Composite insulation layer electromagnetic wire and manufacturing method thereof

Abstract

The invention discloses a composite insulating layer electromagnetic wire, which comprises a conductor, a first polyamide-imide insulating layer, a nano inorganic insulating layer and a second polyamide-imide insulating layer which are arranged in sequence from the inside to the outside, wherein the thickness ratio of the first polyamide-imide insulating layer, the nano inorganic insulating layer and the second polyamide-imide insulating layer is 3:4:3; the composite insulating layer electromagnetic wire of the invention can improve the withstand voltage level of the electromagnetic wire, reduce the voltage loss of the insulating layer, and has the advantages of good flexibility, high slot fill rate and good heat dissipation; the invention also discloses a method for making the composite insulating layer electromagnetic wire, wherein the latter two calendering processes can correct and supplement the former two calendering processes, and the deformation rate is controlled within 5‰ to 32‰, thereby effectively avoiding the "rib separation" phenomenon occurring during the calendering process, ensuring the ductility of the electromagnetic wire itself, and eliminating the need for subsequent secondary annealing to soften the electromagnetic wire, thereby improving the overall performance of the electromagnetic wire.

Description

Technical Field

[0001] The invention belongs to the technical field of electromagnetic wires, and in particular relates to a composite insulating layer electromagnetic wire and a manufacturing method thereof. Background Art

[0002] The existing technology of electromagnetic wire is to produce high temperature resistant electromagnetic wire by processing metal materials (copper, aluminum, copper clad aluminum), and through processes such as drawing, etc., and then through enameling equipment; however, the existing technology for producing high temperature electromagnetic wire has certain limitations, and the temperature resistance level of its organic insulating layer can generally only reach 220 levels, and can reach 240 levels at most. The structural characteristics of its organic polymer material itself determine that the temperature resistance level can only reach 240 levels, and under the temperature condition of 240°C, when the electrical and electrical products are operated for more than 5000 hours, the organic polymer material begins to thermoplastically flow, age, and finally carbonize and fail, and under the condition of a certain thickness of the insulating layer, the insulation strength level can only reach 10-15KV; at the same time, under the conditions of high temperature, high frequency, and high voltage, the voltage loss of the organic insulating layer reaches 50-60%, and the quality of the insulating layer is poor, which does not meet the use requirements. Summary of the invention

[0003] The technical problem to be solved by the present invention is to provide a composite insulating layer electromagnetic wire and a manufacturing method thereof, which can effectively solve the problem in the prior art that the quality of the insulating layer is poor and does not meet the use requirements.

[0004] In order to solve the above technical problems, the technical solution adopted in one aspect of the present invention is as follows:

[0005] A composite insulating layer electromagnetic wire comprises a conductor, a first polyamideimide insulating layer, a nano inorganic insulating layer and a second polyamideimide insulating layer arranged in sequence from inside to outside, wherein the thickness ratio of the first polyamideimide insulating layer, the nano inorganic insulating layer and the second polyamideimide insulating layer is 3:4:3.

[0006] As a preferred embodiment of the present invention, the temperature resistance grade of the electromagnetic wire is 260 grade.

[0007] As a preferred solution of the present invention, the first polyamide-imide insulating layer, the nano inorganic insulating layer and the second polyamide-imide insulating layer are coated multiple times.

[0008] As a preferred embodiment of the present invention, the thickness of the first polyamide-imide insulating layer is 0.03 mm.

[0009] As a preferred embodiment of the present invention, the thickness of the nano inorganic insulating layer is 0.04 mm.

[0010] As a preferred embodiment of the present invention, the thickness of the second polyamide-imide insulating layer is 0.03 mm.

[0011] Another aspect of the present invention adopts the following technical solution: A method for manufacturing a composite insulating layer electromagnetic wire, comprising the following steps:

[0012] Step 1: The semi-finished conductor is led out from the wire-laying device and drawn into a round wire by a wire drawing device, and then the wire is cleaned and annealed;

[0013] Step 2: uniformly and densely coating the first polyamide-imide insulation layer on the surface of the conductor through a mold in multiple passes;

[0014] Step 3: The painted wire is baked to undergo a cross-linking and curing reaction, followed by a cooling process;

[0015] Step 4: The nano inorganic insulating layer is uniformly and densely coated on the surface of the conductor through the mold in multiple passes;

[0016] Step 5: The painted wire is baked to undergo a cross-linking and curing reaction, followed by a cooling process;

[0017] Step 6: The second polyamide-imide insulation layer is uniformly and densely coated on the surface of the conductor through a mold in multiple passes;

[0018] Step 7: The painted wire is baked to undergo a cross-linking and curing reaction, followed by a cooling process;

