Method of forming joined, individually coated wires

Abstract

A method for forming a multi-wire structure having two wires insulated from each other and joined by an insulating material includes applying a first fluid coating material to a first wire. A first wire carrying a first fluid coating material is advanced through a first mold, thereby forming a first electrically insulated wire comprising a solid layer of a first insulating material on the first wire. A second wire is disposed adjacent the first electrically insulated wire, and a second fluid coating material is applied to the second wire. The first electrically insulated wire and an adjacent second wire carrying a second fluid coating material are then advanced through a second mold to form a multi-wire structure having two wires electrically insulated from each other and joined to each other by the first and second insulating materials.

Description

Technical Field

[0001] The present disclosure relates to shaped wire, particularly wire suitable for use in stators of electric machines.

[0002] Wires used in electrical devices are usually insulated with electrical insulating materials. In the stator of an electric motor, the insulated wires are often wound into coils, and an electromagnetic field is generated when alternating current is applied to the coil windings.

[0003] As the demand for electric motors in transportation vehicles increases, there is a need for improvements in stator design. Also, there is a need for manufacturing efficiencies in the components used in the stators. Summary of the invention

[0004] In an exemplary embodiment, a method for forming a multi-wire structure is disclosed herein, the multi-wire structure having two wires insulated and connected to each other by an insulating material. The method includes applying a first fluid coating material to a first wire, wherein the first fluid coating material includes a precursor or fluid form of a first insulating material. The first wire with the first fluid coating material is advanced through a first die and forms a first electrically insulated wire having a solid layer of the first insulating material on the first wire. A second wire is disposed adjacent to the first electrically insulated wire, and a second fluid coating material is applied to the second wire, wherein the second fluid coating material includes a precursor or fluid form of a second insulating material. Then, the first electrically insulated wire and the adjacent second wire with the second fluid coating material are advanced through a second die to form a multi-wire structure having two wires electrically insulated from each other and connected to each other by the first insulating material and the second insulating material.

[0005] The method may further include providing a third wire adjacent to the first electrically insulated wire and separated from the second wire by the first electrically insulated wire, wherein the second fluid coating material is also applied to the third wire. Advancing through the second die includes advancing the first electrically insulated wire, the adjacent second wire carrying the second fluid coating material, and the third wire carrying the second fluid coating material through the second die to form a multi-wire structure having three electrical wires electrically insulated from each other and connected to each other by the first insulating material and the second insulating material.

[0006] The method may also include providing an additional conductive wire adjacent to the multi-wire structure, and applying an additional fluid coating material to the additional conductive wire. The additional fluid coating material includes a precursor of an additional insulating material or a fluid form of an additional insulating material, and advancing the additional conductive wire and the adjacent multi-wire structure carrying the additional fluid coating material through an additional die to form a multi-wire structure having a first insulated conductive wire, a second insulated conductive wire, and an additional insulated conductive wire electrically insulated from each other and connected to each other by the first insulating material, the second insulating material, and the additional insulating material. The steps of providing the additional conductive mixture, applying the additional fluid coating material, and advancing through the additional die may be repeated to form a multi-wire structure having four or more insulated conductive wires connected to each other by the first insulating material, the second insulating material, and the additional insulating material.

[0007] Any two or all of the first fluid coating material, the second fluid coating material, and the additional fluid coating material may be the same.

[0008] The application and advancement of the fluid coating material through the mold can be performed in an oven. The mold can be an enamel mold. The method can also include stretching the first wire, the second wire, or both wires to a desired cross-sectional size in an oven before applying the first fluid coating material, the second fluid coating material, or both fluid coating materials.

[0009] The fluid coating material can be a thermoplastic or a thermosetting precursor. For example, the thermoplastic can include polyetheretherketone, polyaryletherketone, polyetheretherketoneketone, polyetherketoneketone, polyetherketone, polyetherketoneketoneetherketone, polyketone, thermoplastic polyimide, aromatic polyamide, aromatic polyester, polyphenylene sulfide, polysulfone, polyphenylsulfone, polyethersulfone or a combination of two or more thereof. In particular, the thermoplastic can be polyether-ether-ketone. As another example, the thermosetting precursor can be one or more precursors of polyvinyl acetal-phenolic resin, polyimide, polyamide-imide, polyester, thermoplastic modified polyester, polyesterimide, polysulfone, polyphenylene sulfone, polysulfide, polyphenylene sulfide, polyetherimide, polyurethane, polyamide or nylon.

[0010] Applying the fluid coating material may include providing the fluid coating material from an extruder.

[0011] The first and second dies may be crosshead dies.

