Rectangular cross-section multi-core insulated wire and its manufacturing method

Abstract

To provide a square cross section multicore insulated wire of construction having a constitution excellent in insulation property, capable of applying to a coil in a non-contact charger, and combining flexibility and shape stability.SOLUTION: A square cross section multicore insulated wire 1 has a cluster of wires 2 in which an insulating layer 2b is formed on an outer periphery of a conductor 2a, and has a composite twist structure formed of a first stranded wire 21, a second stranded wire 22, a third stranded wire 23 and a fourth stranded wire 24, an insulating fiber thread 3 is wound around an outer periphery, and the cross section is formed into a rectangular shape, and a winding direction of the fiber thread 3 is the opposite direction of the twist direction of the outermost twisted wire in the cluster of wires 2.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a rectangular cross-section multi-core insulated electric wire and a method for manufacturing the same. [Background technology]

[0002] A conventional structure has been proposed in which an assembly of wires is compression-molded into a square shape and an insulating layer is provided (Patent Document 1: JP 59-096605 A). Another structure has been proposed in which a Litz wire is compression-molded into a rectangular shape, glass thread is wound around the outer periphery, and the wires are bonded together with a synthetic resin (Patent Document 2: JP 63-006815 A). Another proposed method involves twisting multiple wires together, drawing them into a rectangular shape, and then extruding an insulating layer onto the twisted wire (Patent Document 3: JP 2009-245658 A). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 59-096605 [Patent Document 2] Jpn. Jpn. Appl. KOKAI Publication No. 63-006815 [Patent Document 3] Japanese Patent Application Laid-Open No. 2009-245658 Summary of the Invention [Problem to be solved by the invention]

[0004] When insulated wires are used as coils in contactless charging devices for electrical equipment, electric motors, automobiles, etc., they must be flexible enough to bend into the desired shape. However, conventional technologies make the wires hard overall due to the presence of extruded insulating layers and binder resins, making it difficult to bend them into the desired shape. On the other hand, assemblies of many wires are prone to fraying, making it difficult to maintain their shape without the use of binder resins or other adhesives. [Means for solving the problem]

[0005] The present invention has been made in consideration of the above circumstances, and aims to provide a rectangular cross-section multi-core insulated electric wire having excellent insulation performance, flexibility, and shape stability, which can be applied to coils in contactless charging devices.

[0006] In one embodiment, the above problem is solved by the solution disclosed below.

[0007] The rectangular cross-section multi-core insulated electric wire according to the present invention has an assembly of wires in which an insulating layer is formed on the outer periphery of a conductor, and the assembly of wires includes a first stranded wire formed by twisting the wires, a second stranded wire formed by twisting the first stranded wires, and a third stranded wire formed by twisting the second stranded wires. The fourth stranded wire is made by twisting the third stranded wire. The insulating fiber thread The assembly of wires It is wrapped around the outside, The assembly of wires The cross section is formed into a rectangular shape, The twist directions of the first stranded wire, the second stranded wire, and the third stranded wire are all in a second direction, the twist direction of the fourth stranded wire is opposite to the second direction, and the winding direction of the fiber yarn is in the second direction. It is characterized by:

[0008] This configuration provides flexibility (suppleness) that can adapt to bending processes thanks to the composite twist structure having the first, second, and third twisted wires. Furthermore, by winding the fiber threads in the opposite direction to the twist direction of the outermost twisted wire in the assembly of wires, the fiber threads can cover the wires without digging in between them. Furthermore, the fiber threads can withstand the external force generated when forming the wire into a rectangular shape, protecting the assembly of wires inside and preventing fraying of the assembly of wires.

[0009] As one example, the number of first stranded wires among the number of wires is equal to or greater than the number of second stranded wires among the number of wires, and the number of second stranded wires among the number of wires is equal to or greater than the number of third stranded wires among the number of wires. This configuration provides even greater flexibility (suppleness). As another example, the number of first stranded wires among the number of wires is greater than the number of second stranded wires among the number of wires, and the number of second stranded wires among the number of wires is greater than the number of third stranded wires among the number of wires. As another example, the twist pitch is such that the first pitch of the first stranded wire is smaller than the second pitch of the second stranded wire, and the second pitch of the second stranded wire is smaller than the third pitch of the third stranded wire. This configuration makes it difficult for the assembly to fray, making it easier to maintain the rectangular shape of the assembly.

