Electrically insulated conductor

Abstract

Exemplary embodiments of electrically insulated conductors are disclosed. In an exemplary embodiment, an electrically insulated conductor includes a conductive core and one or more non-conductive layers. The one or more non-conductive layers include an adhesive end that is parallel to and / or extends at least partially longitudinally along the length of the conductive core. The one or more non-conductive layers are at least partially along a perimeter of the conductive core.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of U.S. Provisional Patent Application No. 63 / 340,147, filed on May 10, 2022. The entire disclosure of that provisional application is hereby incorporated by reference. Technical Field

[0003] The present disclosure relates generally to electrically insulated conductors. Background Art

[0004] This section provides background information related to the present disclosure which is not necessarily prior art.

[0005] Electric vehicles are commonly used today, and their use is expected to increase significantly over time. Electric motors used in electric vehicles may be driven by a pulse width modulation (PWM) inverter. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] The drawings described herein are for illustrative purposes only and may not depict all possible implementations, and are not intended to limit the scope of the present disclosure.

[0007] Figure 1 An electrically insulator conductor according to an exemplary embodiment is illustrated. The electrically insulated conductor includes a conductive core (e.g., copper, etc.) and at least one electrically non-conductive or electrically insulating layer (e.g., an anti-corona film, etc.). The at least one non-conductive layer includes an adhered end or edge portion that is substantially parallel to the length of the conductive core and / or extends longitudinally at least partially along the length of the conductive core. The at least one non-conductive layer at least partially or peripherally along or around the periphery of the conductive core. Compared to conventional insulation solutions, anti-corona films can be lower cost (e.g., 1 / 8 less, etc.) and better formability. Although Figure 1 Copper conductors and anti-corona films are illustrated, but other electrical conductors (eg, aluminum, stainless steel, copper alloys, other alloys, other metals, etc.) and other insulators may be used.

[0008] Figure 2 An electrically insulator conductor according to another exemplary embodiment is illustrated. The electrically insulated conductor includes a conductive core (e.g., copper, etc.), an enamel, and at least one electrically non-conductive or electrically insulating layer (e.g., an anti-corona film, etc.). The enamel is coated or otherwise applied at least partially along the length of the conductive core. The at least one electrically non-conductive layer includes an adhered end or edge portion that is generally parallel to the length of the conductive core and / or extends longitudinally at least partially along the length of the conductive core. The at least one electrically non-conductive layer extends at least partially along the length of the conductive core and covers at least a portion of the enamel. Although Figure 2Copper conductors, enamels, and anti-corona films are exemplified, but other electrical conductors (e.g., aluminum, stainless steel, copper alloys, other alloys, other metals, electrical conductors having non-rectangular cross-sectional shapes, etc.) and other insulators may also be used. Figure 1 and Figure 2 As shown, the electrical insulator conductor may include: without any enamel coating along the conductive core ( Figure 1 ) or after providing an enamel coating along the conductive core ( Figure 2 ), one or more non-conductive layers provided along a conductive core.

[0009] Figure 3 An electrical insulator conductor according to another exemplary embodiment is illustrated. The electrically insulated conductor includes a conductive core (e.g., copper, aluminum, stainless steel, alloys thereof, other metals, electrical conductors having non-rectangular cross-sectional shapes, etc.) and at least one non-conductive or electrically insulating layer (e.g., an anti-corona film, a functionalized dielectric layer designed for through-plane thermal conductivity and / or anti-partial discharge, etc.). In this example, the conductive core has a generally rectangular cross-sectional shape, and at least one non-conductive layer is folded approximately perpendicular to the length of the conductive core around the entire generally rectangular periphery of the conductive core. The at least one non-conductive layer may include an adhered end or edge portion, the end or edge portion being approximately parallel to the length of the conductive core and / or extending longitudinally at least partially along the length of the conductive core. In this example, the adhered end or edge portion is linear or straight, and generally defines a longitudinally linear or straight seam between them, which extends longitudinally at least partially along the length of the conductive core. But other exemplary embodiments may include one or more non-conductive layers having non-linear end or edge portions (e.g., S-shaped, zigzag, staggered patterns, etc.). For example, opposing end or edge portions of the non-conductive layer may include complementary shapes such that when the non-conductive layer is folded around the conductive cover, one end or edge portion is staggered with the other end or edge portion.

[0010] Figure 4 Exemplary systems that can be used to provide a non-conductive or electrically insulating layer (e.g., an anti-corona film, a functionalized dielectric layer designed for through-plane thermal conductivity and / or partial discharge resistance, etc.) to a conductive core (e.g., copper, aluminum, stainless steel, copper alloys, other alloys, other metals, etc.) are illustrated. Typically, the system includes a folding system, laser outer diameter control, tension control, winding or reeling, and a process control system. DETAILED DESCRIPTION

[0011] Example embodiments will now be described more fully with reference to the accompanying drawings.

[0012] The electric vehicle industry is moving toward silicon carbide (SiC) and gallium nitride (GaN) inverter technology to increase the DC voltage to the stator windings, although the effects of dv / dt and the resulting rise time are not fully understood or known. As recognized herein, the increased DC voltage and current applied to the stator windings will increase the electrical stress on the electrical insulation system. If not addressed, the increased electrical stress (phase-to-phase and turn-to-turn) can shorten the operating life of the electrical insulation and the electric motor.

