COIL WIRE, CURRENT SENSOR COMPONENT, AND CURRENT SENSOR

• US 20200132730A1
• Filed: 09/13/2019
• Published: 04/30/2020
• Est. Priority Date: 10/26/2018
• Status: Active Grant

• Current Assignee: Sumida Corporation
• Original Assignee: Sumida Corporation
• Inventors: HASHIMOTO, Masateru, SAITO, Masaki
• Granted Patent: US 11,506,690 B2
• Time in Patent Office: Days
• CPC Class Codes: G01R 15/181 using coils without a magnetic core, e.g. Rogowski coils
• CPC Class Codes: G01R 15/183 using transformers with a magnetic core
• CPC Class Codes: G01R 19/0092 measuring current only all subgroups of G01R19/00 take precedence
• CPC Class Codes: H01F 27/06 Mounting, supporting or suspending transformers, reactors or choke coils not being of the signal type
• CPC Class Codes: H01F 27/25 made from strips or ribbons H01F27/26 takes precedence
• CPC Class Codes: H01F 27/2823 Wires H01F27/2866 takes precedence
• CPC Class Codes: H01F 27/29 Terminals; Tapping arrangements for signal inductances
• CPC Class Codes: H01F 27/325 Coil bobbins formers for coils in general H01F5/02
• CPC Class Codes: H01F 38/30 Constructions
• CPC Class Codes: H01F 5/02 wound on non-magnetic supports, e.g. formers
• CPC Class Codes: H01F 5/06 Insulation of windings

Abstract

A coil wire includes a core wire and a winding wire. The winding wire is wound around a circumference of the core wire so as to form a plurality of spirals. The coil wire satisfies one of: (i) an outer surface of the core wire is exposed, and a distance between the outer surface of the core wire and an inner circumferential surface of part of the winding wire is smaller than a thickness of a first insulating film coated on the winding wire; or (ii) the outer surface of the core wire is coated by a second insulating film, and a distance between an outer surface of the second insulating film and the inner circumferential surface of part of the winding wire is smaller than a thickness of a thicker one of the first insulating film and the second insulating film.

Claims

1. A coil wire comprising:

a core wire having flexibility and conductivity; and

a winding wire configured with a conductive wire and a first insulating film that entirely coats the conductive wire,

wherein a first end of the core wire is electrically connected to a first end of the winding wire, the winding wire is wound around a circumference of the core wire so as to form a plurality of spirals, and the core wire is a common central axis of the plurality of spirals, and

the coil wire satisfies one of a condition (i) or a condition (ii);

(i) an outer surface of the core wire is exposed, and a shortest distance between the outer surface of the core wire and an inner circumferential surface of at least part of the plurality of spirals of the winding wire is smaller than a thickness of the first insulating film;

or

(ii) the outer surface of the core wire is coated by a second insulating film, and a shortest distance between an outer surface of the second insulating film and the inner circumferential surface of at least part of the plurality of spirals of the winding wire is smaller than a thickness of a thicker one of the first insulating film and the second insulating film.

2. The coil wire according to claim 1,

wherein, when the outer surface of the core wire is exposed, at least part of the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts the outer surface of the core wire, and

when the second insulating film coats the outer surface of the core wire, at least part of the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts the outer surface of the second insulating film.

3. The coil wire according to claim 1,

wherein, when the outer surface of the core wire is exposed, the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts an entirety of a perimeter of the outer surface of the core wire, and

when the second insulating film coats the outer surface of the core wire, the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts an entirety of a perimeter of the outer surface of the second insulating film.

4. The coil wire according to claim 1,

wherein two adjacent conductive wires forming two adjacent spirals of the plurality of spirals directly contact each other at part of the winding wire.

5. The coil wire according to claim 2,

wherein two adjacent conductive wires forming two adjacent spirals of the plurality of spirals directly contact each other at part of the winding wire.

6. The coil wire according to claim 3,

wherein two adjacent conductive wires forming two adjacent spirals of the plurality of spirals directly contact each other at part of the winding wire.

7. A current sensor component comprising:

a bobbin having a cylindrical member;

a coil wire, the coil wire being wound around a center axis of the cylindrical member of the bobbin several times, the coil wire having;

a core wire having flexibility and conductivity; and

a winding wire configured with a conductive wire and a first insulating film that coats the conductive wire;

a first lead wire connected to a first end of the core wire and a first end of the winding wire; and

a second lead wire connected to a second end of the core wire and a second end of the winding wire,

wherein the winding wire is wound around a circumference of the core wire so as to form a plurality of spirals, and the core wire is a common central axis of the plurality of spirals, and

the coil wire satisfies one of a condition (i) or a condition (ii);

(i) an outer surface of the core wire is exposed, and a shortest distance between the outer surface of the core wire and an inner circumferential surface of at least part of the plurality of spirals of the winding wire is smaller than a thickness of the first insulating film;

or

(ii) the outer surface of the core wire is coated by a second insulating film, and a shortest distance between an outer surface of the second insulating film and the inner circumferential surface of at least part of the plurality of spirals of the winding wire is smaller than a thickness of a thicker one of the first insulating film and the second insulating film.

