JP4617634B2 - Manufacturing method of electrical equipment - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a method for manufacturing an electrical device.
[0002]
[Prior art]
  Conventionally, the insulation of electric wires has been performed by covering a conductor with a synthetic resin. By the way, as this synthetic resin, polyamide imide, polyimide, or the like called a heat resistant resin is known. The heat resistance temperature of these synthetic resins is defined as 220 degrees Celsius and 240 degrees Celsius by the International Electrotechnical Commission (IEC) and the US NEMA standards, etc., and the heat resistant insulated wires coated with these synthetic resins are based on their reliability. Used in electrical equipment (such as electric motors) that creates a relatively harsh environment. However, the lifespan of these synthetic resins is relatively short under extremely harsh environments, and it is necessary to replace parts of the electrical equipment relatively frequently. In order to solve this problem, an electric wire coated with an inorganic substance (a substance having an insulating property such as a ceramic) that is more excellent in heat resistance than a synthetic resin has been developed (see Patent Document 1). As is well known, inorganic materials are very hard and poor in flexibility, so it is extremely difficult to make a coil after coating the wires with the inorganic material. Therefore, this wire is coated with a resin containing silicon such as a silicone resin, a modified silicone resin, or polycarbosilane that is mineralized by heat treatment, and the wire is exposed to a high temperature after the coil is manufactured. Making ceramic wire coils has been performed. At this time, the inorganic powder may be mixed in advance in consideration of the film thickness and the like. Moreover, all the insulated wires shown above can be produced by a method known to those skilled in the art (hereinafter, this method is referred to as a conventional method).
[0003]
[Patent Document 1]
          Japanese Unexamined Patent Publication No. 2000-11768 (Section 2-3, FIG. 1)
[0004]
[Problems to be solved by the invention]
  However, since silicone resins, modified silicones, polycarbosilanes, and the like are relatively expensive, they are difficult to apply to consumer devices in terms of cost.
[0005]
  The subject of this invention is providing the manufacturing method of the electric equipment which can be applied also to consumer equipment at cost.
[0006]
[Means for Solving the Problems]
  According to a first aspect of the present invention, there is provided a method for manufacturing an electrical device comprising: an inorganic powder-containing resin-coated electric wire having a conductor coated with a resin in which inorganic powder is dispersed (excluding a resin containing silicon as a part of its skeleton); An inorganic powder-containing resin-coated electric wire coil manufacturing process for preparing a powder-containing resin-coated electric wire coil, an introduction process for introducing a raw material powder of a powdered iron core into the inorganic powder-containing resin-coated electric wire coil, and a green powder A powder iron core preparation step for producing a powder iron core by compressing and further sintering the raw material powder of the iron core, and in the powder iron core preparation step, the resin contained in the coil is thermally decomposed This produces an inorganic material-coated insulating coil.The “resin in which the inorganic powder is dispersed” mentioned here is polyethylene, polypropylene, polyvinyl chloride, polyvinyl acetal, polycarbonate, polyalpha-methylstyrene, polyacrylic acid, polyacrylic acid ester, polymethacrylic acid. , Polymethacrylate, polyester (polyethylene terephthalate, polybutylene terephthalate, unsaturated polyester, etc.), polyamide (nylon (registered trademark), etc.), polysulfone, polyethersulfone, polyarylate, polyphenylether, polyetheretherketone, Polyetherketone, Polyamideimide, Polyetherimide, Polyesterimide, Fluororesin (Polytetrafluoroethylene, FEP or PFA, etc.), Polyolefin, Polyvinyl Mar, polyurethane, or a copolymer of any combination of skeleton of these resins (random, block, graft, or alternating copolymer) and the like. Further, an additive that promotes the decomposition of the resin in which these inorganic powders are dispersed by heat may be added in advance to the resin in which these inorganic powders are dispersed. Resins in which the inorganic powders exemplified here are dispersed include resins that are more expensive than silicone resins, modified silicone resins, or polycarbosilanes, but can be used if the price drops in the future. is there. The “conductor” here is a copper wire, an aluminum wire, a silver wire, a nickel wire, a chromium wire, a stainless steel wire, a silver plated wire, a silver clad wire, a nickel plated copper wire, a nickel clad copper wire, or the like. The “resin containing silicon as a part of the skeleton” is a silicone resin, a modified silicone resin, polycarbosilane, or the like. The “inorganic powder” referred to here is a powder composed of silicon nitride or the like. Ceramic raw materials such as silicon nitride have excellent insulating properties and do not deteriorate at the thermal decomposition temperature of the resin in which the inorganic powder is dispersed. Here, “sintering” refers to a step of decomposing the binder of the dust core and further strengthening the core, and is usually performed at a temperature of 200 to 400 degrees Celsius.