[0013] Exemplary embodiments of electrically insulated conductors are developed and / or disclosed herein that can be configured to increase lifetime due to electrical stresses (phase-to-phase and turn-to-turn) and reduce the amount of insulation material used for wire windings compared to conventional techniques. Although conventional anti-corona insulation solutions may be robust enough to handle the increased DC voltages and currents applied to stator windings, conventional anti-corona insulation solutions tend to be relatively expensive and uneconomical.

[0014] In the exemplary embodiments disclosed herein, the electrical conductor may be provided with an insulator that is particularly targeted at high electric field areas on a magnetic wire (e.g., copper, aluminum, stainless steel, alloys thereof, other metals, other electrical conductors, etc.) in a winding driven by a converter device (e.g., a stator winding in an electric motor or other power electronic device, etc.). The magnetic wire can be insulated with an anti-corona film without significantly increasing the total cross-sectional area of ​​the magnetic wire. For example, the anti-corona film may include a thin anti-corona film that includes a single-sided fluoropolymer coating that can be thermally melted with copper and itself. Alternatively, other electrical insulating materials can be used, which are preferably relatively thin, have good dielectric strength, and are coated with a functionalized single-sided adhesive system for dv / dt resistance and corona resistance. The electrical insulating material may include a functionalized dielectric layer designed for through-plane thermal conduction and / or partial discharge resistance. The electrical insulating material may have a multilayer structure including at least one or more dielectric layers. The at least one or more dielectric layers may include one or more of an enamel (or other polymer coating), an anti-corona enamel, an adhesion promoter, a varnish, an extruded polymer, a polymer film and / or a polymer functionalized with inorganic particles. The multilayer structure may include one or more semiconductive layers, for example, configured to help reduce corona-induced insulation breakdown, etc.

[0015] The exemplary embodiments disclosed herein may provide or include one or more (but not necessarily any or all) of the following benefits or features, such as higher efficiency, lower operating temperature, increased power density, increased electric motor voltage, dv / dt resistance, tolerance to SiC / GaN inverters, higher copper filling, longer operating life and reliability, and / or improved partial discharge initiation voltage (PDIV). By using an anti-corona film (e.g., a single-layer film, a multi-layer structure, etc.), less insulating material (e.g., 1 / 8 less material, etc.) can be used in the exemplary embodiments disclosed herein compared to conventional insulation methods. Exemplary embodiments may include a high copper filling factor and improve electric motor efficiency. Using the same battery pack and / or a smaller battery pack, the improved electric motor efficiency translates into more mileage, resulting in a lower cost per battery pack for each electric vehicle. The exemplary embodiments disclosed herein may also fundamentally enable original equipment manufacturers (OEMs) to have higher efficiency and design freedom. In an exemplary embodiment, the anti-corona film can be adhered using one or more methods, such as fluoropolymers (e.g., perfluoroalkoxyalkanes (PFA), fluorinated ethylene propylene (FEP), etc.) and / or polyimides having a certain Tg (glass transition point) of 220 to 400 degrees Celsius (°C) under a cured enamel and after applying an available In the case of a film, processing and curing are performed, etc. Regarding design freedom, exemplary embodiments may allow for reduced slot size, higher copper content for the same slot size, smaller packaging, insulation for 3D printed coils, and / or dielectric barriers for distributed electrical windings.

[0016] Typically, the thickness of the insulator can be significantly increased to accommodate the increased DC voltage and current applied to the stator windings. However, the increased insulation thickness reduces the copper fill factor, which in turn reduces efficiency. In contrast, the exemplary embodiments disclosed herein can provide an economical way to increase reliability and achieve market trends in electromobility, such as in aerospace electromobility applications where stresses can be significantly higher. For example, exemplary embodiments can include a conductive core that is only partially (e.g., not on all sides, etc.) provided with an insulator, which can reduce insulation material for such embodiments that do not require the conductive core / wire to be completely wrapped with an insulator.

[0017] The exemplary embodiments disclosed herein are not limited to use with only electric motors of electric vehicles. The exemplary embodiments disclosed herein can be used in a wide range of electronic devices, including power electronics for aircraft, ships, industry, automobiles, etc., electric motors driven by pulse width modulation inverters, high switching frequency converters providing signals with high levels of dv / dt, traction electric motors for electric mobility applications, other windings driven by converter devices, etc.

[0018] In an exemplary embodiment, the electrically insulated conductor includes a conductive core and one or more non-conductive and / or insulating layers. The one or more non-conductive layers include adhesive ends extending longitudinally parallel to and / or at least partially along the length of the conductive core. The one or more non-conductive layers are at least partially along the periphery of the conductive core.