8. The current sensor component according to claim 7,

wherein, when the outer surface of the core wire is exposed, at least part of the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts the outer surface of the core wire, and

when the second insulating film coats the outer surface of the core wire, at least part of the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts the outer surface of the second insulating film.

9. The current sensor component according to claim 7,

wherein, when the outer surface of the core wire is exposed, the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts an entirety of a perimeter of the outer surface of the core wire, and

when the second insulating film coats the outer surface of the core wire, the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts an entirety of a perimeter of the outer surface of the second insulating film.

10. The current sensor component according to claim 7,

wherein two adjacent conductive wires forming two adjacent spirals of the plurality of spirals directly contact each other at part of the winding wire.

11. A current sensor component comprising:

an elongated conductor member having terminals at both ends; and

a coil wire wound around the conductor member, the coil wire having;

a core wire having flexibility and conductivity; and

a winding wire configured with a conductive wire and a first insulating film that entirely coats the conductive wire,

wherein a first end of the core wire is electrically connected to a first end of the winding wire, the winding wire is wound around a circumference of the core wire so as to form a plurality of spirals, and the core wire is a common central axis of the plurality of spirals, and

the coil wire satisfies one of a condition (i) or a condition (ii);

(i) an outer surface of the core wire is exposed, and a shortest distance between the outer surface of the core wire and an inner circumferential surface of at least part of the plurality of spirals of the winding wire is smaller than a thickness of the first insulating film;

or

(ii) the outer surface of the core wire is coated by a second insulating film, and a shortest distance between an outer surface of the second insulating film and the inner circumferential surface of at least part of the plurality of spirals of the winding wire is smaller than a thickness of a thicker one of the first insulating film and the second insulating film.

12. The current sensor component according to claim 11, further comprising:

a bobbin having a cylindrical member that is assembled to an outer circumference of the elongated conductor member,

wherein the coil wire is wound around the cylindrical member of the bobbin.

13. The current sensor component according to claim 11,

wherein, when the outer surface of the core wire is exposed, at least part of the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts the outer surface of the core wire, and

when the second insulating film coats the outer surface of the core wire, at least part of the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts the outer surface of the second insulating film.

14. The current sensor component according to claim 11,

wherein, when the outer surface of the core wire is exposed, the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts an entirety of a perimeter of the outer surface of the core wire, and

when the second insulating film coats the outer surface of the core wire, the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts an entirety of a perimeter of the outer surface of the second insulating film.

15. The current sensor component according to claim 11,

wherein two adjacent conductive wires forming two adjacent spirals of the plurality of spirals directly contact each other at part of the winding wire.

16. A current sensor comprising:

a coil wire, the coil wire having;

a core wire having flexibility and conductivity; and

a winding wire configured with a conductive wire and a first insulating film that entirely coats the conductive wire; and

a detector connected between a first end of the core wire and a first end of the winding wire so as to detect an electric signal,

wherein a second end of the core wire is electrically connected to a second end of the winding wire, the winding wire is wound around a circumference of the core wire so as to form a plurality of spirals, and the core wire is a common central axis of the plurality of spirals, and

the coil wire satisfies one of a condition (i) or a condition (ii);

(i) an outer surface of the core wire is exposed, and a shortest distance between the outer surface of the core wire and an inner circumferential surface of at least part of the plurality of spirals of the winding wire is smaller than a thickness of the first insulating film;

or

(ii) the outer surface of the core wire is coated by a second insulating film, and a shortest distance between an outer surface of the second insulating film and the inner circumferential surface of at least part of the plurality of spirals of the winding wire is smaller than a thickness of a thicker one of the first insulating film and the second insulating film, and

the detector is configured to detect the electric signal corresponding to an electric current flowing through a coil wire spiral, and the coil wire spiral is formed by spiraling the coil wire.

17. The current sensor according to claim 16,

wherein, when the outer surface of the core wire is exposed, at least part of the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts the outer surface of the core wire, and

when the second insulating film coats the outer surface of the core wire, at least part of the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts the outer surface of the second insulating film.

18. The current sensor according to claim 16,

wherein, when the outer surface of the core wire is exposed, the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts an entirety of a perimeter of the outer surface of the core wire, and

when the second insulating film coats the outer surface of the core wire, the inner circumferential surface of at least part of the plurality of spirals of the winding wire contacts an entirety of a perimeter of the outer surface of the second insulating film.

19. The current sensor according to claim 16,

wherein two adjacent conductive wires forming two adjacent spirals of the plurality of spirals directly contact each other at part of the winding wire.