Preparation method and manufacturing equipment for a composite coating enameled braided flat wire

Abstract

The present invention discloses a preparation method and manufacturing equipment for a composite coated enameled braided flat wire. The composite coated enameled braided flat wire prepared by this method includes a braided flat wire body and a polyester wrapping layer, and the polyester wrapping layer is composed of polyimide, high ortho phenolic resin, silicon carbide, boron nitride, nano-aluminum oxide, polyethersulfone, diisocyanate, styrene-maleic anhydride copolymer, solvent and silane coupling agent in specific proportions. Through the ultrasonic dispersion + high-speed shearing process, it is ensured that the fillers are evenly dispersed and the coating thickness deviation is small. By adopting the multi-stage gradient curing and segmented cooling technologies, the internal stress is effectively reduced and the coating cracking is avoided. The present invention also provides a manufacturing equipment for realizing the above preparation method, including an equipment body and a controller, and the controller realizes the automatic control of the preparation method by executing a computer program.

Description

Technical Field

[0001] The present invention relates to the technical field of wires, and specifically relates to a preparation method and manufacturing equipment for a composite coating enameled braided flat wire. Background Art

[0002] With the improvement of the working level, the enameled wire industry has developed well. Enameled wires are widely used in various fields. However, the existing enameled wire structure contains many enamel layers, and each enamel layer structure is composed of many single layers.

[0003] Currently, there is a problem of uneven thickness distribution in the single-layer coating of enameled wires, resulting in insufficient consistency in the overall structural performance, especially poor performance in terms of high-temperature resistance. Due to the sensitivity of the material to temperature fluctuations, when the working temperature exceeds the tolerance threshold, the coating is prone to softening and deformation, which in turn leads to problems such as a decrease in adhesion and deterioration of insulation performance, ultimately significantly shortening the service life of the enameled wire. Summary of the Invention

[0004] (I) Technical Problems to be Solved

[0005] To solve the above problems, the present invention proposes a preparation method and manufacturing equipment for a composite coating enameled braided flat wire, aiming to solve the problems of short service life and poor adhesion performance of enameled wires in the prior art.

[0006] (II) Technical Solutions

[0007] A preparation method for a composite coating enameled braided flat wire of the present invention, wherein the composite coating enameled braided flat wire includes:

[0008] A braided flat wire body and a polyester wrapping layer;

[0009] The formulation ratio of the polyester wrapping layer includes:

[0010] 10 - 15% of polyimide, 18 - 25% of high ortho-phenolic resin, 8 - 15% of silicon carbide, 5 - 12% of boron nitride, 10 - 15% of nano-aluminum oxide, 6 - 8% of polyethersulfone, 3 - 4% of diisocyanate, 8 - 10% of styrene-maleic anhydride copolymer, 3 - 5% of solvent, 1 - 2% of silane coupling agent,

[0011] The preparation process of the polyester wrapping layer includes the following steps:

[0012] S100: Mix silicon carbide, boron nitride, nano-aluminum oxide with a silane coupling agent, add 50% of the total amount of the solvent, and perform ultrasonic dispersion and high-speed shearing to form a uniform slurry;

[0013] S200: Add polyimide, high ortho-phenolic resin, and polyethersulfone to the remaining solvent, and stir at a constant temperature of 60°C until completely dissolved;

[0014] S300. Mix the resin solution with the filler slurry, add styrene-maleic anhydride copolymer, control the temperature at 80 °C and continuously stir, then add diisocyanate and stir until the viscosity of the system is stable to obtain a mixed paint solution;

[0015] S400. Immerse the copper wire in a 10% dilute sulfuric acid solution to remove the surface oxide layer, dry it in an oven for 10 min, evenly coat the surface of the flat wire body with the mixed paint solution by dip coating method, with a coating thickness of 10 - 15 μm, preheat at 80 °C for 5 minutes to initially volatilize the solvent, and then perform electrostatic spraying for secondary coating with a thickness of 5 - 8 μm and a voltage set at 50 kV to ensure a smooth surface;

[0016] S500. Cure the composite coated enameled woven flat wire processed in step S400 by multi-stage gradient curing, and cool the composite coated enameled woven flat wire in segments to prevent thermal stress cracking.

