Rectangular cross-section multi-core insulated wire, and method for manufacturing same

Abstract

A rectangular cross-section multi-core insulated wire includes an assembly of wires in which insulating layers are formed on peripheries of conductors, and the assembly of the wires is a composite twisted structure, and includes first twisted wires formed by twisting the wires, second twisted wires formed by twisting the first twisted wires, and third twisted wires formed by twisting the second twisted wires. An insulating fiber thread is wound around a periphery, a cross-section is formed in a rectangular shape, and a winding direction of the fiber thread is a direction opposite to a twisting direction of outermost twisted wires in the assembly of the wires.

Claims

1. A rectangular cross-section multi-core insulated wire comprising: an assembly of wires in which insulating layers are formed on peripheries of conductors, wherein the assembly of the wires is a composite twisted structure consisting of first twisted wires formed by twisting the wires, second twisted wires formed by twisting the first twisted wires, third twisted wires formed by twisting the second twisted wires, and fourth twisted wires formed by twisting the third twisted wires, an insulating fiber thread is wound around a periphery, a cross-section is formed in a rectangular shape, a winding direction of the fiber thread is a direction opposite to a first direction, a twisting direction of each of the first twisted wires, the second twisted wires, and the third twisted wires is in the second direction, and a twisting direction of the fourth twisted wire is the first direction.

2. The rectangular cross-section multi-core insulated wire according to claim 1, wherein the conductors are 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 wires is greater than or equal to 2000.

3. A method for manufacturing a rectangular cross-section multi-core insulated wire, the method comprising: using wires in which insulating layers are formed on peripheries of conductors, forming an assembly of the wires of a composite twisted structure consisting of first twisted wires formed by twisting the wires, second twisted wires formed by twisting the first twisted wires, third twisted wires formed by twisting the second twisted wires, and fourth twisted wires formed by twisting the third twisted wires; winding an insulating fiber thread on a periphery of the assembly of the wires in a second direction opposite to a first direction; subsequently forming a cross-section into a rectangular shape, a twisting direction of each of the first twisted wires, the second twisted wires, and the third twisted wires is the second direction, and a twisting direction of the fourth twisted wire is the first direction.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) FIG. 1 is a structural diagram schematically showing the structure of a rectangular cross-section multi-core insulated wire according to an embodiment of the invention.

(2) FIG. 2A is a diagram schematically showing a wire in an example of the rectangular cross-section multi-core insulated wire shown in FIG. 1, FIG. 2B is a diagram showing a state in which wires of FIG. 2A are twisted to form a first twisted wire, and FIG. 2C is a diagram showing a state in which first twisted wires of FIG. 2B are twisted to form a second twisted wire.

(3) FIG. 3A is a diagram showing a state in which second twisted wires of FIG. 2C are twisted to form a third twisted wire, FIG. 3B is a diagram showing a state in which third twisted wires of FIG. 3A are twisted to form a fourth twisted wire, and FIG. 3C is a diagram showing a state in which the fourth twisted wire of FIG. 3B is covered with a fiber thread.

(4) FIG. 4A is a diagram schematically showing a wire in another example of the rectangular cross-section multi-core insulated wire shown in FIG. 1, FIG. 4B is a diagram showing a state in which wires of FIG. 4A are twisted to form a first twisted wire, and FIG. 4C is a diagram showing a state in which first twisted wires of FIG. 4B are twisted to form a second twisted wire.

(5) FIG. 5A is a diagram showing a state in which second twisted wires of FIG. 4C are twisted to form a third twisted wire, FIG. 5B is a diagram showing a state in which third twisted wires of FIG. 5A are twisted to form a fourth twisted wire, and FIG. 5C is a diagram showing a state in which the fourth twisted wire of FIG. 5B is covered with a fiber thread.

(6) FIG. 6 is a diagram showing a state in which the rectangular cross-section multi-core insulated wire shown in FIG. 1 is coiled.

DESCRIPTION OF EMBODIMENTS

(7) Referring to the drawings, an embodiment of the invention is now described in detail. In one example, a rectangular cross-section multi-core insulated wire 1 of the present embodiment is applied to a coil in a noncontact charger such as an electric device, an electric motor, or an automobile. Throughout the figures illustrating embodiments, members having the same functions are denoted by the same reference numerals, and repeated description thereof may be omitted.