[0010] As an example, the conductor is made of copper or a copper alloy, and the insulating layer is made of polyurethane. This allows for a configuration with high conductivity and excellent solderability. As an example, the fiber thread is made of polyester. This makes it easier for the insulating resin to spread when applied to a coil and impregnated with the insulating resin, resulting in high adhesiveness. As an example, the number of the strands is 2,000 or more. This allows for even greater flexibility and a configuration with excellent electrical conductivity in the high-frequency band. As an example, the number of the strands is 4,000 or less. This allows for an increased space factor of the conductor while ensuring the bending strength required for application to a coil.

[0013] The method for manufacturing a rectangular cross-section multi-core insulated electric wire according to the present invention is to manufacture a wire having an insulating layer formed on the outer periphery of a conductor. The assembly of wires includes: a first stranded wire obtained by twisting the wires together, a second stranded wire obtained by twisting the first stranded wires together, and a third stranded wire obtained by twisting the second stranded wires together; The third stranded wire is twisted to form a fourth stranded wire. , insulating fiber yarn but On the outer periphery of the assembly of wires The assembly of wires is wound cross section but Formed into a rectangular shape a method for manufacturing a rectangular cross-section multi-core insulated electric wire, the method comprising the steps of: twisting the first stranded wire, the second stranded wire, and the third stranded wire in a second direction; twisting the fourth stranded wire in a direction opposite to the second direction; and winding the fiber yarn in the second direction. It is characterized by:

[0014] This configuration provides flexibility (suppleness) that can follow bending processes when applied to coils, etc. Furthermore, the fiber threads can cover the wires without getting caught between them. Furthermore, it protects the internal wire assembly from external forces when forming it into a rectangular shape and prevents the wire assembly from fraying. [Effects of the Invention]

[0015] According to the present invention, it is possible to realize a rectangular cross-section multi-core insulated electric wire having excellent insulating performance, flexibility, and shape stability, which can be used as a coil in a contactless charging device. [Brief explanation of the drawings]

[0016] [Figure 1] FIG. 1 is a structural diagram that schematically shows the structure of a rectangular cross-section multi-core insulated electric wire according to an embodiment of the present invention. [Figure 2] FIG. 2A is a diagram schematically illustrating the wires in the example of the rectangular cross-section multi-core insulated electric wire shown in FIG. 1, FIG. 2B is a diagram illustrating the state in which the wires in FIG. 2A are twisted to form a first twisted wire, and FIG. 2C is a diagram illustrating the state in which the first twisted wire in FIG. 2B is twisted to form a second twisted wire. [Figure 3] FIG. 3A shows the second stranded wire in FIG. 2C twisted to form a third stranded wire, FIG. 3B shows the third stranded wire in FIG. 3A twisted to form a fourth stranded wire, and FIG. 3C shows the fourth stranded wire in FIG. 3B covered with fiber yarn. [Figure 4] FIG. 4A is a diagram schematically showing strands of another example of the rectangular cross-section multi-core insulated electric wire shown in FIG. 1, FIG. 4B is a diagram showing the strands in FIG. 4A twisted together to form a first stranded wire, and FIG. 4C is a diagram showing the first stranded wire twisted together to form a second stranded wire. [Figure 5] FIG. 5A shows the second stranded wire in FIG. 4C twisted to form a third stranded wire, FIG. 5B shows the third stranded wire in FIG. 5A twisted to form a fourth stranded wire, and FIG. 5C shows the fourth stranded wire in FIG. 5B covered with fiber yarn. [Figure 6]FIG. 6 is a diagram showing the rectangular cross-section multi-core insulated electric wire shown in FIG. 1 in a coiled state. DETAILED DESCRIPTION OF THE INVENTION

[0017] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. A rectangular cross-section multi-core insulated electric wire 1 of this embodiment is applied, for example, to a coil in a contactless charging device for an electric device, an electric motor, an automobile, etc. In all drawings used to explain the embodiment, components having the same function are designated by the same reference numerals, and repeated description thereof may be omitted.

[0018] As shown in FIG. 1, the rectangular cross-section multi-core insulated electric wire 1 has an assembly of wires 2 in which an insulating layer 2b is formed on the outer periphery of a conductor 2a, and has a composite twisted structure consisting of a first twisted wire 21, a second twisted wire 22, a third twisted wire 23, and a fourth twisted wire 24. An insulating fiber thread 3 is wound around the outer periphery, and the cross section is formed into a rectangular shape. The winding direction of the fiber thread 3 is opposite to the twisting direction of the outermost twisted wire in the assembly of wires 2.