[0007]
When this electric wire is exposed to a temperature at which the resin in which the inorganic powder is dispersed is decomposed and the decomposed product is vaporized, the inorganic powder remaining on the conductor forms a film. Moreover, since this electric wire has moderate flexibility by the resin in which the inorganic powder is dispersed, it is easy to produce a coil. For this reason, a ceramic electric wire coil can be obtained without using a relatively expensive resin such as a silicone resin, a modified silicone resin, or polycarbosilane. Therefore, it is possible to manufacture a heat-resistant insulating coil that can be applied to consumer equipment in terms of cost. Moreover, this electric wire can be manufactured using the conventional insulated wire manufacturing apparatus. For this reason, it is not necessary to introduce a new manufacturing apparatus. Therefore, the manufacturing cost can be kept low.
[0008]
Moreover, here, when this manufacturing method is implemented, the raw material powder of a powder iron core will be introduce | transduced with respect to an inorganic powder containing resin-coated electric wire coil by an introduction process. Next, in the dust core manufacturing step, the powder core of the dust core is compressed and further sintered to produce a dust core. In the dust core manufacturing process, the resin contained in the coil is thermally decomposed to generate an inorganic substance-coated insulating coil. For this reason, an insulating layer can be formed in a coil simultaneously with forming a dust core in a coil. Therefore, the iron core can be introduced into the inorganic substance-coated insulating coil without increasing the production process. In addition, if the dust core is formed on the coil in this way, the raw material powder enters into the recesses on the inner surface generated between the coil and the electric wires constituting the coil, so that the space factor of the coil conductor is improved. Can do.
[0009]
In general, an electric wire coated with an inorganic substance is poor in flexibility. For this reason, it is difficult to produce a coil by winding an electric wire coated with an inorganic substance. On the other hand, the inorganic powder-containing resin-coated electric wire has a certain degree of flexibility. Therefore, the coil can be easily manufactured. When the resin is pyrolyzed and removed after the coil is manufactured, a coil coated with an inorganic substance can be manufactured.
[0010]
  According to a second aspect of the present invention, there is provided a method for manufacturing an electrical device comprising: an inorganic powder-containing resin-coated electric wire in which a conductor is coated with a resin in which inorganic powder is dispersed (excluding a resin containing silicon as a part of its skeleton). A two-layer coated wire coil production process for producing a two-layer coated wire coil from a two-layer coated wire coated with a resin not containing powder (excluding a resin containing silicon as a part of the skeleton), and a two-layer coating Wire coilInOn the other hand, it has an introduction step of introducing the raw material powder of the dust core, and a dust core preparation step of producing a dust core by compressing and sintering the raw material powder of the dust core. In the dust core manufacturing process, the resin contained in the coil is thermally decomposed to generate an inorganic substance-coated insulated coil.The “resin in which the inorganic powder is dispersed” mentioned here is polyethylene, polypropylene, polyvinyl chloride, polyvinyl acetal, polycarbonate, polyalpha-methylstyrene, polyacrylic acid, polyacrylic acid ester, polymethacrylic acid. , Polymethacrylate, polyester (polyethylene terephthalate, polybutylene terephthalate, unsaturated polyester, etc.), polyamide (nylon (registered trademark), etc.), polysulfone, polyethersulfone, polyarylate, polyphenylether, polyetheretherketone, Polyetherketone, Polyamideimide, Polyetherimide, Polyesterimide, Fluororesin (Polytetrafluoroethylene, FEP or PFA, etc.), Polyolefin, Polyvinyl Mar, polyurethane, or a copolymer of any combination of skeleton of these resins (random, block, graft, or alternating copolymer) and the like. Further, an additive that promotes the decomposition of the resin in which these inorganic powders are dispersed by heat may be added in advance to the resin in which these inorganic powders are dispersed. Resins in which the inorganic powders exemplified here are dispersed include resins that are more expensive than silicone resins, modified silicone resins, or polycarbosilanes, but can be used if the price drops in the future. is there. The “conductor” here is a copper wire, an aluminum wire, a silver wire, a nickel wire, a chromium wire, a stainless steel wire, a silver plated wire, a silver clad wire, a nickel plated copper wire, a nickel clad copper wire, or the like. The “resin containing silicon as a part of the skeleton” is a silicone resin, a modified silicone resin, polycarbosilane, or the like. The “inorganic powder” referred to here is a powder composed of silicon nitride or the like. Ceramic raw materials such as silicon nitride have excellent insulating properties and do not deteriorate at the thermal decomposition temperature of the resin in which the inorganic powder is dispersed. Here, “sintering” refers to a step of decomposing the binder of the dust core and further strengthening the core, and is usually performed at a temperature of 200 to 400 degrees Celsius.