[0019] In an exemplary embodiment, an electrically insulated conductor for a winding driven by a converter device comprises a conductive core and one or more non-conductive and / or insulating layers. One or more non-conductive layers extend longitudinally at least partially along the length of the conductive core. One or more non-conductive layers may be uneven and / or asymmetric at least partially along the periphery of the conductive core in the longitudinal direction. Or the one or more non-conductive layers may be longitudinally symmetrical at least partially along the periphery of the conductive core. The one or more non-conductive layers are longitudinally configured to aim at one or more predetermined high electric field regions along the conductive core in the winding. At least a portion of the one or more non-conductive layers will be located or adjacent to one or more predetermined high electric field regions along the conductive core in a winding driven by a converter device (e.g., a stator winding in an electric motor or other power electronic device, etc.).

[0020] In an exemplary embodiment, the one or more non-conductive layers include end or edge portions that are at least partially adhered along at least one side of the conductive core.

[0021] In an exemplary embodiment, one or more non-conductive layers are at least partially folded longitudinally around the periphery of the conductive core. One or more non-conductive layers can be completely folded around the periphery of the conductive core. One or more non-conductive layers can be completely folded around the periphery of the conductive core with at least one overlapping portion, so that at least a portion of the one or more non-conductive layers overlaps with at least one other portion of the one or more non-conductive layers. One or more non-conductive layers can be completely folded around the periphery of the conductive core with multiple overlapping portions, so that multiple portions of the one or more non-conductive layers overlap with multiple other portions of the one or more non-conductive layers.

[0022] In an exemplary embodiment, the one or more non-conductive layers are folded at least partially around the perimeter of the conductive core generally perpendicular to the length of the conductive core.

[0023] In an exemplary embodiment, the one or more non-conductive layers are non-uniform and / or asymmetric at least partially along the perimeter of the conductive core. In other exemplary embodiments, the one or more non-conductive layers are symmetric at least partially along the perimeter of the conductive core.

[0024] In an exemplary embodiment, the one or more non-conductive layers are configured to electrically insulate the conductive core to target one or more predetermined high electric field regions along the conductive core in a winding driven by a converter device (e.g., a stator winding in an electric motor or power electronic device, etc.) At least a portion of the one or more non-conductive layers will be located at or adjacent to the one or more predetermined high electric field regions along the conductive core in the stator winding, such as an inter-turn region of the conductive core.

[0025] In an exemplary embodiment, one or more non-conductive layers include at least one functionalized dielectric layer designed for through-plane heat conduction and / or partial discharge resistance. For example, an exemplary embodiment may include a thermal substrate as disclosed in U.S. Patent Application Publication US2021 / 0111097, the entire contents of which are incorporated herein by reference. In this exemplary embodiment, the thermal substrate includes a multilayer film, which includes a first outer layer, a core layer, and a second outer layer. The first outer layer includes a first thermoplastic polyimide. The core layer includes polyimide. The second outer layer includes a second thermoplastic polyimide. The first conductive layer adheres to the first outer layer of the multilayer film. The second conductive layer adheres to the second outer layer of the multilayer film. The total thickness of the multilayer film is in the range of 5 microns (μm) to 150 microns (μm). The first outer layer, the core layer, and the second outer layer each include a thermally conductive filler. The first conductive layer and the second conductive layer each have a thickness in the range of 250 microns (μm) to 3000 microns (μm).

[0026] In an exemplary embodiment, one or more non-conductive layers include a multilayer structure. The multilayer structure may include at least one or more dielectric layers, the dielectric layer including one or more enamels, adhesion promoters, varnishes, extrusion and / or engineering polymers, polymer films and / or polymer films functionalized with inorganic and / or organic particles (e.g., anti-corona, foaming), etc. The multilayer structure may include at least one or more dielectric layers, the dielectric layer including one or more enamels containing a certain type of varnish. A certain type of varnish may include polyimide, polyamide-imide, polyesterimide, and / or a combination thereof, and / or a certain type of varnish may be functionalized with inorganic and / or organic particles (e.g., anti-corona, foaming), etc. The multilayer structure may include one or more semiconductive layers, for example, configured to help reduce insulation breakdown caused by corona, etc.

[0027] In an exemplary embodiment, the electrically insulated conductor includes an adhesive for adhesively attaching one or more non-conductive layers. The adhesive is capable of maintaining a relative thermal index of at least about 180 degrees Celsius. The adhesive may be capable of adhesively bonding to conductive surfaces, metal surfaces, and polymer surfaces.

[0028] In an exemplary embodiment, the electrically insulated conductor includes a polymer surface (e.g., enamel or other polymer coating, etc.) along at least a portion of the conductive core. One or more non-conductive layers cover at least a portion of the polymer surface, such that the covered portion of the polymer surface is between the conductive core and the one or more non-conductive layers. The polymer surface may include at least one region that is not covered by the one or more non-conductive layers and is generally located between at least two spaced apart discontinuous portions of the one or more non-conductive layers. Alternatively, the one or more non-conductive layers may cover the entire polymer surface. The polymer surface may be along the entire periphery of the conductive core.

[0029] In an exemplary embodiment, the one or more non-conductive layers include enamel or other polymer coating.

[0030] In an exemplary embodiment, the one or more non-conductive layers include a first non-conductive layer. The electrically insulated conductor includes a second non-conductive layer including an enamel (or other polymer coating) extending longitudinally at least partially along the length of the conductive core and at least partially around the periphery of the conductive core.