[0019] Step 8: The painted wire is subjected to the first longitudinal rolling treatment, with a deformation rate of 5‰ to 32‰;

[0020] Step 9: The painted wire is subjected to the first transverse rolling treatment, with a deformation rate of 5‰ to 32‰;

[0021] Step 10: The wire after the painting is subjected to a second longitudinal rolling treatment, and the deformation rate is 5‰ to 32‰;

[0022] Step 11: The wire after the painting is subjected to a second transverse rolling treatment, and the deformation rate is 5‰ to 32‰;

[0023] Wherein, the thickness ratio of the first polyamide-imide insulating layer, the nano inorganic insulating layer and the second polyamide-imide insulating layer is 3:4:3.

[0024] As a preferred embodiment of the present invention, between step 6 and step 7, the method further comprises extruding a self-adhesive material uniformly and densely onto the second polyamide-imide insulating layer through an extruder.

[0025] As a preferred embodiment of the present invention, the temperature resistance grade of the electromagnetic wire is 260 grade.

[0026] The composite insulation layer electromagnetic wire and the manufacturing method thereof provided by the present invention have the following beneficial effects compared with the prior art:

[0027] The electromagnetic wire of the present invention comprises a conductor, a first polyamide-imide insulating layer, a nano inorganic insulating layer and a second polyamide-imide insulating layer which are sequentially arranged from the inside to the outside, wherein the thickness ratio of the first polyamide-imide insulating layer, the nano inorganic insulating layer and the second polyamide-imide insulating layer is 3:4:3, and under the conditions of high temperature, high frequency and high voltage, the voltage loss of the insulating layer of the electromagnetic wire as a whole can be reduced to 10-20%, that is, the voltage level is kept at more than 80% of the normal temperature condition; due to the arrangement of the nano inorganic insulating layer, the space charge can be effectively dispersed when power is turned on, thereby preventing the electric breakdown phenomenon caused by excessive local electric field strength. The product's withstand voltage level can be improved, thereby improving the withstand voltage level of the product; thereby, the withstand voltage level of the electromagnetic wire can be improved, the voltage loss of the insulating layer can be reduced, and it has the advantages of good flexibility, high slot fill rate and good heat dissipation; in addition, in the process of making the composite insulating layer electromagnetic wire, four calendering processes are included, and the last two calendering processes can correct and supplement the first two calendering processes to avoid the occurrence of inadequate processing, and the deformation rate is controlled at 5‰~32‰, which effectively avoids the "rib separation" phenomenon that occurs during the calendering process and ensures the ductility of the electromagnetic wire itself. Therefore, there is no need to rely on the subsequent secondary annealing process to soften the electromagnetic wire, thereby improving the overall performance of the electromagnetic wire. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] In order to more clearly illustrate the technical solution of the embodiment of the present invention, the drawings of the embodiment are briefly introduced below.

[0029] Figure 1 It is a schematic structural diagram of a composite insulation layer electromagnetic wire provided in an embodiment of the present invention.

[0030] Markings in the figure:

[0031] Conductor 1; first polyamide-imide insulating layer 2; nano inorganic insulating layer 3; second polyamide-imide insulating layer 4; self-adhesive layer 5. DETAILED DESCRIPTION

[0032] The specific implementation of the present invention is further described in detail below in conjunction with the accompanying drawings and examples. The following examples are used to illustrate the present invention, but are not intended to limit the scope of the present invention.

[0033] In the description of the present invention, it should be understood that the terms "upper", "lower", "left", "right", "front", "back", "top", "bottom", etc. indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on the present invention. It should be understood that the terms "first", "second", etc. are used in the present invention to describe various information, but such information should not be limited to these terms, which are only used to distinguish the same type of information from each other. For example, without departing from the scope of the present invention, "first" information may also be referred to as "second" information, and similarly, "second" information may also be referred to as "first" information.

[0034] like Figure 1 As shown, a preferred embodiment 1 of the present invention provides a composite insulating layer electromagnetic wire, which includes a conductor 1, a first polyamide-imide insulating layer 2, a nano inorganic insulating layer 3 and a second polyamide-imide insulating layer 4 arranged in sequence from the inside to the outside, and the thickness ratio of the first polyamide-imide insulating layer 2, the nano inorganic insulating layer 3 and the second polyamide-imide insulating layer 4 is 3:4:3.

