conventional insulating layers. On the other hand, the thickness of conventional insulating layers is 5 μm or more. In contrast, for conductors other than those processed into wound coils, the thickness of the insulating layer is made up of 5-10 Maghemite microparticles stacked on top of each other, and since the size of the microparticles is 13 nm, the thickness of the insulating layer is 65-130 nm. Furthermore, for the insulating layer of conductors processed into wound coils, 20 Maghemite microparticles are stacked on top of each other, resulting in an insulating layer thickness of 260 nm. In this way, since the insulating layer is formed from an aggregate of microparticles, the thickness of the insulating layer is less than 1 / 20 of the thickness of conventional insulating layers. On the other hand, the density of Maghemite is 5.24 g / cm³. 3 The density of the synthetic resin that forms the conventional insulating layer is 0.9-1.4 g / cm³. 3 In contrast, although the density of maghemite is nearly 4-6 times higher, the thickness of the insulating layer of maghemite microparticles is thin, so insulated wires made up of aggregates of maghemite microparticles are also lightweight.

[0016] The organoiron compound described in paragraph 14 is iron naphthenate, and using iron naphthenate as the organoiron compound that precipitates ferrous oxide (FeO) by thermal decomposition as described in paragraph 14, the method of continuously performing all eight steps described in paragraph 14 is such that the magnetized Maghemite fine particles are saturated with magnetization. each other Magnetic adsorption The mite particles then gathered in the magnet. Lamination So The magnesium is composed of a collection of fine particles. Regardless of the shape of the conductor of the electric wire, surface of the conductor Cover the whole thing, Insulation Let A method for continuously manufacturing conductors for electric wires.

