Copper-clad aluminum composite enameled wire core
By using a composite structure of hollow copper wire wrapped around solid aluminum wire and a multi-layer protective layer design, the problem of existing enameled wires being heavy and inconvenient to carry has been solved, achieving lightweighting and cost reduction, while improving safety and insulation.
Patent Information
- Application Number
- CN202580001892.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-17
- Publication Date
- 2026-01-23
AI Technical Summary
Existing enameled wire core conductor structures are simple; copper wire is heavy and expensive, while aluminum wire is light but has poor conductivity, resulting in enameled wires that are inconvenient to carry and have limited applications.
It adopts a composite structure of hollow copper wire wrapped with solid aluminum wire, combined with wear-resistant, fire-resistant and insulating layers. The design of positioning slots and plates achieves a tight fit, reducing weight and cost.
While maintaining conductivity and corrosion resistance, the weight and cost of the wire core are reduced, and portability is improved, while abrasion resistance, fire resistance and insulation properties are enhanced.
Smart Images
Figure CN121399696A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The present application relates to the technical field of enameled wire, for example to a copper-clad aluminum composite enameled wire core. BACKGROUND
[0002] Enameled wire, also known as winding wire, is an electric wire coated with a layer of insulating paint on the conductor, mainly used in electrical equipment to realize electromagnetic energy conversion, and is one of the main components of transformers. The structure of enameled wire has two parts: conductor and insulation. According to the different shapes and conductors and insulations, enameled wire has different divisions. The structure of enameled wire is divided into two parts: conductor and insulation. The conductor material is copper, aluminum, and alloy. The insulating material is divided into insulating paint, such as acetal paint, polyester paint, polyester-imine paint, polyurethane paint, polyamide paint, polyamide-imide paint, aromatic polyimide paint, and polyamide-imide paint. According to the conductor shape, enameled wire can also be divided into round wire, flat wire, and hollow wire. The related technology has the following problems:
[0003] Because the existing enameled wire core conductor structure is relatively single, it is generally pure copper wire material or aluminum wire material. Although copper wire has better conductivity and corrosion resistance, it is heavier and more expensive, making the manufactured enameled wire inconvenient to carry. Although aluminum material is lighter and less expensive, it has poorer conductivity and corrosion resistance than copper wire, and can only be applied to some low-power electrical appliances.
[0004] CONTENT
[0005] The present application provides a copper-clad aluminum composite enameled wire core to reduce the weight and cost of the core by the mutual cooperation between the hollow copper wire and the solid aluminum wire while ensuring the overall conductivity and corrosion resistance of the core.
[0006] The present application provides a copper-clad aluminum composite enameled wire core, which includes a composite core mechanism, a core protection mechanism is arranged on the outer side of the composite core mechanism, the composite core mechanism includes a plurality of hollow copper wires, a solid aluminum wire is fixedly installed in the inner cavity of each of the plurality of hollow copper wires, a positioning slot one is formed in the top of each of the plurality of hollow copper wires, a positioning clamping plate one is formed in the bottom of each of the plurality of hollow copper wires, a positioning slot two is formed in the left side of each of the plurality of hollow copper wires, and a positioning clamping plate two is fixedly installed on the right side of each of the plurality of hollow copper wires. The positioning clamping plate one at the bottom of the upper hollow copper wire is clamped with the positioning slot one formed at the top of the lower hollow copper wire in the vertically adjacent hollow copper wires, and the positioning slot two on the left side of the right hollow copper wire is clamped with the positioning clamping plate two on the right side of the left hollow copper wire in the horizontally adjacent hollow copper wires.
[0007] In one embodiment, the core protection mechanism includes a wear-resistant layer, a fireproof layer is fixedly installed on the inner wall of the wear-resistant layer, an insulation layer is fixedly installed on the inner wall of the fireproof layer, and the composite core mechanism is located in the inner cavity of the insulation layer. Attached Figure Description
[0008] Figure 1 This is a schematic diagram of the overall structure of this application;
[0009] Figure 2 This is a schematic diagram of the composite wire core mechanism of the present application.
[0010] Figure 3 This is a schematic diagram of the disassembled state of the hollow copper wire structure in this application.
[0011] Figure 4 This is a schematic diagram of the wire core protection mechanism of the structure in this application.
[0012] In the diagram: 1. Composite wire core mechanism; 11. Hollow copper wire; 111. Positioning slot one; 112. Positioning plate one; 113. Positioning slot two; 114. Positioning plate two; 12. Solid aluminum wire; 2. Wire core protection mechanism; 21. Wear-resistant layer; 22. Fireproof layer; 23. Insulation layer. Detailed Implementation
[0013] Example 1
[0014] like Figures 1-4 As shown, this application provides a copper-clad aluminum composite enameled wire core, including a composite wire core mechanism 1, a wire core protection mechanism 2 is provided on the outside of the composite wire core mechanism 1, the composite wire core mechanism 1 includes a plurality of hollow copper wires 11, and a solid aluminum wire 12 is fixedly installed in the inner cavity of each of the plurality of hollow copper wires 11.
[0015] In this embodiment, the overall composite core mechanism 1 is constructed by wrapping a solid aluminum wire 12 with a hollow copper wire 11. The hollow copper wire 11 is located on the outer wall of the solid aluminum wire 12, which can ensure its corrosion resistance and improve its conductivity. At the same time, since its inner cavity is hollow, the solid aluminum wire 12 is lightweight and has a low cost. This allows for a reduction in the weight and cost of the core while maintaining the overall performance of the composite core mechanism 1, making it easier to carry.