[0035] It should also be noted that, in the present embodiment, the temperature resistance grade of the electromagnetic wire is 260. At the same time, by using the electromagnetic wire of the present invention, under the temperature condition of 260°C, the product life is more than 5000 hours, under the temperature condition of 280°C, the product can withstand thermal shock for more than 30 minutes, and under the condition of 400°C, the insulating paint film will not soften within 2 minutes. The thermoplastic fluidity is strong, and a high-performance composite insulating layer electromagnetic wire can be provided, which is suitable for more special application scenarios. For example, in the field of special transformers, when the transformer skeleton size is certain, the product size cannot be increased, and the transformer needs to withstand high frequency, high temperature, and high voltage. Therefore, the composite insulating layer electromagnetic wire of the present invention can meet the use requirements; in addition, in the field of special motors, when the motor design size is certain, it is necessary to increase the power and increase the voltage from 400V to 800V. The composite insulating layer electromagnetic wire of the present invention can solve customer needs.

[0036] Exemplarily, it also includes a self-adhesive layer 5, which is located on the periphery of the second polyamide-imide insulating layer 4; in actual use, a self-adhesive layer 5 can be provided on the outermost layer as needed, and the self-adhesive layer 5 has a self-adhesive function, that is, it does not need to be wound on a skeleton, and a skeleton-free coil can be produced.

[0037] Exemplarily, the first polyamide-imide insulating layer 2 , the nano inorganic insulating layer 3 and the second polyamide-imide insulating layer 4 are coated multiple times.

[0038] Exemplarily, the thickness of the first polyamide-imide insulating layer 2 is 0.03 mm.

[0039] Exemplarily, the thickness of the nano inorganic insulating layer 3 is 0.04 mm.

[0040] Exemplarily, the thickness of the second polyamide-imide insulating layer 4 is 0.03 mm.

[0041] In order to verify the performance of the composite insulation layer electromagnetic wire of the present invention, this scheme conducted a verification test on the 220-grade polyamide-imide enameled wire and the composite insulation layer electromagnetic wire in this scheme, and the results are as follows:

[0042]

[0043] It can be seen from the above table that, under the premise that the diameter of conductor 1 and the thickness of the paint film are the same, the insulation breakdown voltage of the 220-grade polyamide-imide enameled wire is 12000V, and the breakdown voltage under high temperature conditions is 6000V, while the composite insulating layer electromagnetic wire of the present invention can reach an insulation breakdown voltage of 14000V, and the breakdown voltage under high temperature conditions can reach 12000V; as for the ability to withstand thermal shock, the 220-grade polyamide-imide enameled wire can only withstand thermal shock for more than 30 minutes at 240°C, while the composite insulating layer electromagnetic wire of the present invention can withstand thermal shock for more than 30 minutes at 280°C; in addition, the insulating paint film of the 220-grade polyamide-imide enameled wire will soften within two minutes at 400°C, and the thermoplastic fluidity is poor, while the composite insulating layer paint film of the present invention will soften within two minutes at 420°C, and the thermoplastic fluidity is strong.

[0044] A second preferred embodiment of the present invention provides a method for manufacturing a composite insulating layer electromagnetic wire, comprising the following steps:

[0045] Step 1: Lead the semi-finished conductor out of the wire-laying equipment, and draw it into a round wire through the wire drawing equipment, and then clean the wire and perform annealing treatment; wherein, the semi-finished conductor 1 is copper or copper-clad aluminum, of course, different materials can also be selected according to actual needs, and ultrasonic cleaning equipment can be used during the cleaning process. The cleaning step can remove copper powder, oil or other dirt on the surface of the electromagnetic wire, and ensure the adhesion of the insulating paint during the subsequent painting process. The annealing process can soften the electromagnetic wire at high temperature, and can further remove copper powder, oil or other dirt on the surface of the electromagnetic wire, ensuring that the surface of the electromagnetic wire is clean, which is convenient for subsequent painting operations; in addition, the annealing temperature of the electromagnetic wire is: 400-500°C.

[0046] Step 2: coating the first polyamide-imide insulation layer 2 uniformly and densely on the surface of the conductor 1 through a mold in multiple passes;

[0047] Step 3: The painted wire is baked to undergo a cross-linking and curing reaction, followed by a cooling process;

[0048] Step 4: coating the nano inorganic insulating layer 3 uniformly and densely on the surface of the conductor 1 through a mold in multiple passes;

[0049] Step 5: The painted wire is baked to undergo a cross-linking and curing reaction, followed by a cooling process;

[0050] Step 6: coating the second polyamide-imide insulation layer 4 uniformly and densely on the surface of the conductor 1 through a mold in multiple passes;

[0051] Step 7: The painted wire is baked to undergo a cross-linking and curing reaction, followed by a cooling process;

[0052] Step 8: The painted wire is subjected to the first longitudinal rolling treatment, with a deformation rate of 5‰ to 32‰;

[0053] Step 9: The painted wire is subjected to the first transverse rolling treatment, with a deformation rate of 5‰ to 32‰;

[0054] Step 10: The wire after the painting is subjected to a second longitudinal rolling treatment, and the deformation rate is 5‰ to 32‰;

[0055] Step 11: The wire after the painting is subjected to a second transverse rolling treatment, and the deformation rate is 5‰ to 32‰;

[0056] Wherein, the thickness ratio of the first polyamide-imide insulating layer, the nano inorganic insulating layer and the second polyamide-imide insulating layer is 3:4:3.