[0017] In other words, the oxygen ion (O) that makes up the carboxyl group -In carboxylic acid metal compounds, the oxygen ion acts as a ligand, approaching the metal ion and forming a coordinate bond. This leads to the deposition of metal oxides upon thermal decomposition. Specifically, in carboxylic acid metal compounds where the oxygen ion constituting the carboxyl group acts as a ligand and approaches the metal ion to form a coordinate bond, the oxygen ion approaches the largest ion, the metal ion, to form the coordinate bond, thus shortening the distance between them. As a result, the oxygen ion covalently bonded to the metal ion is the one that is at the longest distance from the ion covalently bonded on the opposite side of the metal ion. When the boiling point of the carboxylic acid constituting the carboxylic acid metal compound is exceeded, the bond between the oxygen ion constituting the carboxyl group and the ion covalently bonded on the opposite side of the metal ion is broken first, and the compound decomposes into a metal oxide (metal ion and oxygen ion) and a carboxylic acid. Further heating absorbs the heat of vaporization and vaporizes, and the metal oxide precipitates after the vaporization of the carboxylic acid is complete. On the other hand, iron carboxylate compounds that precipitate ferrous oxide (FeO) upon thermal decomposition contain oxygen ions (O) that make up the carboxyl group. - ) acts as a ligand, and the divalent iron ion (Fe 2+ ) approaches the iron ion and forms a coordinate bond. Examples of iron carboxylate compounds that do this include iron acetate, iron caprylate, iron benzoate, and iron naphthenate, in order of molecular weight. However, in the case of iron acetate, iron caprylate, and iron benzoate, the oxygen ion approaches the iron ion and forms a coordinate bond, forming a binuclear complex salt, so the iron oxide precipitated by thermal decomposition is unstable, and multiple types of iron oxide precipitate. In contrast, iron naphthenate has a large molecular weight, so the thermal decomposition temperature is high, but it precipitates ferrous oxide during thermal decomposition, and the precipitated ferrous oxide is stable. For this reason, iron naphthenate is suitable as an iron carboxylate compound that precipitates ferrous oxide. Naphthenic acid is a saturated fatty acid C with a 5-membered ring. n H 2n-1 A mixture of saturated fatty acids with 5-membered rings, having a COOH molecular weight of 180-350 and a boiling point of 140-350°C, with the main component being nonanoic acid C9H, which has a boiling point of 255°C and a molecular weight of 158. 17It consists of COOH. Therefore, at 140°C in an atmospheric environment, thermal decomposition of iron naphthenate begins, breaking it down into ferrous oxide and saturated fatty acids with five-membered rings. At 350°C in an atmospheric environment, thermal decomposition is completed, breaking it down into ferrous oxide and saturated fatty acids with all the five-membered rings that make up naphthenic acid. By leaving it at 350°C for a certain period of time, the vaporization of saturated fatty acids with all the five-membered rings that make up naphthenic acid is completed, and aggregates of ferrous oxide precipitate. Furthermore, the aforementioned iron carboxylate compounds are all inexpensive industrial chemicals that can be easily synthesized. Specifically, reacting a common carboxylic acid with a strong alkali produces an alkali metal carboxylic acid compound. Subsequently, reacting this alkali metal carboxylic acid compound with an inorganic iron compound synthesizes an iron carboxylate compound. Therefore, iron naphthenate is an inexpensive industrial chemical. Therefore, if iron naphthenate is used as the organic iron compound that precipitates ferrous oxide (FeO) by the thermal decomposition described in paragraph 14, and all eight steps of the treatment described in paragraph 14 are carried out in sequence, the surface of the conductor will be insulated by an aggregate of maghemite particles. On the other hand, oxidizing ferrous oxide to magnetite requires leaving it at 380°C in an atmospheric environment for a certain period of time. In other words, the oxidation reaction of ferrous oxide (FeO) is an oxidation reaction in which the divalent iron ions of ferrous oxide (FeO) become trivalent iron ions at 380°C. In the initial stages of this oxidation reaction, some of the divalent iron ions of ferrous oxide (FeO) become trivalent iron ions, forming ferric oxide (Fe2O3), which is then oxidized to magnetite with the chemical formula FeO·Fe2O3. Magnetite (FeO·Fe2O3) is a conductive ferromagnetic material, and magnetite particles are magnetically attracted to each other. Furthermore, if the time at 380°C is extended, the oxidation reaction in which divalent iron ions become trivalent iron ions progresses, and all of the ferrous oxide (FeO) is oxidized to magnetite (FeO·Fe2O3). Furthermore, if left at 380°C for an extended period, all of the divalent iron ions constituting magnetite (FeO·Fe2O3) become trivalent iron ions, forming ferric oxide (Fe2O3), and the oxidation reaction is completed. This ferric oxide (Fe2O3) is maghemite (γ-Fe2O3), the gamma phase of ferric oxide (Fe2O3), which has the same cubic crystal system as magnetite (FeO·Fe2O3). As explained above, iron naphthenate is suitable as a raw material for maghemite.

[0018] The organic compound described in paragraph 14 is 2-ethylhexyl palmitate. Ru An organic compound belonging to any one of the carboxylic acid esters consisting of cetyl 2-ethylhexanoate or bis(2-ethylhexyl) sebacate, either A method is used in which one type of organic compound is used as an organic compound possessing the four properties described in paragraph 14, and all eight steps described in paragraph 14 are carried out in succession, where the magnetization of the Maghemite fine particles is saturated. each other Magnetic adsorption The mite particles then gathered in the magnet. Lamination So The magnesium is composed of a collection of fine particles. Regardless of the shape of the conductor of the electric wire, surface of the conductor Cover the whole thing, Insulation Let A method for continuously manufacturing conductors for electric wires.