[0031] In an exemplary embodiment, the conductive core has a cross-sectional shape that is substantially rectangular, circular, elliptical, rhomboid, or chamfered rectangular, or other cross-sectional shapes having at least one side. The electrically insulated conductor has a cross-sectional shape that is substantially rectangular, circular, elliptical, rhomboid, or chamfered rectangular, or other cross-sectional shapes having at least one side defined by the conductive core and the one or more non-conductive layers. However, in other exemplary embodiments, the conductive core and / or the electrically insulated conductor may be configured differently and have cross-sectional shapes different from those disclosed in this paragraph.

[0032] In an exemplary embodiment, the conductive core includes a magnetic wire. The magnetic wire may include copper wire, aluminum wire, stainless steel wire, copper alloy wire, other magnetic wires, wires made of other metals, and wires made of other metal alloys.

[0033] In an exemplary embodiment, the conductive core includes a copper wire, an aluminum wire, or a stainless steel wire having a substantially rectangular, circular, elliptical, rhombus, or chamfered rectangular cross-sectional shape or other cross-sectional shapes having at least one side. However, in other exemplary embodiments, the conductive core may be configured differently, for example, including different conductive materials and / or having a cross-sectional shape different from that disclosed in this paragraph.

[0034] In an exemplary embodiment, the one or more non-conductive layers are at least partially folded around the perimeter of the conductive core such that no portion of the one or more non-conductive layers is overlapped and covered by another portion of the one or more non-conductive layers.

[0035] In an exemplary embodiment, one or more non-conductive layers are folded around the entire periphery of the conductive core so that only the first and second longitudinal edge portions or ends of the one or more non-conductive layers overlap, and other portions of the one or more non-conductive layers do not overlap with another portion of the one or more non-conductive layers. The first and second longitudinal edge portions or ends may be straight, linear, or non-linear (e.g., S-shaped, zigzag, staggered pattern, etc.). Therefore, exemplary embodiments are not limited to non-conductive layers having only straight or linear edge portions or ends.

[0036] In an exemplary embodiment, one or more non-conductive layers are folded around the entire periphery of the conductive core such that the one or more non-conductive layers include opposing first longitudinal edge portions or ends and second longitudinal edge portions or ends adjacent to each other, and no portion of the one or more non-conductive layers is overlapped and covered by another portion of the one or more non-conductive layers.

[0037] In an exemplary embodiment, the one or more non-conductive layers are folded around less than the entire periphery of the conductive core such that the one or more non-conductive layers include opposing first and second longitudinal edge portions or ends, the first and second longitudinal edge portions or ends being spaced apart and discontinuous from each other, the spaced apart first and second longitudinal edge portions or ends defining a gap therebetween, the gap extending longitudinally at least partially along the length of the conductive core.

[0038] In an exemplary embodiment, one or more non-conductive layers are folded around the entire periphery of the conductive core such that the one or more non-conductive layers include opposing first longitudinal edge portions or ends and second longitudinal edge portions or ends adjacent to each other, the adjacent first longitudinal edge portions or ends and second longitudinal edge portions or ends defining a longitudinal seam therebetween, which extends longitudinally at least partially along the length of the conductive core.

[0039] In an exemplary embodiment, one or more non-conductive layers may include straight, linear, or non-linear (e.g., S-shaped, zigzag, staggered pattern, etc.) first longitudinal edge portions or ends and second longitudinal edge portions or ends. Therefore, exemplary embodiments are not limited to non-conductive layers having only straight or linear edge portions or ends.

[0040] In an exemplary embodiment, one or more non-conductive layers are folded around the entire periphery of the conductive core such that the one or more non-conductive layers include opposing first and second longitudinal edge portions or ends that overlap each other, the overlapping first and second longitudinal edge portions or ends defining an overlapping seam therebetween that extends at least partially along the length of the conductive core.

[0041] In an exemplary embodiment, the conductive core includes a plurality of sides defining a perimeter. The one or more non-conductive layers are folded such that the one or more non-conductive layers at least partially extend longitudinally along at least two of the plurality of sides of the conductive core.

[0042] In an exemplary embodiment, the one or more non-conductive layers are folded such that the one or more non-conductive layers extend at least partially longitudinally along each of the plurality of sides of the conductive core.

[0043] In an exemplary embodiment, the conductive core includes a plurality of sides defining a perimeter. The one or more non-conductive layers are folded such that the one or more non-conductive layers extend longitudinally along less than all of the plurality of sides of the conductive core.

[0044] In an exemplary embodiment, the conductive core includes a plurality of sides defining a perimeter. The one or more non-conductive layers are disposed along only one of the plurality of sides of the conductive core.

[0045] In an exemplary embodiment, the conductive core includes a plurality of sides defining a perimeter. One or more non-conductive layers are spirally wrapped with a polymer film (e.g., with an adhesive, etc.). And the electrically insulated conductor includes one or more second non-conductive layers disposed along only one side of the conductive core or along the plurality of sides.

[0046] In an exemplary embodiment, the conductive core includes a plurality of sides defining a perimeter. The one or more non-conductive layers are disposed along only one side or along the plurality of sides of the conductive core, and the electrically insulated conductor includes one or more second non-conductive layers spirally wound with a polymer film (e.g., with an adhesive, etc.).