[0011]
When this electric wire is exposed to a temperature at which the resin in which the inorganic powder is dispersed is decomposed and the decomposed product is vaporized, the inorganic powder remaining on the conductor forms a film. Moreover, since this electric wire has moderate flexibility by the resin in which the inorganic powder is dispersed, it is easy to produce a coil. For this reason, a ceramic electric wire coil can be obtained without using a relatively expensive resin such as a silicone resin, a modified silicone resin, or polycarbosilane. Therefore, it is possible to manufacture a heat-resistant insulating coil that can be applied to consumer equipment in terms of cost. Moreover, this electric wire can be manufactured using the conventional insulated wire manufacturing apparatus. For this reason, it is not necessary to introduce a new manufacturing apparatus. Therefore, the manufacturing cost can be kept low.
[0012]
Moreover, here, when this manufacturing method is implemented, the raw material powder of a powdered iron core will be introduce | transduced with respect to a double layer covering electric wire coil by an introduction process. Next, in the dust core manufacturing step, the powder core of the dust core is compressed and further sintered to produce a dust core. In the dust core manufacturing process, the resin contained in the coil is thermally decomposed to generate an inorganic substance-coated insulating coil. For this reason, an insulating layer can be formed in a coil simultaneously with forming a dust core in a coil. Therefore, the iron core can be introduced into the inorganic substance-coated insulating coil without increasing the production process. In addition, if the dust core is formed on the coil in this way, the raw material powder enters into the recesses on the inner surface generated between the coil and the electric wires constituting the coil, so that the space factor of the coil conductor is improved. Can do.
[0013]
Moreover, a part of inorganic powder may protrude from the surface of the inorganic powder-containing resin-coated electric wire. For this reason, this electric wire often has a problem in sliding performance. This becomes a big problem when a coil is manufactured at high speed. For this reason, here, the resin-coated electric wire containing inorganic powder was further coated with a resin to ensure the sliding property of the electric wire. Therefore, the coil can be manufactured at high speed.
[0014]
In general, an electric wire coated with an inorganic substance is poor in flexibility. For this reason, it is difficult to produce a coil by winding an electric wire coated with an inorganic substance. On the other hand, the double-layer covered electric wire has a certain degree of flexibility. Therefore, the coil can be easily manufactured. When the resin is pyrolyzed and removed after the coil is manufactured, a coil coated with an inorganic substance can be manufactured.
[0015]
  According to a third aspect of the present invention, there is provided a method of manufacturing an electrical device, in which an inorganic powder-containing resin-coated electric wire in which a conductor is coated with a resin in which inorganic powder is dispersed (excluding a resin containing silicon as a part of the skeleton) is prepared. An inorganic powder-containing resin-coated electric wire preparation step, an iron-containing coil preparation step of winding an inorganic powder-containing resin-coated electric wire around an iron core to produce an iron core-containing coil, and a heat treatment step of heat-treating the iron core-containing coil, In the heat treatment step, the resin contained in the coil portion of the iron core-containing coil is thermally decomposed to generate an inorganic substance-coated insulated coil.The “resin in which the inorganic powder is dispersed” mentioned here is polyethylene, polypropylene, polyvinyl chloride, polyvinyl acetal, polycarbonate, polyalpha-methylstyrene, polyacrylic acid, polyacrylic acid ester, polymethacrylic acid. , Polymethacrylate, polyester (polyethylene terephthalate, polybutylene terephthalate, unsaturated polyester, etc.), polyamide (nylon (registered trademark), etc.), polysulfone, polyethersulfone, polyarylate, polyphenylether, polyetheretherketone, Polyetherketone, Polyamideimide, Polyetherimide, Polyesterimide, Fluororesin (Polytetrafluoroethylene, FEP or PFA, etc.), Polyolefin, Polyvinyl Mar, polyurethane, or a copolymer of any combination of skeleton of these resins (random, block, graft, or alternating copolymer) and the like. Further, an additive that promotes the decomposition of the resin in which these inorganic powders are dispersed by heat may be added in advance to the resin in which these inorganic powders are dispersed. Resins in which the inorganic powders exemplified here are dispersed include resins that are more expensive than silicone resins, modified silicone resins, or polycarbosilanes, but can be used if the price drops in the future. is there. The “conductor” here is a copper wire, an aluminum wire, a silver wire, a nickel wire, a chromium wire, a stainless steel wire, a silver plated wire, a silver clad wire, a nickel plated copper wire, a nickel clad copper wire, or the like. The “resin containing silicon as a part of the skeleton” is a silicone resin, a modified silicone resin, polycarbosilane, or the like. The “inorganic powder” referred to here is a powder composed of silicon nitride or the like. Ceramic raw materials such as silicon nitride have excellent insulating properties and do not deteriorate at the thermal decomposition temperature of the resin in which the inorganic powder is dispersed. The “heat treatment” mentioned here includes not only sintering of the iron core but also improving the magnetic properties of the iron core and generating an oxide film of the iron core. Here, the “iron core” is a laminated core, a dust core, an amorphous core, or the like.