(8) As shown in FIG. 1, the rectangular cross-section multi-core insulated wire 1 includes an assembly of wires 2, in which insulating layers 2b are formed on the peripheries of conductors 2a, and is a composite twisted structure including first twisted wires 21, second twisted wires 22, third twisted wires 23, and a fourth twisted wire 24, an insulating fiber thread 3 is wound around the periphery, the cross-section is formed into a rectangular shape, and a winding direction of the fiber thread 3 is a direction opposite to a twisting direction of the outermost twisted wires in the assembly of the wires 2.

(9) The conductor 2a forming each wire 2 is a solderable conductor with electrical conductivity and is made of copper or a copper alloy, for example. The insulating layer 2b is an insulating film that has excellent insulating properties and does not interfere with soldering, and is made of polyurethane or polyester, for example. An enameled wire can be used as the wire 2. The insulating fiber thread 3 is a covering thread and is selected from polyester thread, acrylic thread, polypropylene thread, and polyurethane thread, for example. The material of the fiber thread 3 can be appropriately set according to the application.

(10) In the rectangular cross-section multi-core insulated wire 1, the assembly of the wires 2 is covered with the fiber thread 3 to be protected and insulated from the outside. As shown in FIG. 1, the assembly of the wires 2 is shaped so as to have a rectangular cross-section. In the example of FIG. 1, the twisting direction of the fourth twisted wire 24 is a first direction v1, and the winding direction of the fiber thread 3 is a second direction v2 opposite to the twisting direction. The first direction v1 and the second direction v2 as used herein indicate a relative relationship, and there may be a case in which the twisting direction of the fourth twisted wire 24 is the second direction v2 and the winding direction of the fiber thread 3 is the second direction v2 opposite to the twisting direction. For example, the twisting direction is right-hand twisting or S-twisting, and the winding direction of the fiber thread 3 is left-hand winding. Also, for example, the twisting direction is left-hand twisting or Z-twisting, and the winding direction of the fiber thread 3 is right-hand winding. In one example, an apparatus for manufacturing the rectangular cross-section multi-core insulated wire 1 includes a twisting apparatus, a forming apparatus, and a winding apparatus, which are arranged in this order from the upstream side.

(11) Next, the first example of the rectangular cross-section multi-core insulated wire 1 and its manufacturing procedure are described below.

First Example

(12) As shown in FIG. 2A, wires 2 each including a conductor 2a, which is made of copper or a copper alloy, and an insulating layer 2b, which is made of polyurethane or polyester, are used. Then, as shown in FIG. 2B, 7 or more and 21 or less wires 2 are twisted in a first direction v1 to form a first twisted wire 21. The length in the longitudinal direction of one turn of the first wire in the wires 2 is a first pitch P1. Then, as shown in FIG. 2C, three or more and nine or less first twisted wires 21 are twisted in the first direction v1 to form a second twisted wire 22. The length in the longitudinal direction of one turn of the first wire in the first twisted wires 21 is a second pitch P2. As shown in FIG. 3A, three or more and seven or less second twisted wires 22 are then twisted in the first direction v1 to form a third twisted wire 23. The length in the longitudinal direction of one turn of the first wire in the second twisted wires 22 is a third pitch P3. As shown in FIG. 3B, three or more and seven or less third twisted wires 23 are then twisted in the first direction v1 to form a fourth twisted wire 24. The length in the longitudinal direction of one turn of the first wire in the fourth twisted wire 24 is a fourth pitch P4. Then, as shown in FIG. 3C, an insulating fiber thread 3 is wound around the periphery of the fourth twisted wire 24 in a second direction v2 opposite to the first direction v1. Subsequently, it is sandwiched between rollers of the forming apparatus to form its cross-section into a rectangular shape so that a rectangular cross-section multi-core insulated wire 1 is provided. Then, the formed rectangular cross-section multi-core insulated wire 1 is wound on a drum.

(13) Next, the second example of a rectangular cross-section multi-core insulated wire 1 and its manufacturing procedure are described below.