[0012] The method may include collecting the multi-wire structure on a spool.

[0013] The method may include forming the multi-filar structure into a winding for a stator of an electric machine.

[0014] The above features and advantages and other features and advantages of the present disclosure are apparent from the following detailed description when taken in conjunction with the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] Other features, advantages and details appear, by way of example only, from the following detailed description, which refers to the accompanying drawings, in which:

[0016] Figure 1 is a simplified schematic diagram of one example of an apparatus for performing the method as described herein;

[0017] Figure 2 is a schematic diagram of an example of an apparatus for performing the method as described herein;

[0018] Figure 3 is a schematic diagram of an example of the method described herein;

[0019] Figure 4 is a schematic diagram of an example of the method described herein;

[0020] Figure 5 is a cross-sectional schematic diagram of an example of a multi-wire article as manufactured by the methods described herein; and

[0021] Figure 6 is a cross-sectional schematic diagram of an example of a multi-wire article as made by the methods described herein. DETAILED DESCRIPTION

[0022] The following description is merely exemplary in nature and is not intended to limit the present disclosure, its application, or uses. It should be understood that throughout the drawings, corresponding reference numerals indicate the same or corresponding parts and features.

[0023] According to exemplary embodiments, the methods described herein can be performed in an oven. Figure 1 As shown, a first wire 10 is fed into an oven 100 and passed through a die 115 (e.g., an enamel die) where a first fluid coating material is applied to the wire. After passing through the die 115, the coating material solidifies to form a first electrically insulated wire 11 of the wire 10 as the wire 10 advances through the oven 100, the first electrically insulated wire 11 carrying a layer of the first insulating material. A second wire 20 is fed into the oven 100 and positioned adjacent to the first electrically insulated wire 11. Both the wire 20 and the first electrically insulated wire 11 advance through a second die 125 (e.g., an enamel die) where a second fluid coating material is applied. After passing through the second die 125, the second fluid coating material solidifies to form a second insulating material. The resulting multi-wire structure 30 has two electrically insulated wires 10 and 20 insulated from each other by the first insulating material and / or the second insulating material and connected to each other by the second insulating material. The wires can be routed around a pin or roller 110.

[0024] According to another exemplary embodiment, the method described herein can be performed using an extruder. Figure 2 As shown, the first conductor 10 is fed through a first crosshead die 215, and the first crosshead die 215 provides a first fluid coating material to the wire 10 from an extruder 200. The coating material solidifies and / or solidifies to form a first electrically insulated conductor 11 of the conductor 10 carrying the first insulating material layer. The second conductor 20 is fed adjacent to the first electrically insulated conductor 11 through a second crosshead die 225, in which a second fluid coating material is provided from the extruder 200, and then solidified to form a second insulating material. This forms a multi-wire structure 30 with two electrically insulated conductors 10 and 20, which are insulated from each other by a first insulating material and an optional second insulating material and are connected to each other by a second insulating material. As an alternative, two separate extruders can be used, each extruder feeding one of the crosshead dies.

[0025] When viewed in a cross section perpendicular to the length of the wire, the method described herein is performed as follows: Figure 3 and Figure 4 The example shown is further illustrated in FIG. Figure 3 , a first wire 10 is provided. In a first mold 15, a first fluid coating material 12 is applied around the first wire 10. The first fluid coating material 12 is cured to form a first electrically insulated wire 11, which has a layer of a first insulating material 14 surrounding the first wire 10. A second wire 20 is then disposed adjacent to the first electrically insulated wire 11. In a second mold 25, a second fluid coating material 22 is applied around the first electrically insulated wire 11 and the second wire 20. The second fluid coating material is cured to form a multi-wire structure 30 having two electrically insulated wires 10 and 20 that are insulated from each other but are linked together by the first insulating material 14 and the second insulating material 24. As shown in the figure, the insulating material 24 is located around the wire 20 and the insulating material 14 and between the wire 20 and the insulating material 14.

[0026] Note that the second insulating material 24 does not need to surround the first insulating material. Figure 5 As shown, if the insulating material 24 surrounds the wire 20 and adheres to the insulating material 14 but does not surround the insulating material 14, then a bond can be achieved. Further note that the wire 20 can abut the insulating material 14. Therefore, in yet another embodiment, as shown in FIG. Figure 6 As shown, the wire 20 may be in direct contact with the insulating material 14. The insulating material 24 may surround other surfaces of the wire 20, and may optionally also surround surfaces of the insulating material 14 that do not contact the wire 20.