[0016]
When this electric wire is exposed to a temperature at which the resin in which the inorganic powder is dispersed is decomposed and the decomposed product is vaporized, the inorganic powder remaining on the conductor forms a film. Moreover, since this electric wire has moderate flexibility by the resin in which the inorganic powder is dispersed, it is easy to produce a coil. For this reason, a ceramic electric wire coil can be obtained without using a relatively expensive resin such as a silicone resin, a modified silicone resin, or polycarbosilane. Therefore, it is possible to manufacture a heat-resistant insulating coil that can be applied to consumer equipment in terms of cost. Moreover, this electric wire can be manufactured using the conventional insulated wire manufacturing apparatus. For this reason, it is not necessary to introduce a new manufacturing apparatus. Therefore, the manufacturing cost can be kept low.
[0017]
Moreover, here, when this manufacturing method is implemented, in an iron core containing coil production process, an inorganic powder containing resin-coated electric wire is wound around the iron core to produce an iron core containing coil. Next, in the heat treatment step, the iron core-containing coil is heat treated. In the heat treatment step, the resin contained in the coil portion of the iron core-containing coil is thermally decomposed to generate an inorganic substance-coated insulating coil. For this reason, when an unsintered iron core is used, an insulating layer can be formed on the coil at the same time as the iron core is sintered. Therefore, an inorganic substance-coated insulated coil can be produced without increasing the production process.
[0018]
  According to a fourth aspect of the present invention, there is provided a method of manufacturing an electric device comprising: an inorganic powder-containing resin-coated wire in which a conductor is coated with a resin in which inorganic powder is dispersed (excluding a resin containing silicon as a part of the skeleton). A two-layer covered electric wire production process for producing a two-layer covered electric wire coated with a resin not containing powder (excluding a resin containing silicon as a part of the skeleton), and winding the two-layer coated electric wire around an iron core An iron-cored coil manufacturing process for manufacturing a cored coil and a heat-treatment process for heat-treating the core-cored coil, and in the heat-treatment process, the resin contained in the coil part of the core-cored coil is thermally decomposed to cover the inorganic substance An insulating coil is generated.The “resin in which the inorganic powder is dispersed” mentioned here is polyethylene, polypropylene, polyvinyl chloride, polyvinyl acetal, polycarbonate, polyalpha-methylstyrene, polyacrylic acid, polyacrylic acid ester, polymethacrylic acid. , Polymethacrylate, polyester (polyethylene terephthalate, polybutylene terephthalate, unsaturated polyester, etc.), polyamide (nylon (registered trademark), etc.), polysulfone, polyethersulfone, polyarylate, polyphenylether, polyetheretherketone, Polyetherketone, Polyamideimide, Polyetherimide, Polyesterimide, Fluororesin (Polytetrafluoroethylene, FEP or PFA, etc.), Polyolefin, Polyvinyl Mar, polyurethane, or a copolymer of any combination of skeleton of these resins (random, block, graft, or alternating copolymer) and the like. Further, an additive that promotes the decomposition of the resin in which these inorganic powders are dispersed by heat may be added in advance to the resin in which these inorganic powders are dispersed. Resins in which the inorganic powders exemplified here are dispersed include resins that are more expensive than silicone resins, modified silicone resins, or polycarbosilanes, but can be used if the price drops in the future. is there. The “conductor” here is a copper wire, an aluminum wire, a silver wire, a nickel wire, a chromium wire, a stainless steel wire, a silver plated wire, a silver clad wire, a nickel plated copper wire, a nickel clad copper wire, or the like. The “resin containing silicon as a part of the skeleton” is a silicone resin, a modified silicone resin, polycarbosilane, or the like. The “inorganic powder” referred to here is a powder composed of silicon nitride or the like. Ceramic raw materials such as silicon nitride have excellent insulating properties and do not deteriorate at the thermal decomposition temperature of the resin in which the inorganic powder is dispersed. The “heat treatment” mentioned here includes not only sintering of the iron core but also improving the magnetic properties of the iron core and generating an oxide film of the iron core. Here, the “iron core” is a laminated core, a dust core, an amorphous core, or the like.
[0019]
When this electric wire is exposed to a temperature at which the resin in which the inorganic powder is dispersed is decomposed and the decomposed product is vaporized, the inorganic powder remaining on the conductor forms a film. Moreover, since this electric wire has moderate flexibility by the resin in which the inorganic powder is dispersed, it is easy to produce a coil. For this reason, a ceramic electric wire coil can be obtained without using a relatively expensive resin such as a silicone resin, a modified silicone resin, or polycarbosilane. Therefore, it is possible to manufacture a heat-resistant insulating coil that can be applied to consumer equipment in terms of cost. Moreover, this electric wire can be manufactured using the conventional insulated wire manufacturing apparatus. For this reason, it is not necessary to introduce a new manufacturing apparatus. Therefore, the manufacturing cost can be kept low.