[0047] In an exemplary embodiment, one or more non-conductive layers are configured to electrically insulate the conductive core for use in a distributed electrical winding. The one or more non-conductive layers are configured to provide a dielectric barrier to the distributed electrical winding defined by the electrically insulated conductor.

[0048] In an exemplary embodiment, the electrically insulated conductor is configured to withstand a voltage stress of 1,6KvPK 20KHz for at least about 15 to 20 hours.

[0049] Exemplary embodiments include windings driven by a converter device (e.g., stator windings for an electric motor or other power electronic device, etc.), the converter device including an electrically insulated conductor as disclosed herein. One or more non-conductive layers of the electrically insulated conductor are located at or adjacent to one or more predetermined high electric field regions along a conductive core in the winding.

[0050] An exemplary method of manufacturing an electrically insulated conductor for a winding driven by a converter device (e.g., a stator winding of an electric motor or power electronic device, etc.) is also disclosed. In an exemplary embodiment, the method includes: longitudinally adhering one or more non-conductive layers parallel to and / or at least partially along the length of a conductive core. The one or more non-conductive layers are at least partially along the periphery of the conductive core and are configured to target one or more predetermined high electric field regions along the conductive core in the winding driven by the converter device.

[0051] In an exemplary embodiment, the method includes folding the one or more non-conductive layers at least partially around the periphery of the conductive core so that the one or more non-conductive layers are non-uniform and / or asymmetric at least partially along the periphery of the conductive core; or so that the one or more non-conductive layers are symmetric at least partially along the periphery of the conductive core. At least a portion of the one or more non-conductive layers will be located at or adjacent to the one or more predetermined high electric field regions along the conductive core in a winding driven by the converter device.

[0052] In an exemplary embodiment, the method includes positioning the electrically insulated conductor within a winding such that at least a portion of one or more non-conductive layers will be located at or adjacent to the one or more predetermined high electric field regions along the conductive core in the winding driven by the converter device.

[0053] In an exemplary embodiment, the method includes selectively applying the one or more non-conductive layers at least partially along the length of the conductive core, thereby resulting in an environmentally sustainable reduction in the use of non-conductive materials.

[0054] In an exemplary embodiment, the method includes selectively applying one or more non-conductive layers at spaced apart indexed locations along the length of the conductive core.

[0055] In an exemplary embodiment, the method includes manufacturing an electrically insulated conductor as disclosed herein.

[0056] In an exemplary embodiment, a system is configured to perform a method of manufacturing an electrically insulated conductor as disclosed herein.

[0057] Exemplary embodiments are provided so that the present disclosure will be thorough and will fully convey its scope to those skilled in the art. Many specific details, such as examples of specific components, devices, and methods, are set forth to provide a thorough understanding of the embodiments of the present disclosure. It will be apparent to those skilled in the art that specific details need not be adopted, that the exemplary embodiments may be embodied in many different forms, and that they should not be construed as limiting the scope of the present disclosure. In some example embodiments, well-known processes, well-known device structures, and well-known techniques are not described in detail. In addition, the advantages and improvements that may be achieved by one or more exemplary embodiments of the present disclosure are provided for illustrative purposes only and do not limit the scope of the present disclosure, because the exemplary embodiments disclosed herein may provide all or none of the above-mentioned advantages and improvements and still fall within the scope of the present disclosure.

[0058] The specific numerical dimensions and values, specific materials and / or specific shapes disclosed herein are exemplary in nature and do not limit the scope of the present disclosure. The disclosure of the specific value and specific value range of a given parameter herein does not exclude other values ​​and value ranges that can be used in one or more examples disclosed herein. In addition, it is envisioned that any two specific values ​​of a specific parameter described herein can define the endpoints of the value range applicable to a given parameter (the disclosure of the first value and the second value of a given parameter can be interpreted as disclosing that any value between the first and second values ​​can also be adopted for a given parameter). For example, if parameter X is exemplified herein as having value A and also exemplified as having value Z, it is envisioned that parameter X can have the range of values ​​from about A to about Z. Similarly, it is envisioned that the disclosure of two or more ranges of the value of a parameter (whether such ranges are nested, overlapped or different) includes all possible combinations of the range of values ​​that may be required using the endpoints of the disclosed range. For example, if parameter X is illustrated herein as having values ​​in the range of 1 to 10, or 2 to 9, or 3 to 8, it is also contemplated that parameter X may have other ranges of values ​​including 1 to 9, 1 to 8, 1 to 3, 1 to 2, 2 to 10, 2 to 8, 2 to 3, 3 to 10, and 3 to 9.

[0059] The terms used herein are only used for the purpose of describing specific exemplary embodiments and are not intended to be limiting. As used herein, the singular forms "one", "a kind of" and "the" may also be intended to include plural forms unless the context clearly indicates otherwise. The terms "include", "comprise", "contain", "have", "have" and "contain" are inclusive, and therefore specify the presence of the features, integers, steps, operations, elements and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or combinations thereof. The method steps, processes and operations described herein should not be interpreted as necessarily requiring them to be performed in the specific order discussed or shown, unless explicitly identified as an execution order. It should also be understood that additional or alternative steps may be adopted.