[0027] Alternatively, if Figure 3 As shown, an additional conductor 40 may be disposed adjacent to the multi-wire structure 30. In an additional mold 35, an additional fluid coating material 32 is applied around the multi-wire structure 30 and the additional conductor 40. The additional fluid coating material is cured to form a multi-wire structure 50 having three conductors 10, 20, and 40 insulated from one another and bonded together with insulating materials 14, 24, and 34. The optional steps may be repeated with additional conductors placed adjacent to the multi-wire structure and coated in an additional mold.

[0028] As another example, Figure 4 As shown, a first conductor 10 is provided. In a first mold 15, a first fluid coating material 12 is applied around the first conductor 10. The first fluid coating material 12 is cured to form a first electrically insulated conductor 11, which has a layer of a first insulating material 14 surrounding the first conductor 10. A second conductor 20 is disposed adjacent to the first electrically insulated conductor 11. An additional conductor 40 is disposed adjacent to the electrically insulated conductor 11 and is separated from the second conductor by the first electrically insulated conductor. In a second mold 25, a second fluid coating material 22 is applied around the first electrically insulated conductor 11, the second conductor 20, and the additional conductor 40. The second fluid coating material 22 is cured to form a multi-wire structure 50, which has electrically insulated conductors 10, 20, and 40 that are insulated from each other and connected together by the first insulating material 14 and the second insulating material 24.

[0029] The method may include stretching the first wire, the second wire, or the additional wire to a desired cross-sectional size prior to coating. If desired, such stretching may occur in oven 100.

[0030] The method may include forming additional layers of insulating material by adding additional coating dies.For example, the second layer may be added to electrically insulated conductor 11 before joining electrically insulated conductor 11 to second conductor 20.

[0031] The method may include collecting the multi-wire structure 30 or 50 on a reel or spool.

[0032] Each conductor 10, 20 or 40 can be any conductor, such as copper or aluminum. Each conductor 10, 20 or 40 can have the same composition as other conductors 10, 20 or 40 in the multi-wire structure 30 or 50 or a different composition. Each conductor 10, 20 or 40 can have a desired cross-section, such as a spherical or rectangular shape. Each conductor 10, 20 or 40 can have the same cross-sectional shape as other conductors 10, 20 or 40 in the multi-wire structure 30 to 50 or a different cross-sectional shape. Each conductor 10, 20 or 40 can have a maximum cross-sectional size of 1 to 4 or 1.5 to 3 mm. Each conductor 10, 20 or 40 can have the same cross-sectional size as other conductors 10, 20 or 40 in the multi-wire structure 30 or 50 or a different cross-sectional size.

[0033] The first fluid coating material, the second fluid coating material and the additional fluid coating material can be the same, or they can be different. The fluid coating material can be, for example, a thermoplastic or a thermosetting plastic. The fluid coating material can be, for example, an enamel material for coating wire.

[0034] Thermoplastic fluid coating material will be in fluid form when applied, for example, higher than the melting temperature of the material, but will solidify to form insulating material when cooled. Examples of thermoplastics that can be used for coating and insulating wire 10, 20 or 40 include polyetheretherketone ("PEEK"), polyaryletherketone ("PAEK"), polyetheretherketoneketone ("PEEKK"), polyetherketoneketone ("PEKK"), polyetherketone ("PEK"), polyetherketoneketoneketone ("PEKKEK"), polyketone ("PK"), any other suitable material including at least one ketone group, thermoplastic polyimide ("PI"), aromatic polyamide, aromatic polyester, polyphenylene sulfide ("PPS"), polysulfone ("PSU"), polyphenylsulfone ("PPSU"), polyethersulfone ("PESU"), and materials combining one or more fluoropolymers with substrates, fluoroethylene, and siloxane group polymers. Thermoplastic material in fluid form can be provided, for example, from an extruder.

[0035] Thermosetting fluid coating materials will be in fluid form when applied, but will irreversibly cure after application (e.g., upon heating) to cure to form an insulating material. Examples of thermosetting systems include polyvinyl acetal-phenolic resins, polyimides ("PI"), polyamideimides ("PAI"), polyesters, THEIC-modified polyesters (e.g., trishydroxymethyl isocyanate-modified polyesters), polyesterimides, polysulfones, polyphenylene sulfones, polysulfides, polyphenylene sulfides, polyetherimides, polyurethanes, polyamides, and nylons.

[0036] The multilayer structure made according to the above method can be formed into windings for the stator of an electric motor. Such motors can be used in industrial fans, blowers and pumps, machine tools, household appliances, power tools, vehicles or disk drives. Examples of vehicles include cars, trucks, motorcycles and electric bicycles. The multilayer structure can also be used as a cable or in magnetic levitation applications.

