Flat cable, coil, and method for manufacturing flat cable

Abstract

To provide a flat cable windable easily even to a small-diameter bobbin.SOLUTION: A flat cable 100 has a laminated wire 1 formed by laminating multiple flat wires, and an insulator layer 2 for coating the outer periphery of the laminated wire 1. The flat wire is formed by coating the outer periphery of a flat conductor wire with an insulator layer, and the laminated wire 1 has a rugged shape continuing in a longer direction, on both surfaces in the lamination direction.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a flat cable, a coil using the same, and a method for manufacturing the flat cable. [Background technology]

[0002] In recent years, there has been a demand for power supply transformers to be smaller and have lower loss (low heat generation). In particular, for chargers for mobile devices, not only is miniaturization necessary, but heat generation due to rapid charging (high output) is becoming a problem. However, manufacturers have not taken measures to reduce loss in the wires used in transformers, and instead have adopted a charging method that controls power while detecting the temperature of the transformer.In addition, to dissipate heat from the transformer, they have adopted a structure in which the transformer is in contact with the outer case by using thermal grease, filling with silicone rubber, or using a silicone sheet. The electric wires currently used in transformers are standard round wires (with a round cross section), either as a single wire or as litz wires twisted together. Litz wires can reduce the skin effect more than round single wires, but have the disadvantage of increasing loss due to the proximity effect. In contrast, rectangular wires, which have a rectangular cross section, can suppress the increase in electrical resistance due to the skin effect and can be arranged without gaps, which improves the space factor and is advantageous in terms of reducing heat generation and miniaturization.

[0003] Patent Document 1 describes a high-frequency laminated rectangular enameled electric wire having a laminated wire in which multiple enameled wires, each having an enamel coating formed on the outer periphery of a central conductor, are stacked with a bonding coating interposed between them, a long object wound around the outer periphery of the laminated wire with the bonding coating interposed between them, an insulating coating layer formed around the outer periphery of the long object, and a fusion layer formed around the outer periphery of the insulating coating layer. Patent document 2 describes a flat wire having a laminated conductor section formed by stacking flat wires having flat conductors whose outer periphery is covered with a thermosetting resin layer, and a thermoplastic resin layer that covers the outer periphery of the laminated conductor section, in which the flat wires in the laminated conductor section are not bonded together. In other words, Patent Documents 1 and 2 describe a flat cable having a laminated wire in which multiple flat wires are stacked, and an insulating layer that covers the outer periphery of the laminated wire, and the flat wire is a flat conductor wire whose outer periphery is covered with an insulating layer. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2003-86036 [Patent Document 2] Japanese Patent Application Publication No. 2019-75312 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the flat cables described in Patent Documents 1 and 2 are difficult to bend, and when attempting to wind them around a small diameter bobbin with a diameter of 30 mm or less, problems occur such as the flat wires on the outside being cut during winding. An object of the present invention is to provide a flat cable that can be easily wound onto a small diameter bobbin. [Means for solving the problem]

[0006] In order to solve the above problem, one embodiment of the flat square cable of the present invention comprises a laminated wire in which multiple flat square wires are stacked, and an insulating layer that covers the outer periphery of the laminated wire, wherein the flat square wire is a flat square conductor whose outer periphery is covered with an insulating layer, and the laminated wire has a continuous uneven shape in the longitudinal direction on both sides in the stacking direction. [Effects of the Invention]

