Instruction and Expertise for Usage of TEX-E

The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
Technical Brochure No. 5749
Issued: May 5, 1997
Revised: Oct 6, 2003
Instruction and Expertise for Usage of TEX-E
This is a technical brochure describing instructions and expertise for usage of TEX-E.
It should be noted that this brochure does not contain specifications for TEX-E, nor does its
description guarantee the performance of TEX-E. The optimum using conditions for TEX-E
changes, application by application, depending on the users' process design and processing
conditions. Users are requested to make the best use of TEX-E, referring to this brochure.
Contents
1. Storage
P.1
2. Service Environment
P.2
3. Winding Method
P.2
3.1 Winding Tension
P.3
3.2 Instructions for Winding
P.3
4. Soldering
P.3
4.1 Soldering Mechanism of TEX-E
P.3
4.2. Use of Still-Solder Bath
P.4
4.3 Use of Flow-Solder Bath with Cooling Air Blow
P.5
4.4 Hint on Bobbin Shape
P.7
4.5 Removal of Insulation on the Conductor
P.7
4.6 Other Instructions for Soldering
P.9
Appendix A Manufacturing tips against physical stresses
P.11
1. Storage
TEX-E should be stored avoiding high humidity, high temperature, sunshine, and dust.
Check before use its withstand voltage, break-down voltage, flexibility, if its storage exceeds
the time limit. The following storage conditions are recommended:
Temperature : -25 up to 45
Humidity : 5 up to 75%
Storage Term : 1 year after shipment
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
2. Service Environment
The performance of TEX-E may be degraded by adverse design of its application, severe
processing conditions, or harsh service environment of the product. The following service
environment, in particular, may hostility affect the performance of TEX-E, so that its
adaptability should be confirmed beforehand:
(1) Alkaline atmosphere
(2) Hermetic condition with high temperature, high humidity and high pressure
It must avoid to use TEX-E in the condition which are together with above each factors.
(3) Varnish impregnation
(4) Detergent
When TEX-E is used under a working voltage exceeding its partial discharge inception
voltage, its insulation is attacked by partial discharge. In this case, the product employing
TEX-E should be provided additional insulation between primary and secondary coil.
The partial discharge inception voltage of twist pair, TEX-E and TEX-E/2-UEW is as follows:
At power frequency 50Hz, at room temperature,
TEX-E / TEX-E : approximately 1.4kVp
TEX-E / 2-UEW : approximately 1.0kVp
3. Winding Method
The insulation layers of TEX-E are prepared to function appropriately as reinforced
insulation stipulated by safety regulations. If the surface layers are excessively deformed or
damaged by external stresses, the insulation deteriorates and its function as reinforced
insulation may no longer satisfy the requirements stipulated by safety regulations. Thus,
excessive external stresses on the insulation layer, whether they are mechanical or thermal,
should be avoided as far as possible.
Figure 1 Recommended winding tension vs. wire size for TEX-E
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
3.1 Winding Tension
Recommended winding tension for TEX-E is, as shown in Figure 1, 58.8MPa (6kg/
) or
less.
3.2 Instructions for Winding
When improperly maintained, the following is likely to cause damage on the insulation of
TEX-E, so that they should be carefully checked to be in good conditions.
(1) Wire guide nozzle of winding machine: The inner diameter of the wire guide nozzle
should be 2 to 3 times of the outer diameter of TEX-E, and its exit end corner should be
rounded as large and as smooth as possible.
(2) Wire guide and guide pulley of winding machine: The guides should have smooth
surfaces, and should be properly maintained to be free from damage, wear, or stiff rotation.
(3) Bobbin: The bobbins should have no burrs on the inside and on the flanges. The square
barrel bobbin corner where TEX-E touches should have an appropriately large radius of
curvature.
(4) End of wire: The ends of wire, because they are unexpectedly sharp, should be kept
away from the insulation layer of TEX-E to avoid the damage.
Appendix A shows manufacturing tips against physical stresses.
4. Soldering
TEX-E can be soldered without removing its insulation layers. However, because the layers
are made of thermo-plastic resins, its insulation performance may be degraded, if proper
care is not taken, when the layer of the portion just above the solder bath deform by the heat
emitted by the solder. A soldering bath is suited to solder TEX-E, while it is difficult to solder
the wire using a soldering iron. Although the melting temperature for the insulation resin is
260-280
, the temperature for the soldering bath should be 420
or higher, in order to
solder within a short time avoiding the melt-up of the insulation layer. Below is given the
soldering mechanism of TEX-E and the method to suppress the melt-up of insulation layer.