[0019] The following three types of organic compounds, belonging to the carboxylic acid ester group, possess the four properties described in paragraph 14. These carboxylic acid esters are common industrial chemicals used as raw materials for cosmetics, medicated soaps, shampoos and conditioners, lubricants and cutting oils, and as topical additives for pharmaceuticals. When an organic compound belonging to the carboxylic acid ester group is mixed with an aggregate of fine iron naphthenate crystals and then stirred with a stirrer, a first suspension is created in which the aggregate of fine iron naphthenate crystals is dispersed in the organic compound, because the organic compound does not dissolve or disperse the iron naphthenate crystals. Note that the organic solvent in which iron naphthenate disperses in a molecular state is limited to lower alcohols consisting of straight-chain saturated hydrocarbons (called alkanes) with 5 or fewer carbon atoms. On the other hand, when processing a conductor with an insulating layer formed from stacked maghemite microparticles into winding coils of various shapes, the greatest stress acts as tensile stress on the maghemite microparticle clusters on the outside of the bend, tearing apart the magnetic adsorption of the maghemite microparticles forming the outer surface layer of the bend, and pulling the maghemite microparticles apart. For this reason, the insulating layer of the conductor processed into a winding coil is configured with a maximum thickness of 20 stacked maghemite microparticles, so that even if the magnetic adsorption of the surface maghemite microparticles is torn apart, the maghemite microparticles inside the surface layer will magnetically adhere to each other, ensuring the insulation of the conductor. The viscosity of the fourth suspension, which stacks 20 maghemite microparticles, is low at 4 mPa·s. In contrast, the three organic compounds belonging to carboxylic acid esters have relatively high viscosities of 11-18 mPa·s at 25°C. Therefore, a large amount of an organic solvent with a remarkably low viscosity of 0.3-0.6 mPa·s at 20°C was added to the third suspension, diluting the organic compound with a large amount of the organic solvent and reducing the viscosity of the fourth suspension to 1-4 mPa·s. For example, if an organic solvent with a viscosity of 0.3 mPa·s is added to an organic compound with a viscosity of 11 mPa·s, it is necessary to add an organic solvent that accounts for 94% of the volume of the solution in order to reduce the viscosity of the solution to 1 mPa·s. 2-ethylhexyl palmitate Ru(CH3)2CH(CH2) 14 COOCH(C2H5)(CH2)3CH3 is an organic compound belonging to the saturated fatty acid ester group, with a viscosity of 11 mPa·sec at 25°C and a boiling point of 407°C. Cetyl 2-ethylhexanoate CH3(CH2)3CHCH2CH3COOCH2(CH2) 14 CH3 is an organic compound belonging to the branched fatty acid ester group, with a viscosity of 14 mPa·sec at 25°C and a boiling point of 407°C. Bis(2-ethylhexyl)(CH2)8[COOCH2CH(C2H5)(CH2)3CH3]2 sebacate is an organic compound belonging to the linear dicarboxylic acid ester class, with a viscosity of 18 mPa·sec at 25°C and a boiling point of 436°C. These three organic compounds belonging to the carboxylic acid esters possess the following properties: firstly, that iron naphthenate crystals do not dissolve or disperse; secondly, that their boiling point is higher than 380°C, the temperature at which ferrous oxide (FeO) is oxidized to ferric oxide (Fe2O3); thirdly, that they do not chemically react with fine particles of either ferrous oxide (FeO) or ferric oxide (Fe2O3); and fourthly, that their viscosity at 25°C is 11-18 mPa·s.

[0020] The organic solvent described in paragraph 14 is one of the following organic solvents: acetone, methyl ethyl ketone, toluene, or methanol. either A method using one type of organic solvent as an organic solvent possessing both of the properties described in paragraph 14, and performing all eight steps described in paragraph 14 in succession, is achieved when the magnetization of the Maghemite fine particles is saturated. each other Magnetic adsorption The mite particles then gathered in the magnet. Lamination So The magnesium is composed of a collection of fine particles. Regardless of the type of conductor in the electric wire, surface of the conductor whole of Cover, Insulation Let A method for continuously manufacturing conductors for electric wires.