[0060] When an element or layer is referred to as being "on another element or layer," "engaged to another element or layer," "connected to another element or layer," or "coupled to another element or layer," it may be directly on, engaged, connected, or coupled to another element or layer, or there may be intervening elements or layers. Conversely, when an element is referred to as being "directly on another element or layer," "directly engaged to another element or layer," "directly connected to another element or layer," or "directly coupled to another element or layer," there may be no intervening elements or layers. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between" versus "directly between," "adjacent" versus "directly adjacent," etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0061] When applied to a value, the term "about" means that the calculation or measurement allows some slight imprecision in the value (some precision in the value is close; close to or reasonably close to the value; close). If for some reason the imprecision provided by "about" is not understood in this ordinary sense in the art, then "about" as used herein at least indicates changes that may be caused by ordinary methods of measuring or using such parameters. For example, the terms "roughly", "about" and "substantially" can be used herein to indicate within manufacturing tolerances. Or, for example, when modifying the amount or use of the ingredients or reactants of the present invention, the term "about" as used herein refers to changes in the amount of the numerical value that may occur through the typical measurement and processing procedures used, for example, when preparing concentrates or solutions in the real world through unintentional errors in these procedures; by differences in the manufacture, source or purity of the ingredients used to prepare the composition or implement the method; and so on. The term "about" also covers different amounts due to different equilibrium conditions of the composition produced by a specific initial mixture. Whether or not modified by the term "about", the claims include equivalents of the amount.

[0062] Although the terms first, second, third, etc. can be used here to describe various elements, components, regions, layers and / or parts, these elements, components, regions, layers and / or parts should not be limited by these terms. These terms can only be used to distinguish an element, component, region, layer or part from another region, layer or part. Terms such as "first", "second" and other numerical terms do not imply order or sequence when used in this article unless the context clearly indicates. Therefore, without departing from the teaching of exemplary embodiments, the first element, component, region, layer or part can be referred to as the second element, component, region, layer or part.

[0063] Spatially relative terms, such as "inside," "outside," "below," "lower," "above," "upper," and the like, may be used herein to facilitate description of the relationship of one element or feature to another element or feature, as illustrated in the figures. In addition to the orientations shown in the figures, spatially relative terms may include different orientations of the device in use or operation. For example, if the device in the figure is turned over, elements described as being "below" or "below" other elements or features will be oriented "above" the other elements or features. Thus, the exemplary term "below" may include both above and below orientations. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially relative descriptors used herein are interpreted accordingly.

[0064] The foregoing description of the embodiments has been provided for the purpose of illustration and description. It is not intended to be exhaustive or to limit the present disclosure. Individual elements, intended or stated uses or features of a particular embodiment are generally not limited to the particular embodiment, but are interchangeable and can be used in selected embodiments when applicable, even if not explicitly shown or described. They can also be varied in many ways. Such variations should not be considered as departing from the present disclosure, and all such modifications are intended to be included within the scope of the present disclosure.

Claims

1. An electrically insulated conductor, comprising: a conductive core having a length and a circumference; as well as One or more non-conductive layers, the one or more non-conductive layers including adhesive ends, the adhesive ends extending longitudinally parallel to the length of the conductive core and / or at least partially along the length of the conductive core, the one or more non-conductive layers at least partially along the periphery of the conductive core.

2. The electrically insulated conductor of claim 1, wherein: The one or more non-conductive layers are configured to electrically insulate the conductive core to target one or more predetermined high electric field regions along the conductive core in a winding driven by a converter device, whereby at least a portion of the one or more non-conductive layers will be located at or adjacent to the one or more predetermined high electric field regions along the conductive core in the winding, such as an inter-turn region of the conductive core.

3. An electrically insulated conductor according to any one of the preceding claims, wherein: The one or more non-conductive layers are non-uniform and / or asymmetric at least partially along the periphery of the conductive core; or The one or more non-conductive layers are symmetrical at least partially along the perimeter of the conductive core.

4. An electrically insulated conductor for a winding driven by a converter device, the electrically insulated conductor comprising: a conductive core having a length and a circumference; as well as one or more non-conductive layers extending longitudinally at least partially along the length of the conductive core such that: The one or more non-conductive layers are non-uniform and / or asymmetric at least partially along the periphery of the conductive core; or The one or more non-conductive layers are symmetrical at least partially along the periphery of the conductive core; Wherein, the one or more non-conductive layers are configured to target one or more predetermined high electric field regions along the conductive core in the winding driven by the inverter device, whereby at least a portion of the one or more non-conductive layers will be located at or adjacent to the one or more predetermined high electric field regions along the conductive core in the winding driven by the inverter device.

5. An electrically insulated conductor according to any one of the preceding claims, wherein The one or more non-conductive layers include ends at least partially adhered along at least one side of the conductive core.

6. An electrically insulated conductor according to any one of the preceding claims, wherein The one or more non-conductive layers are at least partially folded longitudinally around the periphery of the conductive core.

7. The electrically insulated conductor of claim 4, wherein: The one or more non-conductive layers are completely folded around the periphery of the conductive core.