4.1 Soldering Mechanism of TEX-E
Because TEX-E is quite different from such enameled wires as polyurethane wires (UEW) in
its materials, construction, and manufacturing process, its soldering mechanism is also
different from that of those wires as described below.
UEW:
When heated by the solder, the polyurethane layer dissolves and the wire is
soldered.
TEX-E:
The insulation layers of TEX-E will not dissolve when heated under regular
soldering conditions of temperature and time. Instead, the resin melts and floats
off due to difference specific gravity, resin and solder to admit the solder invasion
between melted resin and conductor, and the wire is soldered. Because the
layers do not dissolve, the melted resin tends to stay at the base of terminal pins.
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
Size effects are found in the soldering of TEX-E. The soldering conditions are roughly
summarized as follows; they can not be specified uniformly because they change depending
on the shape of transformer with different heat capacity and heat emission.Less than 0.4mm
in diameter: A high temperature solder (420
or higher) is recommended to solder in a
relatively short time. Conventional still-solder baths can be used to effect a soldering with
reasonably small insulation layer melt-ups, when the soldering condition is controlled to
around 420
for 3sec. Other additional means as described in Sections 4.2 or 4.6 works
effectively in many cases.
0.4mm or more in diameter: A high-temperature/long-time soldering is necessary, so that
some preventive means as described in Section 4.3 and following is required to suppress
large melt-ups. In this connection, the variation of the color of insulation layer compared with
the normal portion may be useful in telling whether the layer has suffered an excessive heat
or not. The resin does not deteriorate under normal soldering condition, but the change of
layer thickness due to the thermal deformation induces irregular diffraction to give dissimilar
colors.
4.2 Use of Still-Solder Bath
Expertise for using still-solder baths which are usually employed in soldering transformer
bobbins will be presented here. This soldering method works well for the wires less than
0.4mm in diameter.
(1) Swift motion or shaking of bobbin in the bath
Horizontal swift motion or shaking of bobbins in the bath is often effective in shortening the
soldering time, suppressing melt-up, and in reducing adhesion of melted resin to the bobbin.
(Figure 2)
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
(2) Repeated soldering
Because the melt-up is caused by dipping the bobbins in the bath for a long time, it can be
suppressed by repeated soldering, whereby the dipping with a short time is repeated a few
times, that is two or three times. The time of dipping has to be confirmed beforehand not to
cause melt-ups; and the time of interruption of soldering, in which the bobbins are kept out
of the bath, should be such that the portion of bobbin which was in the bath still keeps the
after-heat, while which was not becomes cool enough.
4.3 Use of Flow-Solder Bath with Cooling Air Blow
Figure 3 and Photo 1 show the schematic diagram and appearance of the flow-solder bath
with cooling air blow, respectively. Using this apparatus, three to four bobbins are soldered
together. The soldering method with this apparatus has the following advantages. To add a
few hints, the cool air blow may be alternatively replaced by other means such as a metal
heat sink which fits the bobbin flange.
Figure 3 Schematics of flow solder bath cooling air blow
Photo 1 External view of flow solder bath with cooling air blow
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
(1) This method suppresses effectively the melt-up of insulation layer, by blowing cool air
onto the wire in the lead-out groove of the bobbin flanges, thereby cooling the wire.
(2) The flow-solder bath steadily supplies fresh solder of high temperature, so that soldering
is carried out in a relatively short time, taking advantage of its efficient heat conduction over
still-solder baths.
(3) The flow-solder bath has a cleaning effect by washing away the melted resins, so that an
excellent appearance of soldering can be obtained.
(4) This method may also be applied to other manufacturing processes of troublesome
products like conventional transformers where the insulation tape tends to melt easily.
Furukawa Electric has invented this method and has already applied for its patent, but
Furukawa is ready to grant the users of TEX-E its royalty-free use. If you are interested in
the purchase of the apparatus, contact the following for further information:
JAPAN UNIX CO.,LTD.
Head Office
Tel:+81-(0)3-3588-0551
Fax:+81-(0)3-3588-0554
21-25, Akasaka 2-Chome, Minato-ku, Tokyo 107-0052, Japan.