[0020]
Here, when this manufacturing method is carried out, in the iron core-containing coil manufacturing step, the two-layer covered electric wire is wound around the iron core to manufacture the iron core-containing coil. Next, in the heat treatment step, the iron core-containing coil is heat treated. In the heat treatment step, the resin contained in the coil portion of the iron core-containing coil is thermally decomposed to generate an inorganic substance-coated insulating coil. For this reason, when an unsintered iron core is used, an insulating layer can be formed on the coil at the same time as the iron core is sintered. Therefore, an inorganic substance-coated insulated coil can be produced without increasing the production process.
[0021]
Moreover, a part of inorganic powder may protrude from the surface of the inorganic powder-containing resin-coated electric wire. For this reason, this electric wire often has a problem in sliding performance. This becomes a big problem when a coil is manufactured at high speed. For this reason, here, the resin-coated electric wire containing inorganic powder was further coated with a resin to ensure the sliding property of the electric wire. Therefore, the coil can be manufactured at high speed.
[0022]
  A method for manufacturing an electrical device according to a fifth aspect of the present invention is the method for manufacturing an electrical device according to the third or fourth aspect of the present invention, wherein in the heat treatment step, the inorganic substance-coated insulated coil is obtained by thermal decomposition of a resin contained in the coil portion of the iron-cored coil And annealing of the iron core.As used herein, the term “electric device” is used for an electric motor that is particularly suitable for use in a high-temperature environment, such as a turbo compressor that rotates at high speed, or a hermetic compressor used in a high-pressure environment. An electric motor is mentioned.
[0023]
Here, in the heat treatment step, generation of an inorganic substance-coated insulating coil by thermal decomposition of resin contained in the coil portion of the iron core-containing coil and annealing of the iron core are performed. For this reason, the production process of electrical equipment is simplified and the productivity of electrical equipment is improved.
[0024]
  A method for manufacturing an electrical device according to a sixth aspect of the present invention is the method for manufacturing an electrical device according to any one of the first to fifth aspects, wherein the resin in which the inorganic powder is dispersed is decomposed at 400 degrees Celsius or less.It should be noted that the decomposition of the resin in which the inorganic powder is dispersed may be depolymerization, oxidative decomposition, a mixture of depolymerization and oxidative decomposition, or other decomposition. Also good.
[0025]
In general, such electric wires are often used for electric devices and the like. Depending on the electrical equipment, a process for treating a part of the electrical equipment at a temperature of about 200 degrees Celsius may be provided in the manufacturing process. For this reason, when a coil made of an electric wire coated with an inorganic substance is produced by decomposing the resin of the inorganic powder-containing resin-coated electric wire formed into a coil in such a process, a separate process for thermally decomposing the electric wire resin is provided. You can eliminate the need. If a part of the electrical device is not damaged, the same effect can be obtained even if the part of the electrical device is processed at 400 degrees Celsius in such a process. However, considering energy saving, a lower temperature is preferable.
[0026]
  The electrical device manufacturing method according to a seventh aspect of the present invention is the electrical device manufacturing method according to any one of the first to sixth aspects of the invention, wherein the inorganic powder has a scaly shape.In addition, when inorganic powder takes a scale shape, while being excellent in the dispersibility to a resin solution, it is excellent in the orientation. Examples of such inorganic powder include silicon nitride and molybdenum disulfide.
[0027]
The scale-shaped powder is likely to be layered, and therefore, it is assumed that the adhesion area between the particles is larger than that of the spherical powder, and it is easy to form a film. Therefore, a film free from defects such as pinholes can be easily formed.
[0028]
  An electrical device manufacturing method according to an eighth aspect of the present invention is the electrical device manufacturing method according to any one of the first to seventh aspects of the invention, wherein the inorganic powder contains silicon nitride as a component.
[0029]
Silicon nitride has a melting point of 2000 degrees Celsius or higher. For this reason, if a heat-resistant insulating layer mainly composed of silicon nitride can be formed, the life of the electric wire is longer than that of the electric wire coated with polyimide resin or polyamide-imide resin even under extremely severe environments. It should be. For this reason, the frequency | count of parts replacement | exchange etc. of an electric equipment can be reduced.
[0030]
  A method for manufacturing an electrical device according to a ninth aspect of the invention is the method for manufacturing an electrical device according to any one of the first to eighth aspects, wherein the average particle size of the inorganic powder is 0.01 micrometer to 1.5 micrometers. is there.In addition, the measurement of the average particle diameter of this inorganic powder was performed using "Horiba Seisakusho laser diffraction / scattering particle size distribution measuring apparatus, LA-300". The measurement was performed according to the attached manual.