[0021] The following four types of organic solvents possess both the first property of dissolving or miscible with the organic compounds described in paragraph 14, and the second property of having a viscosity of 0.3-0.6 mPa·s at 20°C. All of these organic solvents are commonly used. In other words, in the fourth step described in paragraph 14, a large amount of organic solvent is added to the third suspension in which an aggregate of magnesium fine particles is dispersed in an organic compound, and the large amount of organic solvent is dissolved or mixed with the organic compound, and the viscosity of the third suspension, which is 11-18 mPa·s, is changed to a fourth suspension with a viscosity of 1-4 mPa·s, and in the fifth step, the surface of the conductor of the electric wire whole The fourth suspension is adsorbed onto it. As a result, the viscosity of the organic solvent is remarkably low, at 0.3-0.6 mPa·s at 20°C. For example, if an organic solvent with a viscosity of 0.3 mPa·s is added to an organic compound with a viscosity of 11 mPa·s, in order to make the viscosity of the liquid in which the organic compound is dissolved or mixed with the organic solvent 1 mPa·s, it is necessary to add an amount of organic solvent that accounts for 94% of the volume of the solution. Furthermore, in the fifth step described in paragraph 14, the surface of the conductor of the electric wire whole The fourth suspension is adsorbed onto it, and in the sixth step, the organic solvent is vaporized and the surface of the conductor of the electric wire is exposed. whole A third suspension is adsorbed onto it, and further, in the seventh step, the surface of the conductor of the electric wire whole The organic compound is vaporized from the third suspension adsorbed on the surface of the electric wire conductor. whole This causes a precipitate of magnesium mites. On the other hand, the boiling point of organic solvents is 50-110°C, but the flash point is -18°C. From ℃ The boiling point is low at 11°C. In contrast, the boiling point of organic compounds is high at 407-436°C. Therefore, in the seventh step, to prevent the vaporized organic solvent from igniting, a gas suction device was installed alongside the heat treatment apparatus used in the sixth step, and the gas suction device was kept running at all times. Acetone (CH3COCH3) is soluble in or miscible with the three organic compounds belonging to the carboxylic acid esters described in paragraphs 18-19. It has a viscosity of 0.32 mPa·s at 20°C, a boiling point of 56.5°C, a low flash point of -18°C, and an ignition point of 469°C, which is higher than the boiling points of the organic compounds. Methyl ethyl ketone CH3COC2H5 is soluble in or miscible with the three organic compounds belonging to the carboxylic acid esters described in paragraphs 18-19. It has a viscosity of 0.43 mPa·s at 20°C, a boiling point of 79.6°C, a low flash point of -9°C, and an ignition point of 505°C, which is higher than the boiling points of the organic compounds. Toluene (C6H5CH33) is soluble in or miscible with the three organic compounds belonging to the carboxylic acid esters described in paragraphs 18-19. It has a viscosity of 0.59 mPa·s at 20°C, a boiling point of 110.6°C, a low flash point of 4°C, and an ignition point of 480°C, which is higher than the boiling points of the organic compounds. Methanol (CH3OH) has a viscosity of 0.59 mPa·s at 20°C, a boiling point of 65°C, a low flash point of 11°C, and an ignition point of 464°C, which is higher than the boiling points of organic compounds. As explained above, these four types of organic solvents possess both the first property of being soluble or miscible with organic compounds, and the second property of having a viscosity of 0.3-0.6 mPa·s at 20°C. [Brief explanation of the drawing]

[0022] [Figure 1] This is a schematic diagram illustrating a cross-section of a bare copper single wire, where the surface is covered with an accumulation of layered maghemite microparticles. [Modes for carrying out the invention]