[0037] The terms "one" and "an" do not indicate a limitation of quantity, but rather indicate the presence of at least one of the referenced item. Unless the context clearly indicates otherwise, the term "or" means "and / or". References to "aspects" throughout the specification mean that a particular element (e.g., a feature, structure, step, or characteristic) described in conjunction with that aspect is included in at least one aspect described herein, and may or may not be present in other aspects. In addition, it should be understood that the described elements may be combined in any suitable manner in the various aspects.

[0038] When an element such as a layer, film, region, or substrate is referred to as being "on" another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements present.

[0039] Unless otherwise indicated herein, the test standard is the most recent standard in effect as of the filing date of this application or, if priority is claimed, the filing date of the earliest priority application in which the test standard appears.

[0040] Unless defined otherwise, technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure belongs.

[0041] Although the above disclosure has been described with reference to exemplary embodiments, it will be appreciated by those skilled in the art that various changes may be made and equivalents may be substituted for its elements without departing from its scope. In addition, many modifications may be made to adapt specific circumstances or materials to the teachings of the disclosure without departing from the basic scope of the disclosure. Therefore, it is intended that the disclosure is not limited to the specific embodiments disclosed, but will include all embodiments falling within its scope.

Claims

1. A method comprising: applying a first fluid coating material to the first conductive wire, wherein the first fluid coating material comprises a precursor or fluid form of a first insulating material, advancing the first conductive wire carrying the first fluid coating material through a first die and forming a first electrically insulated conductive wire comprising a solid layer of the first insulating material on the first conductive wire, providing a second conductive wire adjacent to the first electrically insulated conductive wire, applying a second fluid coating material to the second conductive wire, wherein the second fluid coating material comprises a precursor or fluid form of a second insulating material, and The first electrically insulated wire and the adjacent second wire carrying the second fluid coating material are advanced through a second die to form a multi-wire structure having two wires electrically insulated from and connected to each other by the first insulating material and the second insulating material.

2. The method of claim 1 , further comprising providing a third conductive wire adjacent to the first electrically insulated conductive wire and separated from the second conductive wire by the first electrically insulated conductive wire, wherein the second fluid coating material is also applied to the third conductive wire, wherein advancing through the second die comprises advancing the first electrically insulated conductive wire, the adjacent second conductive wire carrying the second fluid coating material, and the third conductive wire carrying the second fluid coating material through the second die to form a multi-wire structure having three electrically conductive wires electrically insulated from each other and connected to each other by the first insulating material and the second insulating material.

3. The method according to claim 1, wherein: The first fluid coating material and the second fluid coating material have the same composition.

4. The method according to claim 1, further comprising: providing an additional wire adjacent to the multi-wire structure, applying an additional fluid coating material to the additional wire, wherein the additional fluid coating material comprises a precursor or fluid form of an additional insulating material, and The additional wire carrying the additional fluid coating material and the adjacent multi-wire structure are advanced through an additional die to form a multi-wire structure having the first insulated wire, the second insulated wire and the additional insulated wire electrically insulated from and connected to each other by the first insulating material, the second insulating material and the additional insulating material.

5. The method of claim 4, comprising repeating the steps of providing, applying and advancing to form a multi-wire structure having four or more insulated wires connected to each other by the first insulating material, the second insulating material and the additional insulating material.

6. The method according to claim 1, wherein: Applying the first and second fluid coating materials and advancing through the first and second molds is performed in an oven, and wherein the first and second molds are enamel molds.

7. The method of claim 6, wherein the first fluid coating material and / or the second fluid coating material is a thermoplastic, the thermoplastic comprising polyetheretherketone, polyaryletherketone, polyetheretherketoneketone, polyetherketoneketone, polyetherketone, polyetherketoneketoneetherketone, polyketone, thermoplastic polyimide, aromatic polyamide, aromatic polyester, polyphenylene sulfide, polysulfone, polyphenylsulfone, polyethersulfone or a combination of two or more thereof.

8. The method of claim 1 , wherein the first fluid coating material and the second fluid coating material are thermoplastic or thermosetting precursors of polyvinyl acetal-phenolic resin, polyimide, polyamide-imide, polyester, thermoplastic modified polyester, polyester-imide, polysulfone, polyphenylene sulfone, polysulfide, polyphenylene sulfide, polyetherimide, polyurethane, polyamide or nylon.

9. The method of claim 1, wherein the applying comprises providing the fluid coating material from an extruder, and wherein the first die and the second die are crosshead dies.

10. The method of claim 1 further comprising forming the multi-filar structure into windings for a stator of an electric machine.

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