[0017] In the present invention, the solvent used is N-methylpyrrolidone.

[0018] In the present invention, in step S100, ultrasonic waves with a frequency of 40 kHz are used for ultrasonic dispersion for 30 min, and high-speed shearing is performed at 5000 rpm for 20 min to form a uniform slurry;

[0019] In step S200, the dissolution time is 1 - 2 h.

[0020] In the present invention, in step S300, when adding styrene-maleic anhydride copolymer, the stirring speed is 300 rpm and continuous stirring is carried out for 30 min. When adding diisocyanate, the stirring speed is 500 rpm and continuous stirring is carried out for 10 min. When the viscosity of the system is 2000 - 3000 mPa·s, it is okay.

[0021] In the present invention, in step S400, the soaking time is 5 min, the drying time is 10 min, and when coating the mixed paint solution, the coating linear speed is 10 - 15 m / min.

[0022] In the present invention, in step S500, the multi-stage curing includes:

[0023] The first stage, 180 °C / 20 minutes, to promote the initial cross-linking of the resin;

[0024] The second stage, 220 °C / 30 minutes, to enhance the cross-linking density and filler binding;

[0025] The third stage, 250 °C / 15 minutes, to form a dense heat-resistant coating;

[0026] The segmented cooling includes:

[0027] In the first stage, the temperature ranges from 250°C to 100°C, and the cooling rate is ≤5°C / min.

[0028] In the second stage, it is forced air-cooled to room temperature.

[0029] Another manufacturing device for the composite coated enameled braided flat wire of the present invention is characterized by including the manufacturing device body of the composite coated enameled braided flat wire and a controller. The controller includes a processor and a computer program stored in a memory and executable on the processor. When the processor executes the program, it implements the steps of the method for preparing the composite coated enameled braided flat wire according to any one of claims 1-6.

[0030] (III) Beneficial effects

[0031] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0032] In the present invention, through the synergistic effect of polyimide (PI), boron nitride (BN), and nano-aluminum oxide (Al2O3), the long-term temperature resistance reaches above 250°C (IEC 60317 standard), which is 40% higher than that of traditional polyester enameled wires (temperature resistance ≤180°C).

[0033] In the present invention, the process of ultrasonic dispersion (40kHz) + high-speed shearing (5000rpm) is adopted, and the fillers are evenly dispersed. The coating thickness deviation is ≤±5% (detected by a laser thickness gauge), avoiding performance fluctuations caused by uneven thickness in the traditional process.

[0034] In the present invention, the introduction of silicon carbide (SiC) and silane coupling agent increases the tensile strength to 180-220 MPa (ASTM D638), and the adhesion reaches grade 1 (ASTM D3359 cross-cut method), significantly extending the service life. Description of the drawings

[0035] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will briefly introduce the drawings required for the description of the embodiments or the prior art. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained based on these drawings without creative efforts.

[0036] Figure 1 It is a schematic flow structure diagram of the preparation process;

[0037] Figure 2 It is a schematic frame structure diagram of the manufacturing device.

[0038] 60. Processor, 61. Memory, 62. Communication interface, 63. Communication bus. Detailed implementation manners

[0039] To further illustrate the technical means and effects adopted by the present invention to achieve the predetermined invention purpose, the present invention will be described in conjunction with embodiments.

[0040] Example 1

[0041] Mixing ratio 1: Polyimide (PI) 15%, high ortho phenolic resin 20%, silicon carbide (SiC) 12%, boron nitride (BN) 10%, nano-aluminum oxide (Al2O3) 12%, polyethersulfone 7%, diisocyanate 3.5%, styrene-maleic anhydride copolymer 8%, N-methylpyrrolidone 4.5%, silane coupling agent 2%.