E-Mail: jpunixin@muc.biglobe.ne.jp
When soldering in flow-solder bath and still-solder bath, the oxides are generated on the
surface of molten solder. These oxides, once generated, must be removed to prevent the
defective soldering. Anti-oxidizing agent (called "SANTOP" and "TOSCUT") are very
effective to attain the anti-oxidizing of molten solder, the elimination of soldering defects and
the prevention of discoloration caused by oxidization under the high temperature and long
storage after soldering. "SUNTOP" and "TOSCUT" are the metal tablets for anti-oxidizing of
molten general Sn-Pb solder and molten Pb-free solder, respectively. If you are interested in
the anti-oxidization, please contact the following for further information:
MEIWA CHEMICAL IND., LTD
Head Office
Tel:+81-(0)3-3451-2429
Fax:+81-(0)3-3452-3708
Itagarasu-Kaikan Bldg. 2F,
3-6-7, Shibaura, Minato-ku, Tokyo 108-0023, Japan.
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
4.4 Hints on Bobbin Shape
For mass production, it is recommended to use a bobbin exclusively designed for TEX-E so
as to make the control of soldering much easier. The exclusive bobbin for TEX-E takes into
consideration in its shape design, the marginal length for soldering (Lm) which is the melt-up
length of insulation layer expected at soldering, in addition to the creepage distance
required by safety regulations, as shown in Figure 4. Moreover, when the flow-solder bath
with cooling air blow is employed, a bobbin with grooves on its flange will work effectively.
If you are interested in the purchase of the apparatus, please contact the following for
further information:
TOWA KAGAKU CO.,LTD.
Mr. MINORU TAKANO : Maneger Sales Dept.
Tel:+81-(0)3-3775-2351
Fax:+81-(0)3-3775-2355
6-4-2, Nishiohi Shinagawa-Ku, Tokyo 140, Japan
TAMAGAWA ELECTRIC CO., LTD.
Mr. RYOICHI SUZUKI : Executive Director
Tel:+81-(0)423-77-6670
Fax:+81-(0)423-78-2756
1289-6, Momura, Inagi-City, Tokyo 206, Japan
4.5 Removal of Insulation
Study removal of insulation layer before soldering in the following cases.
(1) The marginal length for melt-up is not allowed for in the transformer design.
(2) The melt-up of insulation layer is not suppressed enough.
(3) Manual removal of insulation is preferred as pre-treatment of wire.
(4) Diversified small-quantity production prohibits new facilities or exclusive bobbins.
For removal of insulation layer, the undermentioned tool is suited which is based on a
thermal and mechanical mechanism of insulation removal. It basically melts and removes
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
the insulation, so that it does not damage the surface of conductor. Even when small
quantities of insulation remain after removal, high temperature soldering may be used
successfully leading to a small melt-up with good appearance within a short soldering time.
When it is possible to remove the insulation layer completely, low temperature soldering at
about 260
may also be used to have a small melt-up.
Conventional wire strippers based on a mechanical mechanism of insulation removal may
seriously damage TEX-E, because the wire is designed to have a strong adhesion between
conductor and insulation to make it suitable for coil winding. Moreover, since material and
construction of TEX-E insulation are quite different from those of conventional enameled
wires, suitable chemical removers are not available yet.
One of the removers shown in photo 2 is the type of stripping mono wire. The other shown in
photo 3 is the type of stripping multiple wires. These two type of removers are having the
excellent characteristics to each.
Photo 2. Example of wire strippers for TEX-E, HOTWEEZERS(R)
Photo 3. Example of multiple type wire strippers for TEX-E, WAKOH WS-3
Further information on HOTWEEZERS(R) shown in Photo 2 and WAKOH WS-3 shown in
Photo 3 are available from the following sales agent.
ANZEN TRADING CO.,LTD.
Tel:+81-(0)3-3584-4277
Fax:+81-(0)3-3585-4417
Akasaka Pioneer Bldg., No.22-17, Akasaka
2-Chome, Minato-ku, Tokyo 107-0052, Japan
E-Mail: anzen@hkr.jrnet.ne.jp
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
4.6 Other Instructions for Soldering
In addition to the above mentioned information, the following knack may help soldering in
reducing the soldering time and in suppressing the melt-ups.
(1) The end surface of pin winding wire where the conductor of TEX-E is exposed should
show up. Refer to Figure 5, (a), (b), and (c).
(2) Wind only one wire onto a single pin.
(3) The winding pitch on the pin should be loose.
(4) In any case, square pin having sharp edges is better than round pin.
With TEX-E, soldering is done as the resin melts and solder enters the opening between
melted resin and wire conductor. The following pretreatment will work to ease the entering of
solder between melted resin and wire conductor, so that the soldering time is reduced and
the melt-up is suppressed.
(1) Scratch the insulation layer down to the surface of conductor and enlarge the bare
portion of conductor. (Figure6)
(2) Loosen the wrapping pitch of wire onto the pin.