[0019] The conductor 2a constituting the wire 2 is a solderable conductive conductor, made of, for example, copper or a copper alloy. The insulating layer 2b is an insulating coating that has excellent insulating properties and does not interfere with soldering, made of, for example, polyurethane or polyester. An enameled wire can be used for the wire 2. The insulating fiber yarn 3 is a covering yarn, selected from, for example, polyester yarn, acrylic yarn, polypropylene yarn, and polyurethane yarn. The material of the fiber yarn 3 can be selected appropriately depending on the application.

[0020] In the rectangular cross-section multi-core insulated electric wire 1, an assembly of wires 2 is covered with fiber threads 3 for protection and insulation from the outside. As shown in FIG. 1, the assembly of wires 2 has a rectangular cross section. In the example of FIG. 1, the twist direction of the fourth stranded wire 24 is a first direction v1, and the winding direction of the fiber threads 3 is a second direction v2 opposite to the twist direction. Here, the first direction v1 and the second direction v2 indicate a relative relationship, and the twist direction of the fourth stranded wire 24 may be the second direction v2, and the winding direction of the fiber threads 3 may be the second direction v2 opposite to the twist direction. For example, the twist direction may be a right-handed or S-twist, and the winding direction of the fiber threads 3 may be a left-handed winding. Alternatively, the twist direction may be a left-handed or Z-twist, and the winding direction of the fiber threads 3 may be a right-handed winding. In one example, the manufacturing equipment for the rectangular cross section multi-core insulated electric wire 1 includes a twisting device, a forming device, and a winding device, which are arranged in this order from the upstream side.

[0021] Next, a first example of the rectangular cross-section multi-core insulated electric wire 1 and a manufacturing procedure thereof will be described below.

[0022] [Example 1] As shown in FIG. 2A, a wire 2 is used, which includes a conductor 2a made of copper or a copper alloy and an insulating layer 2b made of polyurethane or polyester. Then, as shown in FIG. 2B, seven to twenty-one of the wires 2 are twisted in a first direction v1 to form a first stranded wire 21. The longitudinal length of one full turn of the first wire of the wires 2 is a first pitch P1. Next, as shown in FIG. 2C, three to nine of the first stranded wire 21 are twisted in the first direction v1 to form a second stranded wire 22. The longitudinal length of one full turn of the first wire of the first stranded wire 21 is a second pitch P2. Next, as shown in FIG. 3A, three to seven of the second stranded wires 22 are twisted in the first direction v1 to form a third stranded wire 23. The longitudinal length of one full turn of the first wire of the second stranded wire 22 is a third pitch P3. Next, as shown in FIG. 3B, three to seven third stranded wires 23 are twisted in a first direction v1 to form a fourth stranded wire 24. The longitudinal length of one full turn of the first wire of the fourth stranded wire 24 is a fourth pitch P4. Then, as shown in FIG. 3C, an insulating fiber yarn 3 is wound around the outer periphery of the fourth stranded wire 24 in a second direction v2 opposite to the first direction v1. The wire is then sandwiched between rollers of a molding device to form the cross section into a rectangular shape, thereby forming a rectangular cross-section multicore insulated electric wire 1. The formed rectangular cross-section multicore insulated electric wire 1 is then wound around a drum.

[0023] Next, a second example of the rectangular cross-section multi-core insulated electric wire 1 and a manufacturing procedure thereof will be described below.

[0024] [Example 2] As shown in FIG. 4A, a wire 2 is used, which includes a conductor 2a made of copper or a copper alloy and an insulating layer 2b made of polyurethane or polyester. Then, as shown in FIG. 4B, seven to twenty-one of the wires 2 are twisted in the second direction v2 to form a first stranded wire 21. Next, as shown in FIG. 4C, three to nine of the first stranded wires 21 are twisted in the second direction v2 to form a second stranded wire 22. Next, as shown in FIG. 5A, three to seven of the second stranded wires 22 are twisted in the second direction v2 to form a third stranded wire 23. Next, as shown in FIG. 5B, three to seven of the third stranded wires 23 are twisted in the first direction v1 to form a fourth stranded wire 24. Finally, as shown in FIG. 5C, an insulating fiber thread 3 is wound around the outer periphery of the fourth stranded wire 24 in a second direction v2, which is the opposite direction to the first direction v1. The wire is then sandwiched between rollers in a molding machine to form a rectangular cross section, thereby forming the rectangular multicore insulated electric wire 1. Then, the formed rectangular cross-section multi-core insulated electric wire 1 is wound on a drum.