[0031]
The average particle diameter of the inorganic powder has a great influence on the film formability of the inorganic powder coating, the dispersibility in the resin solution, the handling of the inorganic powder, and the like. When the average particle diameter of the inorganic powder is 0.01 to 1.5 micrometers, a good inorganic powder coating is formed. This is presumably because the adhesion area between the inorganic powders is sufficiently secured. However, when the average particle system is around 0.01 micrometer, the dispersibility in the resin solution becomes relatively poor, and the handling of the inorganic powder becomes difficult. Therefore, the average particle diameter of the inorganic powder is preferably from 0.1 to 1.5 micrometers. In this way, dispersibility in the resin solution and handling of the inorganic powder are improved.
[0032]
  A method for manufacturing an electrical device according to a tenth aspect of the present invention is the method for manufacturing an electrical device according to the second or fourth aspect of the present invention, wherein a resin that does not contain inorganic powder (excluding a resin that includes silicon as part of its skeleton) is a slippery material. Contains a sex agent.The “lubricant” mentioned here is polyolefin, fatty acid ester, wax, fluororesin fine powder or the like.
[0033]
Here, the resin contains a lubricant. For this reason, the sliding property of an electric wire can further be improved. Therefore, the coil can be manufactured at a higher speed.
[0034]
  According to an eleventh aspect of the present invention, there is provided a method for manufacturing an electric device according to the second or fourth aspect of the method for manufacturing an electric device according to the present invention, wherein the inorganic powder is dispersed (excluding a resin containing silicon as a part of the skeleton). The thermal decomposition temperature is higher than the thermal decomposition temperature of a resin not containing inorganic powder (excluding a resin containing silicon as part of its skeleton).
[0035]
Here, the thermal decomposition temperature of the resin in which the inorganic powder is dispersed is higher than the thermal decomposition temperature of the resin not including the inorganic powder. For this reason, when the electric wire is exposed to a high temperature, the outermost resin is first decomposed. Therefore, the decomposition product is quickly vaporized, and the shape of the electric wire covered with the inorganic powder can be kept good.
[0036]
DETAILED DESCRIPTION OF THE INVENTION
  [Embodiment of electric wire manufactured in this embodiment]
  In FIG. 1, the form of the electric wire produced in this Embodiment was shown. In addition, the form of the electric wire which concerns on this invention is demonstrated here with sectional drawing of an electric wire. FIG. 1A is a cross-sectional view of the inorganic powder-containing resin-coated electric wire 21. The inorganic powder-containing resin-coated electric wire 21 includes a conductor 11 and an inorganic powder-containing resin layer 12 that covers the conductor 11. FIG. 1B shows a cross-sectional view of the double-layer covered electric wire 22. The two-layer covered electric wire 22 includes a conductor 11, an inorganic powder-containing resin layer 12 that covers the conductor 11, and a resin layer 13 that further covers the inorganic powder-containing resin layer 12. The resin layer 13 may contain a lubricant. Finally, FIG. 1C shows a cross-sectional view of an insulated wire 23 constituting an inorganic substance-coated insulated coil. The insulated wire 23 includes a conductor 11 and an inorganic material insulating layer 14.
[0037]
  [Material used in this embodiment]
  (1) Conductor 11
  The conductor 11 usable in the present embodiment is a copper wire, an aluminum wire, a silver wire, a nickel wire, a chromium wire, a stainless steel wire, a silver plated wire, a silver clad copper wire, a nickel plated copper wire, a nickel clad copper wire, or the like. It is.
[0038]
  (2) Resin
  Resins that can be used in the present embodiment are polyethylene, polypropylene, polyvinyl chloride, polyvinyl acetal, polycarbonate, polyalpha-methylstyrene, polyacrylic acid, polyacrylic acid ester, polymethacrylic acid, polymethacrylic acid ester, polyester. (Polyethylene terephthalate, polybutylene terephthalate, unsaturated polyester, etc.), polyamide (nylon (registered trademark), etc.), polysulfone, polyethersulfone, polyarylate, polyphenyl ether, polyetheretherketone, polyetherketone, polyamideimide, Polyetherimide, polyesterimide, fluororesin (polytetrafluoroethylene, FEP or PFA, etc.), polyolefin, polyvinyl formal, poly Urethane, or a copolymer of any combination of skeleton of these resins (random, block, graft, or alternating copolymers). Moreover, these resins may be blended. In the present embodiment, the ash content of the resin is preferably as small as possible. Further, when the resin is coated on the conductor, the resin is preferably in the form of a solution. In addition, it is preferable that the resin solution has a viscosity and a resin concentration that are applicable to a conventional method.
[0039]
  (3) Inorganic powder
  The inorganic powder that can be used in this embodiment is a powder containing silicon nitride, silicon oxide, silicon carbide, alumina, silica, magnesia, or the like as a component. A plurality of types of powders may be mixed and used.