[0007] According to the flat cable of the present invention, since the laminated wire has a continuous uneven shape in the longitudinal direction, it is expected that the flat cable will be easily wound around a small diameter bobbin. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a plan view showing a flat cable according to a first embodiment of the present invention. FIG. [Figure 2] 2 is a view showing a cross section parallel to the longitudinal direction of the flat rectangular cable according to the first embodiment of the present invention, and is a cross section taken along line AA in FIG. 1. FIG. [Figure 3] 2 is a view showing a cross section perpendicular to the longitudinal direction of the flat rectangular cable according to the first embodiment of the present invention, and is a cross section taken along line BB in FIG. 1. FIG. [Figure 4] 2A to 2C are diagrams illustrating a method for manufacturing the rectangular cable of FIG. 1. [Figure 5] 2 is a cross-sectional view showing a state in which the flat cable of FIG. 1 is being wound around a small-diameter bobbin to form a coil. [Figure 6] FIG. 4 is a plan view showing a flat cable according to a second embodiment of the present invention. [Figure 7] 7 is a view showing a cross section parallel to the longitudinal direction of a flat rectangular cable according to a second embodiment of the present invention, and is a cross section taken along line AA in FIG. 6. FIG. [Figure 8] 7 is a view showing a cross section perpendicular to the longitudinal direction of the flat cable according to the second embodiment of the present invention, and is a cross section taken along line BB in FIG. 6. FIG. [Figure 9] FIG. 10 is a view showing a cross section parallel to the longitudinal direction of a flat cable according to a third embodiment of the present invention. [Figure 10] FIG. 10 is a view showing a cross section parallel to the longitudinal direction of a flat cable according to a fourth embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present invention will be described, but the present invention is not limited to the following embodiments. In the following embodiments, technically preferable limitations are imposed for carrying out the present invention, but these limitations are not essential requirements for the present invention. First Embodiment <Rectangular cable configuration> FIG. 1 is a plan view of a rectangular cable 100 of this embodiment, and FIG. 2 shows a cross section taken along line AA in FIG. 1, and FIG. 3 shows a cross section taken along line BB in FIG. As shown in Figures 1 to 3, the flat cable 100 of this embodiment is composed of a laminated wire 1 having an uneven shape and an insulating layer 2 that covers the outer periphery of the laminated wire 1. The laminated wire 1 is made up of three (multiple) flat wires 11 stacked together. The flat wire 11 is made up of a flat conductor wire 111 whose outer periphery is covered with an insulating layer 112. There are no particular restrictions on the material that makes up the flat conductor wire 111, and common materials (copper, copper alloy, aluminum alloy, etc.) can be used.

[0010] As shown in Fig. 2, the laminated wire 1 has a continuous corrugated shape in the longitudinal direction. The insulating layer 2 covering the outer periphery of the laminated wire 1 has a continuous pulse-shaped corrugated shape in the longitudinal direction on the surface outside the corrugated surface of the laminated wire 1. The continuous pulse shape of the insulating layer 2 corresponds to the waveform of the laminated wire 1, with convex portions 21 of the insulating layer 2 located outside the convex portions of the waveform of the laminated wire 1 and concave portions 22 of the insulating layer 2 located outside the concave portions of the waveform of the laminated wire 1. As shown in FIG. 3, the cross section of the rectangular cable 100 perpendicular to the longitudinal direction is rectangular. Furthermore, the thickness of the flat conductor wire 111 is, for example, 0.8 mm, the thickness of the insulating layer 112 is, for example, 0.03 mm, the sides of the laminated wire 1 are covered with an insulating layer 2 having a thickness of, for example, 0.1 mm, and the top and bottom surfaces are covered with an insulating layer 2 having a certain thickness (for example, 0.1 mm) or more at the thinnest point.

[0011] The insulating layer 112 that covers the outer periphery of the rectangular conductor wire 111 is made of a thermosetting resin. Hereinafter, this insulating layer 112 will also be referred to as the "first insulating layer." The thermosetting resin usable for the first insulating layer is not particularly limited, as long as it is a thermosetting resin commonly used in electric wires or windings. Examples include polyamideimide (PAI), polyimide (PI), polyetherimide (PEI), polyesterimide (PEsI), polyurethane (PU), polyester (PEst), polybenzimidazole, melamine resin, and epoxy resin. Among these, polyamideimide, polyimide, polyetherimide, polyesterimide, polyurethane, and polyester are preferred. One or more types of thermosetting resins may be contained.