[0023] Example 1 This is an example of forming an insulating layer on the surface of a bare copper single wire using an aggregate of maghemite fine particles. As the organic iron compound, 5% iron naphthenate (a product of Toei Chemical Co., Ltd.) was used. Note that the 5% iron naphthenate powder, at a weight percentage of 5%, dispersed in a solvent with a boiling point of 40°C, has a density of 0.9 g / cm³. 3 It is a liquid composed of the following: The organic compound is 2-ethylhexyl palmitate, which has a viscosity of 11 mPa·s at 25°C and a boiling point of 407°C. Ru(A product of Tokyo Chemical Industry Co., Ltd.) was used. In addition, as an organic solvent, acetone (a product of Fujifilm Wako Pure Chemical Industries, Ltd.) with a viscosity of 0.32 mPa·s at 20°C, a boiling point of 56.5°C, and a flash point of -18°C was used. Furthermore, as a conductor, a product consisting of 2 kg of bare copper single wire with a wire diameter of 0.08 mm wound on a bobbin (a product of Haneda Electric Wire Co., Ltd.) was used. First, 2 kg of 5% iron naphthenate was placed in a 20 cm x 20 cm x 10 cm container, and the container was heated to 40°C to vaporize the iron naphthenate dispersion solvent. Then, 1 kg of methanol was added and stirred to disperse the iron naphthenate powder in the methanol in a molecular state. Furthermore, the container was heated to 65°C to vaporize the methanol and precipitate an aggregate of iron naphthenate crystals. After this, a 20 cm x 20 cm x 12 cm plate was placed on top of the aggregate of iron naphthenate crystals, and nine 5 kg weights were placed on the plate at equal intervals. After removing the weights, impact accelerations of 0.5 G were repeatedly applied to the sides and bottom of the container in three directions: front / back, left / right, and up / down. After repeating this process of applying compressive load and impact acceleration four times, the weights were placed back on the plate, but the plate did not move at all, so the process was stopped. After this, the board was removed from the container. Next, 2-ethylhexyl palmitate Ru Place 150g of the mixture into a container and stir with a stirrer to separate the fine crystals of iron naphthenate from 2-ethylhexyl palmitate. Ru A first suspension was prepared by dispersing the components. Furthermore, the container was moved into the first heat treatment apparatus, the heat treatment apparatus was heated to 350°C, the container was left at 350°C for 5 minutes, the heat treatment apparatus was then heated to 380°C, and the container was left at 380°C for 30 minutes before being removed from the first heat treatment apparatus. After this, 2 kg of acetone was added to the container and stirred to prepare the second suspension. Next, the bare copper wire wound on the first bobbin was continuously drawn out at a pulling speed of 0.5 cm per second, while the drawn-out bare copper wire was continuously immersed in the second suspension in the container, and then continuously moved through the second suspension at a movement speed of 0.5 cm per second. After this, it was continuously pulled out of the second suspension at a pulling speed of 0.5 cm per second. Furthermore, a second heat treatment apparatus, heated to 57°C, was prepared in advance, and the bare copper wire, which had been pulled from the second suspension, was continuously moved through the heat treatment apparatus at a speed of 0.5 cm per second. In addition, an attached suction machine was kept running to continuously aspirate the vaporized acetone. Next, a third heat treatment apparatus, preheated to 410°C, was prepared, and the bare copper single wire, which had been moved from the second heat treatment apparatus, was continuously moved through the third heat treatment apparatus at a speed of 0.5 cm per second. Next, a magnetic field generator was prepared in advance, which generated a 12-kilo-Oersted magnetic field along the length of a bare copper wire. The bare copper wire that had moved outside the third heat treatment apparatus was passed continuously through the magnetic field generator, and the bare copper wire that had moved outside the magnetic field generator was continuously wound onto a second bobbin at a peripheral speed of 0.5 cm per second to continuously prepare samples. First, a portion of the prepared sample was cut, and the surface and cross-section of the sample were observed using an electron microscope. The electron microscope used was an ultra-low acceleration voltage SEM from JFE Techno-Research Corporation. This device is capable of surface observation using ultra-low acceleration voltages starting from 100V, and also has the advantage of allowing direct observation of the sample surface without forming a conductive coating on the sample. Secondary electron beams between 900-1000V of the electron beam reflected from the SEM were extracted and image-processed to observe the sample surface. The sample surface was evenly covered with granular microparticles approximately 13 nm in size. Next, the energy and intensity of characteristic X-rays were image-processed to analyze the types of elements constituting the granular microparticles covering the surface and their distribution. Since both iron and oxygen atoms were uniformly present with no particular areas of uneven distribution, it was confirmed that the microparticles were made of iron oxide. Furthermore, EBSP analysis functionality was added to the SEM to analyze the crystal structure. From these results, it was confirmed that the granular microparticles covering the sample surface were maghemite, the γ phase of ferric oxide. EBSP analysis functionality refers to a function that, when an electron beam is irradiated onto a sample, forms a band-like pattern when backscattered electrons are diffracted by atomic planes in the sample. The symmetry of this band corresponds to the crystal system, and the spacing between the bands corresponds to the interatomic spacing. By analyzing this pattern, the crystal orientation and crystal system can be measured. Furthermore, the sample was cut and its cross-section was observed. Five granular microparticles, each approximately 13 nm in size, were layered on the outside of the bare copper single wire. This cluster of five layered granular microparticles covered the entire outside of the bare copper single wire. Figure 1 shows a schematic, magnified view of the sample's cross-section. 