[0042] The preparation process includes the following steps:

[0043] S100. Filler dispersion treatment: Mix silicon carbide (SiC), boron nitride (BN), nano-aluminum oxide (Al2O3) with the silane coupling agent, add 50% of the total amount of 4.5% N-methylpyrrolidone (NMP), perform ultrasonic dispersion at a frequency of 40 kHz for 30 min and high-speed shearing at a rotation speed of 5000 rpm for 20 min to form a uniform slurry;

[0044] S200. Resin pre-dissolution: Add polyimide (PI), high ortho phenolic resin, and polyethersulfone (PES) to the remaining solvent, and stir in a constant temperature water bath at 60 °C until completely dissolved (about 1 to 2 h);

[0045] S300. Main mixing and toughening modification: Mix the resin solution with the filler slurry, add styrene-maleic anhydride copolymer (SMA), control the temperature at 80 °C and continuously stir at a stirring speed of 300 rpm for 30 min, add diisocyanate, and quickly stir with a stirring device at a rotation speed of 500 rpm for 10 min until the system viscosity is stable to obtain a mixed paint solution;

[0046] It should be noted that the viscosity is detected by a Brookfield viscometer to be 2000~3000 mPa·s.

[0047] S400. Pretreatment and coating of braided flat wire: Immerse the copper wire in a 10% dilute sulfuric acid solution for 5 min to remove the surface oxide layer, dry it in an oven at 120 °C for 10 min, uniformly coat the mixed paint solution on the surface of the flat wire body by dip coating at a wire speed of 12 m / min, with a coating thickness of 10~15 μm, preheat at 80 °C for 5 minutes to initially volatilize the solvent, and perform electrostatic spraying for secondary coating with a thickness of 5~8 μm and a voltage setting of 50 kV to ensure a smooth surface;

[0048] S500. Curing and cooling: The composite coated enamelled braided flat wire obtained in step S400 is cured through the following three stages:

[0049] The first stage: 180°C for 20 minutes to promote the initial cross-linking of the resin;

[0050] The second stage: 220°C for 30 minutes to enhance the cross-linking density and filler binding;

[0051] The third stage: 250°C for 15 minutes to form a dense heat-resistant coating;

[0052] The cured composite coated enameled braided flat wire is cooled in two stages as follows:

[0053] The first stage: from 250°C to 100°C, with a cooling rate ≤ 5°C / min;

[0054] The second stage: forced air cooling to room temperature.

[0055] Gradient curing (180°C → 220°C → 250°C) and staged cooling (cooling rate ≤ 5°C / min) effectively reduce internal stress and avoid coating cracking.

[0056] Example 2

[0057] Mixing ratio 2: Polyimide (PI) 12%, high ortho-phenolic resin 22%, silicon carbide (SiC) 15%, boron nitride (BN) 5%, nano-aluminum oxide (Al2O3) 15%, polyethersulfone 6%, diisocyanate 4%, styrene-maleic anhydride copolymer 10%, N-methylpyrrolidone 5%, silane coupling agent 1%.

[0058] The preparation method is the same as that of Example 1.

[0059] Example 3

[0060] Mixing ratio 3: Polyimide (PI) 10%, high ortho-phenolic resin 25%, silicon carbide (SiC) 8%, boron nitride (BN) 12%, nano-aluminum oxide (Al2O3) 10%, polyethersulfone 8%, diisocyanate 3%, styrene-maleic anhydride copolymer 9%, N-methylpyrrolidone 5%, silane coupling agent 1%.

[0061] The preparation method is the same as that of Example 1.

[0062] Example 4

[0063] Mixing ratio (control group): Polyethylene terephthalate (PET) 20%, epoxy resin 25%, talcum powder 15%, phthalate plasticizer 5%, xylene solvent 35%.

[0064] The preparation method is the same as that of Example 1.

[0065]

[0066] The heat resistance, mechanical strength, and adhesion of Examples 1-3 were significantly better than those of the control group, verifying the effectiveness of the polyimide-based composite coating and the gradient curing process.

[0067] The uniform dispersion of nano-fillers (BN, Al2O3, SiC) is the key to improving the coating uniformity.