[0057] Exemplarily, between step 6 and step 7, the method further includes extruding a self-adhesive material onto the second polyamideimide insulating layer 4 evenly and densely through an extruder.

[0058] The composite insulating layer electromagnetic wire and the manufacturing method thereof of the present invention comprises a conductor 1, a first polyamide-imide insulating layer 2, a nano inorganic insulating layer 3 and a second polyamide-imide insulating layer 4 which are arranged in sequence from the inside to the outside. The thickness ratio of the first polyamide-imide insulating layer 2, the nano inorganic insulating layer 3 and the second polyamide-imide insulating layer 4 is 3:4:3. Under high temperature, high frequency and high voltage conditions, the voltage loss of the insulating layer of the electromagnetic wire as a whole can be reduced to 10-20%, that is, the voltage level is kept at more than 80% of the normal temperature condition. Due to the arrangement of the nano inorganic insulating layer 3, the space charge can be effectively dispersed when power is turned on, thereby preventing the local electric field intensity from being too large. The electric breakdown phenomenon caused by this can be prevented, thereby improving the withstand voltage level of the product; the adoption of the present invention can improve the withstand voltage level of the electromagnetic wire, reduce the voltage loss of the insulating layer, and has the advantages of good flexibility, high slot fill rate and good heat dissipation; in addition, in the process of making the composite insulating layer electromagnetic wire, four calendering processes are included, and the latter two calendering processes can play a role in correcting and supplementing the former two calendering processes, avoiding the occurrence of inadequate processing, and the deformation rate is controlled at 5‰ to 32‰, effectively avoiding the "rib separation" phenomenon that occurs during the calendering process, ensuring the ductility of the electromagnetic wire itself, so there is no need to rely on the subsequent secondary annealing process to achieve the softening of the electromagnetic wire, thereby improving the overall performance of the electromagnetic wire.

[0059] In this embodiment, the temperature resistance grade of the electromagnetic wire is 260 grade.

[0060] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "connected" and "connection" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be an indirect connection through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0061] The above is only a preferred embodiment of the present invention. It should be pointed out that for ordinary technicians in this technical field, several improvements and substitutions can be made without departing from the technical principles of the present invention. These improvements and substitutions should also be regarded as the scope of protection of the present invention.

Claims

1. A method for manufacturing a composite insulation layer electromagnetic wire, characterized in that: The following steps are involved: Step 1: The semi-finished conductor is led out from the wire-laying device and drawn into a round wire by the wire drawing device, and then the wire is cleaned and annealed; Step 2: uniformly and densely coating the first polyamide-imide insulation layer on the surface of the conductor through a mold in multiple passes; Step 3: The painted wire is baked to undergo a cross-linking and curing reaction, followed by a cooling process; Step 4: The nano inorganic insulating layer is uniformly and densely coated on the surface of the conductor through the mold in multiple passes; Step 5: The painted wire is baked to undergo a cross-linking and curing reaction, followed by a cooling process; Step 6: The second polyamide-imide insulation layer is uniformly and densely coated on the surface of the conductor through a mold in multiple passes; Step 7: The painted wire is baked to undergo a cross-linking and curing reaction, followed by a cooling process; Step 8: The painted wire is subjected to the first longitudinal rolling treatment, with a deformation rate of 5‰ to 32‰; Step 9: The painted wire is subjected to the first transverse rolling treatment, with a deformation rate of 5‰ to 32‰; Step 10: The wire after the painting is subjected to a second longitudinal rolling treatment, and the deformation rate is 5‰ to 32‰; Step 11: The wire after the painting is subjected to a second transverse rolling treatment, and the deformation rate is 5‰ to 32‰; Wherein, the thickness ratio of the first polyamide-imide insulating layer, the nano inorganic insulating layer and the second polyamide-imide insulating layer is 3:4:

3.

2. The method for manufacturing a composite insulation layer electromagnetic wire according to claim 1, characterized in that: Between step 6 and step 7, the method further includes extruding a self-adhesive material uniformly and densely onto the second polyamideimide insulation layer through an extruder.

3. The method for manufacturing a composite insulation layer electromagnetic wire according to claim 1, characterized in that: The temperature resistance grade of the electromagnetic wire is 260 grade.

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