Second Example

(14) As shown in FIG. 4A, wires 2 each including a conductor 2a, which is made of copper or a copper alloy, and an insulating layer 2b, which is made of polyurethane or polyester, are used. Then, as shown in FIG. 4B, 7 or more and 21 or less wires 2 are twisted in the second direction v2 to form a first twisted wire 21. As shown in FIG. 4C, three or more and nine or less first twisted wires 21 are then twisted in a second direction v2 to form a second twisted wire 22. As shown in FIG. 5A, three or more and seven or less second twisted wires 22 are then twisted in the second direction v2 to form a third twisted wire 23. As shown in FIG. 5B, three or more and seven or less third twisted wires 23 are then twisted in a first direction v1 to form a fourth twisted wire 24. Then, as shown in FIG. 5C, an insulating fiber thread 3 is wound around the periphery of the fourth twisted wire 24 in the second direction v2 opposite to the first direction v1. Subsequently, it is sandwiched between rollers of the forming apparatus to form its cross-section into a rectangular shape so that a rectangular cross-section multi-core insulated wire 1 is provided. Then, the formed rectangular cross-section multi-core insulated wire 1 is wound on a drum.

(15) The first example above is of same-direction twisting, and the second example is of rope twisting. In the first and second examples, the twisting direction of the fourth twisted wire 24 is the first direction v1, and the winding direction of the fiber thread 3 is the second direction v2. The first direction v1 and the second direction v2 as used herein indicate a relative relationship, and there may be a case in which the twisting direction of the fourth twisted wire 24 is the second direction v2 and the winding direction of the fiber thread 3 is the second direction v2 opposite to the twisting direction.

(16) Table 1 below shows examples of the rectangular cross-section multi-core insulated wire 1.

(17) TABLE-US-00001 TABLE 1 Same-direction twisting Rope twisting First example Third example Second example Fourth example First process S-twisting Z-twisting Z-twisting S-twisting (Right-hand twisting) (Left-hand twisting) (Left-hand twisting) (Right-hand twisting) Second process S-twisting Z-twisting Z-twisting S-twisting (Right-hand twisting) (Left-hand twisting) (Left-hand twisting) (Right-hand twisting) Third process S-twisting Z-twisting Z-twisting S-twisting (Right-hand twisting) (Left-hand twisting) (Left-hand twisting) (Right-hand twisting) Fourth process S-twisting Z-twisting S-twisting Z-twisting (Right-hand twisting) (Left-hand twisting) (Right-hand twisting) (Left-hand twisting) Winding process Z-winding S-winding Z-winding S-winding (Left-hand winding) (Right-hand winding) (Left-hand winding) (Right-hand winding) Forming process Rectangular shape into cross-section forming (Square in cross section, or Rectangular in cross section)

(18) Next, an example of the rectangular cross-section multi-core insulated wire 1 according to the present embodiment is described below.

(19) The method for manufacturing the rectangular cross-section multi-core insulated wire 1 is as described above. Each wire 2 includes a conductor 2a and an insulating layer 2b. The conductor 2a is made of copper wire or copper alloy wire with a diameter of 0.1 mm. The insulating layer 2b is made of polyurethane or polyester with a thickness of 9 m on one side in the radial direction. A fiber thread 3 includes six polyester yarns of 110 dtex. Fourteen wires 2 are twisted in the first direction v1 at a first pitch P1 of 25 mm to form a first twisted wire 21. Then, six first twisted wires 21 are twisted in the first direction v1 at a second pitch of 45 mm to form a second twisted wire 22. Five second twisted wires 22 are then twisted in the first direction v1 at a third pitch of 85 mm to form a third twisted wire 23. Five third twisted wires 23 are twisted in the first direction v1 at a fourth pitch of 115 mm to form a fourth twisted wire 24. The fiber thread 3 is then wound around the periphery of the fourth twisted wire 24 in the second direction v2. Subsequently, it is sandwiched between rollers of the forming apparatus to form its cross-section into a rectangular shape so that a rectangular cross-section multi-core insulated wire 1 is provided.

(20) The rollers are provided in multiple stages.

(21) In one example, as shown in FIG. 6, the rectangular cross-section multi-core insulated wire 1 is bent into a coil shape to be used. If necessary, it is cut to a desired length and subjected to terminal processing such as soldering, fusing treatment, or terminal attachment. According to the present embodiment described above, it is possible to provide a configuration that has both flexibility (pliancy) that can conform to bending, and shape stability. Also, the fiber thread can provide a covering without entering between the wires. Furthermore, it is possible to protect the internal assembly of the wires from an external force during formation into a rectangular shape and to prevent the assembly of the wires from fraying.

(22) The invention is not limited to the embodiments described above, and various modifications can be made without departing from the scope of the invention.