[0068] High-temperature performance test:

[0069]

[0070] Electrical performance test:

[0071]

[0072] Mechanical performance test (ASTM D638 standard):

[0073]

[0074] Adhesion and coating uniformity test:

[0075]

[0076] Process parameter verification experiment

[0077]

[0078] Long-term stability and environmental protection test

[0079]

[0080] Summary of comparative experiments:

[0081] Dispersion of fillers: The ultrasonic plus high-speed shearing process in Example 1 made the fillers (SiC, BN, Al203) disperse evenly (D50 = 0.8 μm), while the fillers in the control group agglomerated due to the absence of coupling agent (D50 = 5 μm).

[0082] Improvement in heat resistance: The synergistic effect of polyimide and nano-fillers enabled the long-term temperature resistance to reach 250 °C, a 40% increase compared to the control group (180 °C).

[0083] Mechanical strength: The tensile strength of Example 1 was 220 MPa, an 83% increase compared to the control group (120 MPa).

[0084] Environmental protection: The solvent usage in Example 1 was reduced by 50%, and the VOC emissions were lower than the international standards.

[0085] Example 5

[0086] An embodiment of the present invention provides a manufacturing device for composite coating enameled braided flat wires.

[0087] Please refer to Figure 2 , Figure 2 which is a schematic structural diagram of a manufacturing device for a composite coated enameled woven flat wire provided by the present invention. The manufacturing device for the composite coated enameled woven flat wire may include:

[0088] A memory for storing computer programs;

[0089] A processor, when executing the computer program, can implement the steps of any of the above intelligent photovoltaic energy storage methods.

[0090] As Figure 2 shown, it is a schematic composition diagram of a manufacturing device for a composite coated enameled woven flat wire. The manufacturing device for the composite coated enameled woven flat wire may include: a processor 60, a memory 61, a communication interface 62, and a communication bus 63. The processor 60, the memory 61, and the communication interface 62 all complete communication with each other through the communication bus 63.

[0091] In the embodiment of the present invention, the processor 60 may be a central processing unit (CPU), an application specific integrated circuit, a digital signal processor, a field programmable gate array, or other programmable logic devices, etc.

[0092] The processor 60 may call the program stored in the memory 61. Specifically, the processor 60 may execute the operations in the embodiment of the button switch fault detection method.

[0093] The memory 61 is used to store one or more programs. The program may include program codes, and the program codes include computer operation instructions. In the embodiment of the present invention, the memory 61 stores at least programs for implementing the following functions:

[0094] Obtain the operating parameters of the battery pack in the energy storage unit through the energy storage monitoring unit, preset a first standard, and when the energy storage unit reaches the first standard, the energy storage monitoring unit sends a second control signal to the switch unit;

[0095] Obtain the power supply status and load status of the power supply unit through the power generation monitoring unit, preset a second standard, and when the power supply unit reaches the second standard, the power generation monitoring unit sends a first control signal to the switch unit;

[0096] After the switch unit obtains the first control signal and the second control signal, it closes the switch to charge and store energy for the battery pack. When the switch unit obtains the second control signal but does not obtain the first control signal, the battery pack drives the photovoltaic energy storage component through the battery management module to charge and store energy for the battery pack.

[0097] In a possible implementation, the memory 61 may include a program storage area and a data storage area. The program storage area may store an operating system and application programs required for at least one function, etc.; the data storage area may store data created during use.

[0098] In addition, the memory 61 may include high-speed random access memory and may also include non-volatile memory, such as at least one magnetic disk storage device or other volatile solid-state storage devices.

[0099] The communication interface 62 may be an interface of a communication module for connecting to other devices or systems.

[0100] Of course, it should be noted that Figure 2 the structure shown does not constitute a limitation on the manufacturing equipment of the composite coated enameled braided flat wire in the embodiments of the present invention. In practical applications, the manufacturing equipment of the composite coated enameled braided flat wire may include more or fewer components than Figure 2 those shown, or combine certain components.

[0101] The present invention is applicable to scenarios such as new energy vehicle motors and high-temperature transformers, and can replace imported high-end enameled wires.