8. An electrically insulated conductor according to claim 7, wherein: The one or more non-conductive layers are completely folded around the perimeter of the conductive core with at least one overlap such that at least a portion of the one or more non-conductive layers overlaps at least one other portion of the one or more non-conductive layers.

9. An electrically insulated conductor according to claim 8, wherein: The one or more non-conductive layers are completely folded around the perimeter of the conductive core with multiple overlaps such that portions of the one or more non-conductive layers overlap with other portions of the one or more non-conductive layers.

10. An electrically insulated conductor as claimed in any preceding claim, wherein The one or more non-conductive layers are folded at least partially around a perimeter of the conductive core substantially perpendicular to a length of the conductive core.

11. An electrically insulated conductor according to any preceding claim, wherein The one or more non-conductive layers include at least one functionalized dielectric layer designed for through-plane thermal conductivity and / or partial discharge resistance.

12. An electrically insulated conductor as claimed in any preceding claim, wherein The one or more non-conductive layers include a multi-layer structure.

13. An electrically insulated conductor according to any preceding claim, wherein The multilayer structure comprises at least one or more dielectric layers comprising one or more enamels, adhesion promoters, varnishes, extruded and / or engineered polymers, polymer films, and / or polymer films functionalized with inorganic and / or organic particles, e.g., anti-corona, foamed, etc.

14. An electrically insulated conductor according to claim 13, wherein: The multilayer structure comprises at least one or more dielectric layers comprising one or more enamel packages comprising a certain type of varnish, and wherein: The certain type of varnish comprises polyimide, polyamide-imide, polyesterimide and / or a combination thereof; and / or Said certain types of varnishes are functionalized with inorganic and / or organic particles, such as anti-corona, foaming, etc.

15. An electrically insulated conductor according to claim 11 or 14, wherein: The multilayer structure includes one or more semiconducting layers.

16. An electrically insulated conductor as claimed in any preceding claim, wherein The electrically insulated conductor includes an adhesive for adhesive attachment of the one or more electrically non-conductive layers.

17. An electrically insulated conductor according to claim 16, wherein: The adhesive is capable of adhesively bonding to conductive surfaces, metallic surfaces, and polymer surfaces.

18. An electrically insulated conductor as claimed in any preceding claim, wherein The electrically insulated conductor comprises a polymer surface along at least a portion of the conductive core, wherein the one or more non-conductive layers cover at least a portion of the polymer surface such that the covered portion of the polymer surface is between the conductive core and the one or more non-conductive layers.

19. An electrically insulated conductor according to claim 18, wherein The polymer surface includes at least one region not covered by the one or more electrically non-conductive layers and generally located between at least two spaced-apart discontinuous portions of the one or more electrically non-conductive layers.

20. The electrically insulated conductor of claim 18, wherein: The one or more non-conductive layers cover the entire polymer surface.

21. The electrically insulated conductor of claim 18, wherein: The polymer surface is along the entire circumference of the conductive core.

22. An electrically insulated conductor as claimed in any one of claims 1 to 17, wherein The one or more non-conductive layers include an enamel coating.

23. An electrically insulated conductor as claimed in any one of claims 1 to 17, wherein: The one or more non-conductive layers include a first non-conductive layer; and The electrically insulated conductor includes a second electrically non-conductive layer comprising an enamel sheath extending longitudinally at least partially along the length of the electrically conductive core and at least partially around the periphery of the electrically conductive core.

24. An electrically insulated conductor as claimed in any preceding claim, wherein: The conductive core has a substantially rectangular, circular, elliptical, rhombus, or chamfered rectangular cross-sectional shape, or other cross-sectional shapes having at least one side; and / or The electrically insulated conductor has a generally rectangular, circular, elliptical, rhomboid, or chamfered rectangular cross-sectional shape, or other cross-sectional shapes having at least one side defined jointly by the conductive core and the one or more non-conductive layers.

25. An electrically insulated conductor as claimed in any preceding claim, wherein The conductive core includes a magnetic wire.

26. An electrically insulated conductor as claimed in any preceding claim, wherein The conductive core includes a copper wire, an aluminum wire or a stainless steel wire having a substantially rectangular, circular, elliptical, rhombus, or chamfered rectangular cross-sectional shape, or other cross-sectional shapes having at least one side.

27. An electrically insulated conductor as claimed in any preceding claim, wherein The one or more non-conductive layers are at least partially folded around the periphery of the conductive core such that no portion of the one or more non-conductive layers is overlapped and covered by another portion of the one or more non-conductive layers.

28. An electrically insulated conductor as claimed in any one of claims 1 to 26, wherein The one or more non-conductive layers are folded around the entire periphery of the conductive core so that only the opposite first and second longitudinal ends of the one or more non-conductive layers overlap, and other portions of the one or more non-conductive layers do not overlap with another portion of the one or more non-conductive layers.

29. An electrically insulated conductor as claimed in any one of claims 1 to 26, wherein The one or more non-conductive layers are folded around the entire periphery of the conductive core so that the one or more non-conductive layers include opposite first and second longitudinal ends adjacent to each other, and no portion of the one or more non-conductive layers is overlapped and covered by another portion of the one or more non-conductive layers.