1 is the bare copper single wire, and 2 is the layered maghemite microparticles. From these results, it was confirmed that five Maghemite microparticles were layered, and the surface of the bare copper single wire was covered with this layered Maghemite aggregate. From these results, it was confirmed that when iron naphthenate is heat-treated in two separate stages for a certain period of time, Maghemite microparticles are magnetically adsorbed evenly onto the surface of the bare copper single wire. Next, the insulation resistance of the sample was measured. Using an insulation resistance meter from Kyoritsu Electrical Instruments, the electrical resistance between the bare copper single wire and the insulating layer was measured. The insulation resistance showed a value exceeding 1 MΩ. Therefore, it was found that the insulating layer possessed the insulation resistance required for an electric wire. Furthermore, the sample was wrapped around a 20mm diameter pipe five times in a row, varying the tension during wrapping. After removing the sample from the pipe, the surface of the pipe was observed using a scanning electron microscope (SEM), but no maghemite microparticles were found. Next, the sample was wrapped around the pipe five times in a row, varying the tension, so that it was triple-layered. After this, the surface of the sample was observed using an SEM, but it remained unchanged from the initial state. No abnormalities such as cracks were observed in the sample. These results indicate that the maghemite microparticles are strongly magnetically attracted to each other and cover the surface of the conductor. These results indicate that the prepared sample can be used as a wound coil. Furthermore, it was found that the magnesium nanoparticles did not detach from the insulating layer of the sample when winding the prepared sample onto a bobbin or when unwinding it from the bobbin. Therefore, the insulating layer of the prepared sample remains unchanged whether it is wound onto a bobbin or unwinded from the bobbin. Next, the pipe around which the sample was wrapped was exposed to -40°C and 400°C for 30 minutes each, and the sample surface was observed using a scanning electron microscope (SEM). There was no change from the initial state. From these results, it was found that the sample has cold resistance at -40°C, heat resistance at 400°C, and excellent thermal shock resistance. Furthermore, the dielectric breakdown voltage was measured using the EB0181 dielectric breakdown tester from Tokyo Seiden Co., Ltd., based on the dielectric breakdown test of the winding test method of JIS-C-3216-1. The dielectric breakdown voltage of the sample was 12kV. This dielectric breakdown voltage is equivalent to that of an enameled wire (for example, Hitachi Metals, Ltd.'s heat-resistant enameled wire IMW) with a polyimide insulating layer thickness of 0.035mm and a bare copper single wire diameter of 1.0mm. On the other hand, despite the insulating layer thickness of the sample being 1 / 540th the thickness of the insulating layer of the aforementioned heat-resistant wire, it had a similar dielectric breakdown voltage, indicating that the insulating layer composed of aggregates of maghemite fine particles has a high dielectric breakdown voltage. As explained above, the prepared sample exhibits excellent heat resistance, cold resistance, thermal shock resistance, dielectric breakdown voltage, flexibility, adhesion between the insulating layer and the conductor, abrasion resistance of the insulating layer, and winding properties. On the other hand, insulated wires insulated by a stack of magnesiumite microparticles are manufactured by sequentially performing the eight simple processes described in paragraph 14. Furthermore, the iron naphthenate described in paragraph 17 is an easily synthesized iron carboxylate compound, the organic compound belonging to fatty acid esters described in paragraph 19 is a common organic compound belonging to carboxylic acid esters, and the organic solvent described in paragraph 21 is the most common organic solvent. Therefore, insulated wires insulated by an insulating layer with excellent performance can be manufactured continuously using inexpensive raw materials and at low processing costs. In Example 1, an example of an insulated wire was shown in which the surface of a bare copper single wire was covered with an aggregate of maghemite fine particles. On the other hand, even if the conductor is a stranded wire, or a flat conductor with a rectangular cross-section, the surface of the conductor can be covered with a low viscosity suspension of 1-4 mPa·s, similar to Example 1. Furthermore, since the conductor covered with the suspension can be continuously heat-treated, insulated wires covered with an aggregate of maghemite fine particles are not limited to conductors made of bare copper single wires. [Explanation of Symbols]