[0102] The above-described embodiments are only used to describe the preferred embodiments of the present invention, and do not limit the concept and scope of the present invention. Without departing from the design concept of the present invention, various variations and improvements made by those of ordinary skill in the art to the technical solutions of the present invention shall fall within the protection scope of the present invention. The technical content claimed by the present invention has been fully recorded in the claims.

Claims

1. A preparation method of a composite-coated enameled braided flat wire, characterized in that, The composite coated enameled braided flat wire includes: A braided flat wire body and a polyester coating layer; The formulation ratio of the polyester coating layer includes: 10 - 15% polyimide, 18 - 25% high ortho phenolic resin, 8 - 15% silicon carbide, 5 - 12% boron nitride, 10 - 15% nano-aluminum oxide, 6 - 8% polyethersulfone, 3 - 4% diisocyanate, 8 - 10% styrene-maleic anhydride copolymer, 3 - 5% solvent, 1 - 2% silane coupling agent, The preparation process of the polyester coating layer includes the following steps: S100: Mix silicon carbide, boron nitride, nano-aluminum oxide with a silane coupling agent, add 50% of the total amount of the solvent, and perform ultrasonic dispersion and high-speed shearing to form a uniform slurry; S200: Add polyimide, high ortho phenolic resin, and polyethersulfone to the remaining solvent, and stir at a constant temperature of 60 °C in water until completely dissolved; S300: Mix the resin solution with the filler slurry, add styrene-maleic anhydride copolymer, control the temperature at 80 °C and continuously stir, add diisocyanate, and stir until the viscosity of the system is stable to obtain a mixed paint solution; S400: Immerse the copper wire in a 10% dilute sulfuric acid solution to remove the surface oxide layer, dry it in an oven for 10 min, uniformly coat the mixed paint solution on the surface of the flat wire body by dip coating method, with a coating thickness of 10 - 15 μm, preheat at 80 °C for 5 minutes to initially volatilize the solvent, and perform electrostatic spraying for secondary coating with a thickness of 5 - 8 μm and a voltage set at 50 kV to ensure a smooth surface; S500: Cure the composite coated enameled braided flat wire processed in step S400 by multi-stage gradient curing, and cool the composite coated enameled braided flat wire in segments to prevent thermal stress cracking.

2. The preparation method of the composite-coated enameled braided flat wire according to claim 1, characterized in that, The solvent used is N-methylpyrrolidone.

3. The method for preparing a composite coated enameled braided flat wire according to claim 2, wherein In step S100, ultrasonic waves with a frequency of 40 kHz are used for ultrasonic dispersion for 30 min and high-speed shearing at 5000 rpm for 20 min to form a uniform slurry; In step S200, the dissolution time is 1 - 2 h.

4. The method for preparing a composite-coated enameled braided flat wire according to claim 3, wherein, In step S300, when adding styrene-maleic anhydride copolymer, the stirring speed is 300 rpm and continuous stirring is for 30 min. When adding diisocyanate, the stirring speed is 500 rpm and continuous stirring is for 10 min. When the viscosity of the system is 2000 - 3000 mPa·s, it is okay.

5. The preparation method of the composite-coated enameled braided flat wire according to claim 4, characterized in that, In step S400, the soaking time is 5 min, the drying time is 10 min, and when coating the mixed paint solution, the coating wire speed is 10 - 15 m / min.

6. The preparation method of the composite coated enameled braided flat wire according to claim 5, characterized in that, In step S500, the multi-stage curing includes: The first stage, 180 °C / 20 minutes, to promote the initial cross-linking of the resin; The second stage, 220 °C / 30 minutes, to enhance the cross-linking density and filler binding; The third stage, 250 °C / 15 minutes, to form a dense heat-resistant coating; The segmented cooling includes: The first stage, from 250 °C to 100 °C, with a cooling rate ≤ 5 °C / min; The second stage, forced air cooling to room temperature.

7. A manufacturing device for a composite-coated enameled braided flat wire, characterized in that, It includes the manufacturing equipment body of the composite-coated enameled braided flat wire and a controller. The controller includes a processor and a computer program stored on a memory and executable on the processor. When the processor executes the program, it implements the steps of the method for preparing the composite-coated enameled braided flat wire according to any one of claims 1-6.

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