[0040]
  (4) Lubricant
  The lubricant that can be used in the present embodiment is polyolefin, fatty acid ester, wax, fluororesin fine powder, or the like. These lubricants may be blended. Further, these lubricants are mixed with the resin at an arbitrary ratio.
[0041]
  [Method for Manufacturing Electric Wire in this Embodiment]
  All of the electric wires 21 and 22 according to the present embodiment can be manufactured by a method (ordinary method) known to those skilled in the art. When the two-layer covered electric wire 22 is produced, the conventional method is used. In this case, the same process may be repeated twice by replacing the dip layer.
[0042]
  [Method of Manufacturing Coil in this Embodiment]
  All the coils according to the present embodiment can also be manufactured by a method (ordinary method) known to those skilled in the art.
[0043]
  [Method of Manufacturing Inorganic Material-Coated Insulated Wire 23 and Inorganic Material-Coated Insulated Coil in the Present Embodiment]
  The inorganic substance-coated insulated wire 23 or the inorganic substance-coated insulated coil according to the present embodiment includes an inorganic powder-containing resin-coated electric wire 21 or an inorganic powder-containing resin-coated coil, or a two-layer coated electric wire 22 or a two-layer coated coil. It is produced by subjecting the resin to thermal decomposition by exposing it to a temperature condition equal to or higher than the thermal decomposition temperature of the corresponding resin and vaporizing the decomposition product.
[0044]
  [Characteristics of electric wires 21, 22, 23 and coils shown in this embodiment]
  (1)
  The inorganic substance-containing resin-coated electric wire 21 according to the present embodiment can be converted into the inorganic material-coated insulated electric wire 23 without using an expensive resin such as a silicone resin, a modified silicone resin, or a polycarbosilane resin.
[0045]
  (2)
  The double-layer covered electric wire 22 according to the present embodiment can withstand the production of a coil by high-speed winding, and without using an expensive resin such as a silicone resin, a modified silicone resin, or a polycarbosilane resin. It can be converted to an inorganic material-coated insulated wire 23.
[0046]
【Example】
  Examples of the present invention will be described below. In addition, this invention is not limited to a following example.
[0047]
  (1) Preparation of silicon nitride powder-dispersed polyurethane resin solution
  After 40 parts of silicon nitride powder was added to 100 parts of polyurethane resin paint (resin concentration 20%), the silicon nitride powder was dispersed in the polyurethane resin paint by stirring with a stirrer. The average particle size of the silicon nitride powder used here was 0.75 micrometers.
[0048]
  (2) Silicon nitride powder-containing polyurethane resin-coated wires
  A polyurethane resin paint in which silicon nitride powder was dispersed was applied to the conductor 11 by a conventional method and then baked to produce a silicon nitride powder-containing polyurethane resin-coated electric wire. The conductor 11 was a nickel-plated copper wire having a diameter of 0.5 mm. The outer diameter of the produced silicon nitride powder-containing polyurethane resin-coated electric wire was 0.535 mm. The thickness of the silicon nitride powder-containing polyurethane resin layer was 0.0175 mm.
[0049]
  (3) Preparation of self-lubricating polyurethane resin paint
  3 parts of wax was added to 100 parts of polyurethane resin paint (resin concentration: 20%), and then stirred with a stirrer to dissolve the wax in the polyurethane resin paint.
[0050]
  (4) Preparation of self-lubricating double-layer covered electric wire
  A polyurethane resin paint with a wax added was applied to a polyurethane resin-coated electric wire containing silicon nitride powder by a conventional method, and then fired to prepare a two-layer coated electric wire.
[0051]
  (5) Production of silicon nitride-coated insulated wires
  The silicon nitride powder-containing polyurethane resin-coated electric wire was left in an oven at 400 degrees Celsius for a predetermined time. As a result, the polyurethane resin was thermally decomposed, the decomposed product was vaporized, and an insulating layer made of silicon nitride was formed on the conductor 11. Similar results were obtained when a two-layer covered electric wire was used.
[0052]
  (6) Production of silicon nitride-coated insulated coil
  After winding the silicon nitride powder-containing polyurethane resin-coated electric wire in a coil shape, it was left in an oven at 400 degrees Celsius for a predetermined time with the coil shape maintained. As a result, the polyurethane resin was thermally decomposed, the decomposed product was vaporized, and a coil having an insulating layer made of silicon nitride was obtained. In addition, when the double-layer covered electric wire was used, the coil could be manufactured at high speed. Further, even when the two-layer covered electric wire was treated in the same manner as described above, a coil having an insulating layer made of silicon nitride was obtained.
[0053]
【The invention's effect】
According to the method for manufacturing an electrical device of the present invention, the manufacturing cost can be kept low.