[0024] 1. Bare copper single wire 2. Laminated maghemite microparticles

Claims

1. A method for continuously manufacturing a wire conductor in which magnetic attraction occurs with saturated magnetization and the surface of the wire conductor is insulated by an aggregate of stacked Maghemite microparticles is, The first step involves dispersing an organic iron compound that precipitates ferrous oxide (FeO) upon thermal decomposition in methanol in its molecular state to create a methanol dispersion of the organic iron compound, then vaporizing the methanol from the methanol dispersion of the organic iron compound to precipitate an aggregate of crystals of the organic iron compound, and finally filling a container with the aggregate of crystals of the organic iron compound. A plate material is placed over the entire surface of the collection of organic iron compound crystals in the container. After this, a compressive load is applied to the entire surface of the plate material to pulverize the organic iron compound crystals in the container. Furthermore, impact acceleration in three directions (front / back, left / right, and up / down) is repeatedly applied to the sides and bottom of the container to rearrange the pulverized collection of organic iron compound crystals within the container. After this, the compressive load is applied again to the entire surface of the plate material to further pulverize the organic iron compound crystals. Furthermore, the impact acceleration in the three directions is repeatedly applied again to the sides and bottom of the container. This pair of processes, consisting of applying the compressive load and applying the impact acceleration, is repeated. When the plate material stops moving when the compressive load is applied, it is determined that the pulverization of the organic iron compound crystals is complete, and the pair of processes is stopped. As a result, the organic iron compound crystals are pulverized into fine crystals of 1 / 5 of their original size. After this, the plate material is removed from the container. The first property is that the crystals of the aforementioned organic iron compound do not dissolve and disperse, and ferrous oxide (FeO) is ferric oxide (Fe ２ O ３ The second property is that the boiling point is higher than the temperature at which it is oxidized to ferrous oxide (FeO), and the fine particles of ferrous oxide (FeO) ２ O ３ A third step involves weighing an organic compound that possesses the third property of not chemically reacting with both the fine particles of the organic iron compound and the fine particles of the organic iron compound, and the fourth property of having a viscosity of 11-18 mPa·s at 25°C, in a weight greater than the aggregate of fine crystals of the organic iron compound in the container, mixing the weighed organic compound into the container filled with the aggregate of fine crystals of the organic iron compound, and further stirring with a stirrer, thereby creating a first suspension in which the aggregate of fine crystals of the organic iron compound is dispersed in the organic compound. Prepare a first heat treatment device for thermally decomposing the fine crystals of the organic iron compound into fine particles of ferrous oxide (FeO). Move the container into the first heat treatment device, heat the first heat treatment device to a temperature at which the fine crystals of the organic iron compound thermally decompose into fine particles of ferrous oxide (FeO), and further hold it at the thermal decomposition temperature for a predetermined time. As a result, fine particles of ferrous oxide (FeO) having a size of around 10 nm precipitate surrounded by the organic compound, and a second suspension composed of an aggregate of fine particles of ferrous oxide (FeO) surrounded by the organic compound is created in the container. Further, heat the first heat treatment device to a temperature at which the fine particles of ferrous oxide (FeO) are oxidized into fine particles of ferric oxide (Fe ２ O ３ ), and further hold it at the oxidation temperature for a predetermined time. As a result, all of the fine particles of ferrous oxide (FeO) are oxidized into fine particles of maghemite (γ-Fe ２ O ３ ), and a third suspension in which the fine particles of maghemite (γ-Fe ２ O ３ ) are dispersed in the organic compound is created in the container. After this, take out the container from the first heat treatment device, and further, a fourth step of creating a fourth suspension having a viscosity of 1 - 4 mPa·s at 25°C by introducing a large amount of an organic solvent having a first property of being soluble or miscible in the organic compound and a second property of having a viscosity of 0.3 - 0.6 mPa·s at 20°C into the third suspension. A fifth step is to continuously pull out the conductor of the electric wire from a first bobbin on which the conductor of the electric wire is wound at a pulling speed of 0.5 cm per second, continuously immerse the pulled-out conductor of the electric wire in a fourth suspension in the container, continuously move it through the fourth suspension at a movement speed of 0.5 cm per second, and then continuously pull it out of the fourth suspension at a pulling speed of 0.5 cm per second. A second heat treatment apparatus is prepared in advance, which is heated to the boiling point of the organic solvent and is equipped with a suction device for sucking up gas. The conductor of the electric wire, which has been lifted out of the fourth suspension, is moved continuously through the second heat treatment apparatus at a speed of 0.5 cm per second, vaporizing the organic solvent, and the vaporized organic solvent is sucked up by the suction device. This causes the conductor of the electric wire, which is covered with the third suspension, to move continuously outside the second heat treatment apparatus. A third heat treatment apparatus is prepared in advance, heated to the boiling point of the organic compound. The conductor of the electric wire that has come out of the second heat treatment is moved continuously through the third heat treatment apparatus at a speed of 0.5 cm per second. As a result, the organic compound vaporizes from the third suspension and the maghemite (γ-Fe) is released onto the surface of the conductor of the electric wire. ２ O ３ As a collection of fine particles of ) precipitates, the precipitated maghemite (γ-Fe ２ O ３ The fine particles of ) are magnetically attracted to each other, and furthermore, the magnetically attracted Maghemite (γ-Fe ２ O ３ The magmite (γ-Fe) consists of layers of fine particles of ) ２ O ３ A seventh step is in which the conductor of the electric wire, which is covered with an aggregate of fine particles, moves continuously outside the third heat treatment apparatus, The aforementioned magnesium (γ-Fe ２ O ３ The process consists of: preparing a magnetic field generator in advance to generate a magnetic field that saturates the magnetization of the fine particles of magneto; continuously moving the conductor of the electric wire, which has been moved outside the third heat treatment apparatus in the seventh step, through the magnetic field generator at a speed of 0.5 cm per second to saturate the magnetization of the magneto fine particles; and in the eighth step, continuously winding the conductor of the electric wire, which has been moved outside the magnetic field generator, onto a second bobbin at a peripheral speed of 0.5 cm per second. A method for continuously manufacturing a wire conductor in which all eight processes described above are carried out in a continuous manner, and the surface of the wire conductor is insulated by an aggregate of stacked Magnemite microparticles while magnetic attraction occurs with saturated magnetization.