(3) Use flux, that is, surface-active agent.
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
Another method to suppress melt-ups is to increase the heat conduction from the wire to the
bobbin, by optimizing the contact of wire onto the flange of bobbin, or by changing the
configuration of lead wire. (Figure 7)
Note) The details of this technical brochure are subject to change without notice. It should
be noted that this technical brochure does not contain specifications for goods, nor does its
description guarantee the performance of goods.
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
Appendix A : Manufacturing tips against physical stresses
1, Sharpened edges
1.1 Bobbin
In the case where TEX-E is wound on a bobbin with sharpened edges such as flanges and
body part, it has a possibility that wire is damaged. With adopting a rounded bobbin and
controlling winding tension as low as possible, the wire can be improved. Please refer to ‘‘3.
Winding Method’’.
It is easy to find a damaged point against the sharpened edge of the flange part in the
following photographs through No.1 from No.3.
Turned around
90 degree
Photo. 1
Photo. 2
Photo.3
1.2 Sharpened tools
Tools such as a tweezers or a knife are not recommendable since they can make TEX-E
damaged. Some operators tend to use them for sequent winding.
Photo. 4
Photo. 5
1.3 Nails
In some case, nails can cause a physical damage to TEX-E. Excess stresses to the wire
shown in Photo.6 are not ideal. It is better to use a rubber safe or glove, and also care the
nails of operators.
Photo. 6
Photo. 7
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
1.4 Physical stress when bending a wire
Using tools or fingers covered by soft material such as rubber are better to avoid physical
stresses when bending the wire. Tweezers or a knife is not recommendable.
Photo. 8
2. Excess tension
Photo. 9
3. Re-winding
Photo. 10
Photo. 11
Avoiding excess tension or a re-winding process is able to reduce physical damage to the
wire
4. Special covers
The following cover shown in Photo 12 and Photo 13 is one of tools reducing the physical
damages to the wire when supplying it to transformers
Photo. 12
Photo. 13
Note) The details of this technical brochure are subject to change without notice. It should
be noted that this technical brochure does not contain specifications for goods, nor does its
description guarantee the performance of goods.
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
Appendix B: Technical tips when soldering TEX-E
The following is a baseline how to solder the wire to transformers.
Is TEX-E adopted in your
transformer
equal
or
more than 0.4mm?
No
Yes
Are dual or more wires wound
Is your bobbin improved against
at a single pin such as the
insulation melting of the wire,
above picture?
shown as the above picture?
No
Yes
No
Yes
Direct soldering is
recommendable.
See Advice No.1
Insulation
removing or some
approaches
is
necessary.
See Advice No2.
Insulation
removing or some
approaches
is
necessary.
See Advice No. 2.
Direct soldering is
recommendable.
See Advice No.1
Reference:
Photo.1 and 4
Reference:
Photo 8 and 10
Reference:
Photo 7 and 9
Reference:
Item 4.4 (P. 7)
Counter
reference at the
same soldering
condition:
Photo 3 and 6
Counter
reference at the
same soldering
condition:
Photo 2 and 5
Advice 1
Advice 2
- Insulation removing (See Item 4.5)
- Soldering conditions controlled at higher
- Soldering conditions controlled at higher
temp. and in a shorter period of time
temp. and in a shorter period of time.
Target: 420-450 degC and less than four
Target: 420-450 degC and less than two
seconds
seconds
- Flux
- Flux
- Multi-times soldering (See Item 4.2)
- Multi-times soldering (See Item 4.2)
- Pre-heating for transformers
- Pre-heating for transformers
- Improvement of winding method
- Improvement of winding method
(See Item 4.6 Fig.7)
(See Item 4.6 Fig.7)
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The Furukawa Electric Co., Ltd
Magnet Wire Division
Technical Dept.
Photo.1
Photo.4
Photo.2
Photo.3
Photo.5
Photo.6
No insulation removing
No insulation removing
TEX-E 0.2mm
TEX-E 0.7mm
450 degC for 0.8s
450 degC for 2s
No insulation removing
TEX-E0.2mm Dual winding
450 degC for 2s
Example of Insulation removing
Photo.7
Photo.8
1. Rubbing the insulation against
the heater plate
Photo.9
Photo.10
Insulation removing
Insulation removing
2. Pulling out the transformer
TEX-E 0.7mm
TEX-E0.2mm Dual winding
after heating the wire
450 degC for 2s
450 degC for 2s
Note) The details of this technical brochure are subject to change without notice. It should be
noted that this technical brochure does not contain specifications for goods, nor does its
description guarantee the performance of goods.
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