[0012] First insulating layer 112 may be formed from one type of thermosetting resin, or may be formed from two or more types of thermosetting resin. The insulating layer 2 that covers the outer periphery of the laminated wire 1 is made of a thermoplastic resin. Hereinafter, this insulating layer 2 is also referred to as a "second insulating layer." The thermoplastic resin usable for the second insulating layer is not particularly limited as long as it is a thermoplastic resin normally used for electric wires or windings. For example, general-purpose engineering plastics such as polyamide (nylon), polyacetal (POM), polycarbonate (PC), polyphenylene ether (PPE, including modified polyphenylene ether), polybutylene terephthalate (PBT), polyethylene terephthalate (PET), polyethylene naphthalate (PEN), and ultra-high molecular weight polyethylene, as well as polysulfone (PSF), polyethersulfone (PES), polyphenylene sulfide (PPS), polyarylate (PAR), polyetherketone (PEK), polyaryletherketone (PAEK), tetrafluoroethylene-ethylene copolymer (ETFE), polyetheretherketone (PEEK, including modified PEEK), poly Examples of such super engineering plastics include polyetherketoneketone (PEKK), tetrafluoroethylene-perfluoroalkylvinyl ether copolymer (PFA), polytetrafluoroethylene (PTFE), thermoplastic polyimide resin (TPI), thermoplastic polyamideimide (TPAI), and liquid crystal polyester, as well as polymer alloys based on polyethylene terephthalate or polyethylene naphthalate, and polymer alloys containing the above engineering plastics, such as ABS / polycarbonate, nylon 6,6, aromatic polyamide resin, polyphenylene ether / nylon 6,6, polyphenylene ether / polystyrene, and polybutylene terephthalate / polycarbonate.

[0013] The second insulating layer 2 may be made of one type of thermoplastic resin, or may be made of two or more types of thermoplastic resin. When the second insulating layer 2 has a laminated structure, the resin components contained in the respective layers at the maximum content may be the same or different from each other. The second insulating layer 2 may contain various additives that are commonly used as coating layers for electric wires or windings. In this case, the content of the additives is not particularly limited, but is preferably 5 parts by mass or less, and more preferably 3 parts by mass or less, per 100 parts by mass of the resin component. The thermoplastic resin forming the second insulating layer is preferably one having a hardness of 50° or less in terms of A hardness measured by the "durometer measurement method" specified in ISO7619, as this makes it easy to bend. <Rectangular cable manufacturing method> The rectangular cable 100 of the first embodiment can be manufactured by the method shown in FIG.

[0014] This method includes the following first to fourth steps. In the first step, a plurality of flat wires 11, each of which has a flat conductor wire coated on its outer periphery with a first insulating layer, are stacked together to obtain a laminated wire 10 without any irregularities. In the second step, the laminated wire 10 obtained in the first step is pressed using dies 4 arranged on both sides of the laminated wire 10 in the stacking direction, thereby forming a continuous concave-convex shape in the longitudinal direction on both sides of the laminated wire 10 in the stacking direction. The laminated wire 1 obtained in this way has a continuous concave-convex shape in the longitudinal direction on both sides of the flat wires 11 in the stacking direction. In the third step, a thermoplastic resin is extrusion-molded to form a second insulating layer on the outer periphery of the laminated wire 1 after the second step. Specifically, the thermoplastic resin 20 is introduced while the laminated wire 1 is passed through a mold of the extrusion molding device 5.

[0015] In the fourth step, the laminated wire having the second insulating layer after the third step is pressed using dies 6 arranged on both sides of the laminated wire in the stacking direction, thereby forming a longitudinally continuous uneven shape on the surface of the second insulating layer 2 that is outside the uneven surface of the laminated wire 1. This produces the flat cable 100 of the first embodiment. <Actions and Effects> In the flat square cable 100 of the first embodiment, the laminated wire 1 has the above-mentioned uneven shape, and the second insulating layer (insulating layer covering the outer periphery of the laminated wire 1) 2 also has the above-mentioned uneven shape.Therefore, when winding the flat square cable 100 around the circumferential surface of a bobbin or the like, by winding the uneven surface facing the circumferential surface, the recesses 22 of the corrugated laminated wire 1 and the second insulating layer on the inner surface (the surface facing the circumferential surface) of the flat square cable 100 shrink, and the recesses 22 of the corrugated laminated wire 1 and the second insulating layer on the outer surface open, making it easy to deform along the circumferential surface.