30. An electrically insulated conductor as claimed in any one of claims 1 to 26, wherein The one or more non-conductive layers are folded around less than the entire periphery of the conductive core so that the one or more non-conductive layers include opposing first and second longitudinal ends, the first and second longitudinal ends being spaced apart and discontinuous from each other, the spaced apart first and second longitudinal ends defining a gap therebetween extending longitudinally at least partially along the length of the conductive core.

31. An electrically insulated conductor as claimed in any one of claims 1 to 26, wherein: The one or more non-conductive layers are folded around the entire periphery of the conductive core so that the one or more non-conductive layers include opposite first and second longitudinal ends adjacent to each other, and the adjacent first and second longitudinal ends define a longitudinal seam therebetween that extends longitudinally at least partially along the length of the conductive core.

32. An electrically insulated conductor as claimed in any one of claims 1 to 26, wherein: The one or more non-conductive layers are folded around the entire periphery of the conductive core so that the one or more non-conductive layers include opposite first and second longitudinal ends that overlap each other, and the overlapping first and second longitudinal ends define an overlapping seam therebetween that extends at least partially along the length of the conductive core.

33. An electrically insulated conductor as claimed in any one of claims 1 to 26, wherein: The conductive core includes a plurality of sides defining the perimeter; and The one or more non-conductive layers are folded such that the one or more non-conductive layers at least partially extend longitudinally along at least two of the plurality of sides of the conductive core.

34. An electrically insulated conductor as claimed in claim 33, wherein: The one or more non-conductive layers are folded such that the one or more non-conductive layers extend longitudinally at least partially along each of the plurality of sides of the conductive core.

35. An electrically insulated conductor as claimed in any one of claims 1 to 26, wherein: The conductive core includes a plurality of sides defining the perimeter; and The one or more non-conductive layers are folded such that the one or more non-conductive layers extend longitudinally along less than all of the plurality of sides of the conductive core.

36. An electrically insulated conductor as claimed in any one of claims 1 to 26, wherein: The conductive core includes a plurality of sides defining the perimeter; and The one or more non-conductive layers are disposed along only one side of the plurality of sides of the conductive core.

37. An electrically insulated conductor as claimed in any one of claims 1 to 26, wherein: The conductive core includes a plurality of sides defining the perimeter; The one or more non-conductive layers are spirally wound with a polymer film; and The electrically insulated conductor includes one or more second non-conductive layers disposed along only one side of the conductive core or along the multiple sides of the conductive core.

38. An electrically insulated conductor as claimed in any one of claims 1 to 26, wherein: The conductive core includes a plurality of sides defining the perimeter; The one or more non-conductive layers are disposed along only one side or along the multiple sides of the conductive core; and The electrically insulated conductor includes one or more second non-conductive layers helically wound with a polymer film.

39. An electrically insulated conductor as claimed in any preceding claim, wherein The one or more non-conductive layers are configured to electrically insulate the electrically conductive core for use in a distributed electrical winding, whereby the one or more non-conductive layers are configured to provide a dielectric barrier to the distributed electrical winding defined by the electrically insulated conductor.

40. A winding driven by a converter device, the winding comprising an electrically insulated conductor according to any preceding claim, wherein: The one or more non-conductive layers are located at or adjacent to one or more predetermined high electric field regions along the conductive core in the winding.

41. A stator winding for an electric motor, the stator winding comprising an electrically insulated conductor according to any one of claims 1 to 39, wherein: The one or more non-conductive layers are located at or adjacent to one or more predetermined high electric field regions along the conductive core in the stator winding.

42. A method of manufacturing an electrically insulated conductor for a winding driven by a converter device, the method comprising: One or more ends of the non-conductive layers are longitudinally adhered parallel to the length of the conductive core and / or at least partially along the length of the conductive core, so that the one or more non-conductive layers are at least partially along the periphery of the conductive core and are configured to target one or more predetermined high electric field regions along the conductive core in the winding driven by the converter device.

43. The method of claim 42, wherein: The method comprises folding the one or more non-conductive layers at least partially around a periphery of the conductive core such that: The one or more electrically non-conductive layers are non-uniform and / or asymmetric at least partially along the periphery of the electrically conductive core; or The one or more non-conductive layers are symmetrical at least partially along a perimeter of the conductive core; Thereby, at least a portion of the one or more non-conductive layers will be located at or adjacent to the one or more predetermined high electric field regions along the conductive core in the winding driven by the converter device.

44. The method according to claim 42 or 43, wherein: The method includes positioning the electrically insulated conductor within the winding such that at least a portion of the one or more non-conductive layers will be located at or adjacent to the one or more predetermined high electric field regions along the conductive core in the winding driven by the converter device.

45. The method according to any one of claims 42 to 44, wherein: The method includes selectively applying the one or more non-conductive layers at least partially along the length of the conductive core.

46. ​​A method according to any one of claims 42 to 45, wherein: The method includes selectively applying the one or more non-conductive layers at spaced apart indexed locations along the length of the conductive core.

47. A method according to any one of claims 42 to 46, wherein: The method comprises manufacturing an electrically insulated conductor according to any one of claims 1 to 39.

48. A system configured to perform the method according to any one of claims 42 to 46.

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