2. A method for continuously producing a conductor for an electric wire in which the surface of the conductor of the electric wire is insulated by an aggregate of stacked magmite fine particles while being magnetically adsorbed with saturated magnetization. The organic iron compound described in claim 1 is iron naphthenate, and iron naphthenate is used as the organic iron compound that precipitates ferrous oxide (FeO) by thermal decomposition as described in claim 1, and all eight steps of the process described in claim 1 are carried out in succession.

3. A method for continuously producing a conductor for an electric wire in which the surface of the conductor of the electric wire is insulated by an aggregate of stacked magnesiumite particles while being magnetically adsorbed with saturated magnetization. The organic compound described in claim 1 is one carboxylic acid ester consisting of 2-ethylhexyl palmitate, cetyl 2-ethylhexanoate, or bis(2-ethylhexyl) sebacate, and the one carboxylic acid ester is used as an organic compound possessing the four properties described in claim 1, and all eight steps described in claim 1 are carried out in succession.

4. A method for continuously producing a conductor for an electric wire in which the surface of the conductor of the electric wire is insulated by an aggregate of stacked magmite fine particles while being magnetically adsorbed with saturated magnetization, wherein the organic solvent described in claim 1 is one of any one of acetone, methyl ethyl ketone, toluene, or methanol, and the one organic solvent is used as an organic solvent that possesses both of the two properties described in claim 1, and all eight steps of the process described in claim 1 are carried out in succession.

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