[Brief description of the drawings]
FIG. 1 is a sectional view of (a) an inorganic powder-containing resin-coated electric wire 21, (b) a two-layer coated electric wire 22, and (c) an inorganic substance-coated insulated electric wire 23 constituting an inorganic substance-coated insulated coil according to the present invention.
[Explanation of symbols]
11 Conductor
12 Inorganic powder-containing resin layer
13 Resin layer
14 Inorganic material insulation layer
21 Resin-coated wires containing inorganic powder
22 Double-layer covered wire
23 Insulated wire covered with inorganic material constituting an insulated coil covered with inorganic material

Claims (11)

Inorganic powder-containing resin coating from an inorganic powder-containing resin-coated electric wire in which the conductor (11) is coated with a resin (excluding a resin containing silicon as a part of the skeleton) (12) in which the inorganic powder is dispersed An inorganic powder-containing resin-coated wire coil manufacturing step for manufacturing the wire coil (21);
An introduction step of introducing a raw material powder of a powdered iron core into the inorganic powder-containing resin-coated electric wire coil (21);
Compressing the raw powder of the powdered iron core and further sintering it to produce a powdered iron core,
With
In the dust core manufacturing process, an inorganic substance-coated insulating coil is generated by thermally decomposing the resin contained in the coil.
Manufacturing method of electrical equipment. Inorganic powder-containing resin-coated electric wires in which the conductor (11) is coated with a resin (excluding a resin containing silicon as a part of the skeleton) (12) in which inorganic powder is dispersed do not contain inorganic powder. A two-layer covered electric wire coil production step of producing a two-layer coated electric wire coil (22) from a two-layer coated electric wire coated with a resin (excluding a resin containing silicon as a part of the skeleton) (13);
An introduction step of introducing a raw material powder of a powdered iron core into the two-layer coated electric wire coil (22);
Compressing the raw powder of the powdered iron core and further sintering it to produce a powdered iron core,
With
In the dust core manufacturing process, an inorganic substance-coated insulating coil is generated by thermally decomposing the resin contained in the coil.
Manufacturing method of electrical equipment. Inorganic powder for producing an inorganic powder-containing resin-coated electric wire (21) in which a conductor (11) is coated with a resin (excluding a resin containing silicon as a part of its skeleton) (12) in which inorganic powder is dispersed Body-containing resin-coated electric wire production process;
An iron core-containing coil manufacturing step of winding the inorganic powder-containing resin-coated electric wire (21) around an iron core to manufacture an iron core-containing coil;
A heat treatment step for heat-treating the iron-cored coil;
With
In the heat treatment step, an inorganic substance-coated insulating coil is generated by thermally decomposing a resin contained in the coil portion of the iron core-containing coil.
Manufacturing method of electrical equipment. An inorganic powder-containing resin-coated wire (21) in which the conductor (11) is coated with a resin (excluding a resin containing silicon as a part of its skeleton) (12) in which the inorganic powder is dispersed is an inorganic powder. A two-layer covered electric wire production step of producing a two-layer covered electric wire (22) covered with a resin (excluding a resin containing silicon as a part of the skeleton) (13),
An iron core-containing coil manufacturing step of winding the two-layer coated electric wire (22) around an iron core to manufacture an iron core-containing coil;
A heat treatment step for heat-treating the iron-cored coil;
With
In the heat treatment step, an inorganic substance-coated insulating coil is generated by thermally decomposing a resin contained in the coil portion of the iron core-containing coil.
Manufacturing method of electrical equipment. In the heat treatment step, an inorganic substance-coated insulating coil is generated by thermal decomposition of a resin contained in a coil portion of the iron core-containing coil, and the iron core is annealed.
The manufacturing method of the electric equipment of Claim 3 or 4. The resin in which the inorganic powder is dispersed decomposes at 400 degrees Celsius or less.
The manufacturing method of the electric equipment of any one of Claim 1 to 5. The shape of the inorganic powder is a scale shape,
The manufacturing method of the electric equipment of any one of Claim 1 to 6. The inorganic powder contains silicon nitride as a component,
The manufacturing method of the electric equipment of any one of Claim 1 to 7. The average particle size of the inorganic powder is 0.01 micrometer to 1.5 micrometers.
The manufacturing method of the electric equipment of any one of Claim 1 to 8. The resin containing no inorganic powder (excluding a resin containing silicon as a part of the skeleton) (13) contains a lubricant.
The manufacturing method of the electric equipment of Claim 2 or 4. The thermal decomposition temperature of the resin in which the inorganic powder is dispersed (excluding a resin containing silicon as a part of the skeleton) (12) is a resin not containing the inorganic powder (including silicon as a part of the skeleton). Excluding resin) higher than the thermal decomposition temperature of (13),
The manufacturing method of the electric equipment of Claim 2 or 4.

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