Motor Conductor Wire Metal Coating Bending Durability
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Solution Overview
Problem
Conventional conductor wires for motors, especially those with resin coatings, lack durability during bending and are prone to eddy current losses due to low strength insulating layers, which can lead to disassembly of fine wires in a bundle when subjected to alternating magnetic fields.
Innovation Solution
A conductor wire with a bundle of fine wires coated with a metal foil having an electrical resistance equal to or greater than the conductor wires, providing enhanced strength and preventing eddy currents, allowing the wire assembly to maintain its state during bending and reducing eddy current losses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If a resin coating is formed on the outer peripheral surface of a bundle of fine wires, then the assembly state of fine wires can be maintained, but the coating part is low in strength and the fine wires come apart when bent
Solution Approach 1:
The invention changes the material parameter of the coating from resin to metal foil, fundamentally altering the strength characteristics while maintaining the coating function. The metal foil provides sufficient strength to maintain fine wire assembly during bending while still serving as an effective coating layer.
2Quantity of substance
If a flat conductor wire with large cross-sectional area is used, then the space factor of the coil is enhanced, but large eddy currents occur in the surface perpendicular to magnetic fluxes
Solution Approach 1:
The invention segments the conductor into multiple fine wires bundled together, each with small cross-sectional area perpendicular to magnetic flux. This segmentation reduces eddy current paths while the bundle arrangement maintains the required space factor and electrical conductivity for the coil.
Solution Approach 2:
The invention creates a composite structure combining multiple fine wires with individual insulating coatings and an outer metal foil coating. This composite approach achieves both high space factor through bundle arrangement and reduced eddy current loss through the fine wire segmentation and insulating layers.
3Ease of manufacture
If a common insulating layer made of insulating paper or plastic tape is used in compound winding, then the flat insulating wires can be stacked, but the insulating layer is low in strength and breaks when bent
Solution Approach 1:
The invention changes the material parameter of the outer coating from conventional insulating paper or plastic tape to metal foil, dramatically increasing the strength of the coating layer while maintaining its function as a protective and binding layer for the stacked flat insulating wires.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The metal-coated conductor wire enhances durability against bending and reduces eddy current losses by maintaining the assembly state of fine wires and minimizing eddy currents, while also simplifying the manufacturing process with improved strength and reduced workload.
Implementation Method 1
when the flat conductor wire is placed in an alternating magnetic field, large eddy currents tend to occur in a surface perpendicular to magnetic fluxes in the flat conductor wire. This may increase eddy current loss.
Implementation Method 2
the coating member is made of metal, the coating member has an electrical resistance value equal to or larger than an electrical resistance value of the conductor
Data Source
AI summary
The present application has a purpose to provide a conductor wire for motor capable of improving durability against bending, and a coil for motor using the conductor wire for motor. One aspect of the invention, therefore, provides a conductor wire for motor comprising a fine wire assembly and a coating member covering an outer peripheral surface of the fine wire assembly, the fine wire assembly consisting of a plurality of fine wires assembled in a bundle, and each of the fine wires including a conductor and an insulating part provided on an outer peripheral surface of the conductor, wherein the coating member is made of metal, and the coating member has an electrical resistance value larger than an electrical resistance value of the conductor.