[0016] In other words, the flat cable 100 of the first embodiment is easier to wind around a small-diameter bobbin than a flat cable in which the laminated wires and the insulating layer covering the outer periphery of the laminated wires do not have the above-mentioned uneven shape. As a result, a coil can be obtained by winding the flat cable 100 around a small-diameter bobbin, and using this coil in a transformer can contribute to reducing the heat generation and size of the transformer. FIG. 5 shows a state in which the flat cable 100 of the first embodiment is being wound around a small diameter bobbin 8 to form a coil 9. Furthermore, the above-described manufacturing method can be implemented by adding a press machine for forming the irregularities to equipment for manufacturing a flat cable in which the laminated wires and the insulating layer covering the outer periphery of the laminated wires do not have the irregularities described above. Therefore, the flat cable 100 of the above-described embodiment can be manufactured by a method that suppresses cost increases. Second Embodiment <Rectangular cable configuration> FIG. 6 is a plan view of a rectangular cable 100A of this embodiment, and FIG. 7 shows a cross section taken along line AA in FIG. 6, and FIG. 8 shows a cross section taken along line BB in FIG.

[0017] As shown in Figs. 6 to 8, the flat cable 100A of this embodiment is composed of a laminated wire 1 having an uneven shape and an insulating layer 2 that covers the outer periphery of the laminated wire 1. The laminated wire 1 is formed by stacking three (multiple) flat wires 11. The flat wire 11 is formed by covering the outer periphery of a flat conductor wire 111 with an insulating layer 112. There are no particular restrictions on the material that makes up the flat conductor wire 111, and common materials (copper, copper alloy, aluminum alloy, etc.) can be used. As shown in Fig. 7, the laminated wire 1 has a continuous corrugated concave-convex shape in the longitudinal direction. The insulating layer 2 covering the outer periphery of the laminated wire 1 has a continuous pulse-shaped concave-convex shape in the longitudinal direction on the surface that is the outer side of the concave-convex surface of the laminated wire 1. The continuous pulse shape of the insulating layer 2 is a shape in which convex portions 21 or concave portions 22 are provided at the same position in the longitudinal direction on both surfaces that are the outer side of the concave-convex surfaces of the laminated wire 1. In other words, outside the convex portions of the corrugations of the laminated wire 1, there are parts where the convex portions 21 of the insulating layer 2 exist and parts where the concave portions 22 exist, and also outside the concave portions of the corrugations of the laminated wire 1, there are parts where the convex portions 21 of the insulating layer 2 exist and parts where the concave portions 22 exist.

[0018] As shown in FIG. 8, the cross section of the rectangular cable 100A perpendicular to the longitudinal direction is rectangular. Except for the above points, the configuration of the flat cable 100A of the second embodiment is the same as that of the flat cable 100 of the first embodiment. The flat cable 100A of the second embodiment can be manufactured by the same method as that of the first embodiment, except that the convex portions of the upper and lower molds 6 are brought into contact with each other in the fourth step. According to the flat cable 100A of the second embodiment, the same functions and effects as those of the flat cable 100 of the first embodiment can be obtained. Third Embodiment As shown in FIG. 9, in a flat cable 100B of the third embodiment, an insulating layer 2 covering the outer periphery of a laminated wire 1 is formed to a substantially constant thickness along the corrugated surface of the laminated wire 1.