[0025] The first example described above is unidirectional twisting, and the second example is rope twisting. In the first and second examples, the twist direction of the fourth stranded wire 24 is the first direction v1, and the winding direction of the fiber thread 3 is the second direction v2. Here, the first direction v1 and the second direction v2 indicate a relative relationship, and there are cases where the twist direction of the fourth stranded wire 24 is the second direction v2, and the winding direction of the fiber thread 3 is the second direction v2, which is opposite to the twist direction.

[0026] Examples of the rectangular cross-section multi-core insulated electric wire 1 are shown in Table 1 below.

[0027] [Table 1]

[0028] Next, examples of the rectangular cross-section multi-core insulated electric wire 1 according to this embodiment will be described below.

[0029] The manufacturing method of the rectangular cross-section multi-core insulated electric wire 1 is as described above. The strands 2 are composed of a conductor 2a and an insulating layer 2b. The conductor 2a is a copper or copper alloy wire with a diameter of 0.1 mm. The insulating layer 2b is made of polyurethane or polyester with a radial thickness of 9 μm. The fiber yarn 3 is made of six polyester threads with a 110 dtex. Fourteen strands 2 are twisted in a first direction v1 with a first pitch P1 of 25 mm to form a first stranded wire 21. Next, six first stranded wires 21 are twisted in the first direction v1 with a second pitch P1 of 45 mm to form a second stranded wire 22. Next, five second stranded wires 22 are twisted in the first direction v1 with a third pitch P1 of 85 mm to form a third stranded wire 23. Next, five third stranded wires 23 are twisted in the first direction v1 with a fourth pitch P1 of 115 mm to form a fourth stranded wire 24. Then, the fiber yarn 3 is wound around the outer periphery of the fourth stranded wire 24 in the second direction v2. Thereafter, the wire is sandwiched between rollers of a molding device to mold the cross section into a rectangular shape, thereby forming the rectangular cross section multi-core insulated electric wire 1. The rollers are provided in multiple stages.

[0030] As an example, the rectangular cross-section multi-core insulated electric wire 1 is used by bending it into a coil, as shown in FIG. 6 . If necessary, it is cut to a desired length and subjected to terminal processing such as soldering, fusing, or the attachment of a terminal. According to the above-described embodiment, a configuration can be achieved that combines flexibility (suppleness) that can follow the bending process with shape stability. Furthermore, the fiber threads can be covered without digging into the wires. Furthermore, the internal assembly of wires can be protected from external forces when forming it into a rectangular shape, and fraying of the assembly of wires can be prevented.

[0031] The present invention is not limited to the above-described embodiments, and various modifications are possible without departing from the scope of the present invention. [Explanation of symbols]

[0032] 1. Rectangular cross-section multi-core insulated wire 2 wire, 2a conductor, 2b insulating layer 3. Fiber yarn 21 1st strand 22 2nd strand 23 Third strand 24 4th strand v1 1st direction v2 2nd direction

Claims

1. The cable has an assembly of wires in which an insulating layer is formed on the outer periphery of a conductor, the assembly of wires comprising a first twisted wire formed by twisting the wires, a second twisted wire formed by twisting the first twisted wires, a third twisted wire formed by twisting the second twisted wires, and a fourth twisted wire formed by twisting the third twisted wires, an insulating fiber thread is wound around the outer periphery of the assembly of wires, the cross section of the assembly of wires is formed into a rectangular shape, the twist directions of the first twisted wire, the second twisted wire, and the third twisted wire are all in a second direction, the twist direction of the fourth twisted wire is opposite to the second direction, and the winding direction of the fiber thread is in the second direction. A rectangular cross-section multi-core insulated electric wire characterized by:

2. The conductor is made of copper or a copper alloy, the insulating layer is made of polyurethane, the fiber thread is made of polyester, and the number of the wires is 2000 or more.

2. The rectangular cross-section multi-core insulated wire according to claim 1,

3. a method for manufacturing a rectangular cross-section multi-core insulated electric wire having an assembly of wires in which an insulating layer is formed on the outer periphery of a conductor, the assembly of wires comprising a first stranded wire formed by twisting the wires, a second stranded wire formed by twisting the first stranded wires, a third stranded wire formed by twisting the second stranded wires, and a fourth stranded wire formed by twisting the third stranded wires, an insulating fiber thread being wound around the outer periphery of the assembly of wires, and the assembly of wires having a cross section shaped like a flat rectangle, wherein the twist directions of the first stranded wires, the second stranded wire, and the third stranded wires are all a second direction, the twist direction of the fourth stranded wire is a direction opposite to the second direction, and the winding direction of the fiber thread is the second direction; A method for manufacturing a rectangular cross-section multi-core insulated electric wire, characterized by the above.

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