[0019] Except for the above points, the configuration of the flat cable 100B of the third embodiment is the same as that of the flat cable 100 of the first embodiment. The flat cable 100B of the third embodiment can be manufactured by a method in which, after the second step of the first embodiment, thermoplastic resin is extruded into a tube shape from an extruder and a corrugated laminated wire 1 is inserted into the tube shape. According to the flat cable 100B of the third embodiment, the same functions and effects as those of the flat cable 100 of the first embodiment can be obtained. Fourth Embodiment 10 , in the flat cable 100C of the fourth embodiment, the laminated wire 1 has a pulse-shaped uneven shape that continues in the longitudinal direction. The insulating layer 2 that covers the outer periphery of the laminated wire 1 has a pulse-shaped uneven shape that continues in the longitudinal direction on the surface that is outside the uneven surface of the laminated wire 1. The continuous pulse shape of the insulating layer 2 corresponds to the pulse shape of the laminated wire 1, with convex portions 21 of the insulating layer 2 located outside the convex portions of the pulse shape of the laminated wire 1 and concave portions 22 of the insulating layer 2 located outside the concave portions of the pulse shape of the laminated wire 1.

[0020] The configuration of the flat cable 100C of the fourth embodiment is the same as that of the flat cable 100 of the first embodiment except for the points mentioned above. The flat cable 100C of the fourth embodiment can be manufactured in the same manner as the first embodiment, except that the shape of the convex portions of the upper and lower molds 4 used in the first step corresponds to the pulse shape. According to the flat cable 100C of the fourth embodiment, the same functions and effects as those of the flat cable 100 of the first embodiment can be obtained. 〔others〕 The insulating layer covering the outer periphery of the laminated wire does not have to have an uneven shape, but even in this case, if the laminated wire has the uneven shape described above, it becomes easier to wind the laminated wire around a small-diameter bobbin compared to a flat cable in which neither the laminated wire nor the insulating layer covering the outer periphery of the laminated wire has the uneven shape described above. [Explanation of symbols]

[0021] 100 Flat cable 100A flat cable 100B flat cable 100C flat cable 1. Laminated wire 10. Laminated wire with no irregularities 11 Flat wire 111 Flat conductor wire 112 Insulating layer covering the outer periphery of the flat wire (first insulating layer) 2. Insulation layer covering the outer periphery of the laminated wire (second insulation layer) 20 Thermoplastic resin 21 Convex portion of second insulating layer 22 Recess in second insulating layer 4. Molds placed on both sides of the laminated wire in the stacking direction used in the second process 5. Extrusion molding equipment used in the third process 6. Molds placed on both sides of the laminated wire in the stacking direction used in the fourth process

Claims

1. a laminated wire in which a plurality of flat wires are laminated; an insulating layer covering the outer periphery of the laminated wire; and The flat wire is a flat conductor wire whose outer periphery is covered with an insulating layer, The laminated wire is a flat cable having a continuous concave-convex shape in the longitudinal direction on both sides in the lamination direction.

2. 2. The rectangular cable according to claim 1, wherein the insulating layer covering the outer periphery of the rectangular conductor is made of a thermosetting resin.

3. 3. The rectangular cable according to claim 1, wherein the insulating layer covering the outer periphery of the laminated wire is made of a thermoplastic resin.

4. 4. The rectangular cable according to claim 1, wherein the cross section perpendicular to the longitudinal direction is rectangular.

5. 5. A flat cable according to claim 1, wherein the insulating layer covering the outer periphery of the laminated wire has a longitudinally continuous uneven shape on the surface outside the uneven surface of the laminated wire.

6. A coil in which the flat cable according to any one of claims 1 to 5 is wound around a bobbin.

7. The method for manufacturing a rectangular cable according to claim 5, a first step of stacking a plurality of flat wires, each of which has a flat conductor wire coated with a first insulating layer, to obtain a laminated wire; a second step of pressing the laminated wire obtained in the first step using dies arranged on both sides of the laminated wire in the stacking direction to form a longitudinally continuous concave-convex shape on both sides of the laminated wire in the stacking direction; a third step of forming a second insulating layer on the outer periphery of the laminated wire after the second step by an extrusion molding method using a thermoplastic resin; a fourth step of pressing the laminated wire having the second insulating layer after the third step using dies arranged on both sides of the laminated wire in the stacking direction to form a continuous concave-convex shape in the longitudinal direction on a surface of the second insulating layer that is outside the surface of the laminated wire having the concave-convex shape; A method for manufacturing a flat cable comprising:

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