[0016] Example 2
[0017] like Figures 1-4As shown, based on Embodiment 1, this application provides a technical solution: Optionally, a positioning slot 111 is provided at the top of each of the plurality of hollow copper wires 11, a positioning plate 112 is provided at the bottom of each of the plurality of hollow copper wires 11, a positioning slot 113 is provided on the left side of each of the plurality of hollow copper wires 11, and a positioning plate 114 is fixedly installed on the right side of each of the plurality of hollow copper wires 11. In the vertical direction, the positioning plate 112 at the bottom of the upper hollow copper wire 11 of the adjacent hollow copper wires 11 engages with the positioning slot 111 at the top of the lower hollow copper wire 11. In the horizontal direction, the positioning slot 113 on the left side of the right hollow copper wire 11 of the adjacent hollow copper wires 11 engages with the positioning plate 114 on the right side of the left hollow copper wire 11.
[0018] In this embodiment, the wear-resistant layer 21 of the core protection mechanism 2, which is wrapped around the outer wall of the overall composite core mechanism 1, is made of nylon braided material and has good wear resistance to prevent cracking during use. Meanwhile, the fireproof layer 22 on the inner wall of the wear-resistant layer 21 is made of rock wool. Rock wool is an inorganic fiber material made of materials such as quartz sand, bedrock, and tar, which has good flame retardancy to prevent fire from affecting the core. Finally, the insulation layer 23, which is in direct contact with the outer wall of the hollow copper wire 11, is made of insulating rubber material, which can effectively prevent leakage. During installation, the insulation layer 23 can be wrapped around the outer wall of multiple hollow copper wires 11 and then heated to make it adhere to the outer wall of the hollow copper wire 11.
[0019] Example 3
[0020] like Figures 1-4 As shown, based on Embodiment 1, this application provides a technical solution: Optionally, the core protection mechanism 2 includes a wear-resistant layer 21, a fireproof layer 22 is fixedly installed on the inner wall of the wear-resistant layer 21, an insulation layer 23 is fixedly installed on the inner wall of the fireproof layer 22, and the composite core mechanism 1 is located in the inner cavity of the insulation layer 23.
[0021] In this embodiment, before wrapping multiple hollow copper wires 11, in order to reduce the gaps between them, the positioning plate 112 at the bottom of the upper hollow copper wire 11 of the adjacent hollow copper wires 11 in the vertical direction is inserted into the positioning plate 112 at the top of the lower hollow copper wire 11 to merge them vertically. The positioning plate 114 on the right side of the left hollow copper wire 11 of the adjacent hollow copper wires 11 in the horizontal direction is inserted into the positioning slot 113 on the left side of the right hollow copper wire 11 to merge them horizontally. This completes the left-right merging, thereby reducing the gaps between the multiple hollow copper wires 11 and avoiding wasted space.
[0022] The working principle of this copper-clad aluminum composite enameled wire core is described below.
[0023] like Figures 1-4As shown, the overall composite core mechanism 1 uses a hollow copper wire 11 wrapped around a solid aluminum wire 12. The hollow copper wire 11, located on the outer wall of the solid aluminum wire 12, ensures corrosion resistance while improving conductivity. Furthermore, due to its hollow interior, the lightweight and low-cost nature of the solid aluminum wire 12 allows for a reduction in core weight and cost while maintaining the overall performance of the composite core mechanism 1, facilitating portability. The core protection mechanism 2, encasing the outer wall of the overall composite core mechanism 1, includes a wear-resistant layer 21 made of nylon braided material, providing excellent wear resistance and preventing breakage during use. The fireproof layer 22 on the inner wall of the wear-resistant layer 21 is made of rock wool, an inorganic fiber material composed of quartz sand, bedrock, tar, and other materials, possessing excellent flame retardancy and fire resistance. To prevent fire from affecting the wire core, the insulation layer 23, which is in direct contact with the inner wall of the fireproof layer 22 and the outer wall of the hollow copper wire 11, is made of insulating rubber. This effectively prevents leakage. During installation, the insulation layer 23 can be wrapped around the outer wall of multiple hollow copper wires 11 and then heated to adhere to the outer wall of the hollow copper wires 11. Before wrapping the multiple hollow copper wires 11, in order to reduce the gaps between them, the positioning plate 112 at the bottom of the upper hollow copper wire 11 is inserted into the positioning plate 112 at the top of the lower hollow copper wire 11 to merge them vertically. The positioning plate 114 on the right side of the left hollow copper wire 11 is inserted into the positioning slot 113 on the left side of the right hollow copper wire 11 to merge them horizontally. This reduces the gaps between the multiple hollow copper wires 11 and avoids wasting space.
[0024] Due to the adoption of the above technical solutions, compared with related technologies, this application has the following advantages: 1. The copper-clad aluminum composite enameled wire core provided by this application, through the mutual cooperation between hollow copper wire and solid aluminum wire, reduces the weight and cost of the wire core while ensuring the overall conductivity and corrosion resistance of the core, and facilitates carrying. 2. The copper-clad aluminum composite enameled wire core provided by this application, through the mutual cooperation between positioning slot one, positioning plate one, positioning slot two, and positioning plate two, allows the hollow copper wires to be tightly fitted together by a snap-fit method, maintaining stability and avoiding waste of the inner cavity space of the insulation layer, while also facilitating the wrapping and installation of the insulation layer.
[0025] This application provides a copper-clad aluminum composite enameled wire core. Through the cooperation between the wear-resistant layer, the fire-resistant layer, and the insulation layer, the outer wall of the enameled wire core has good wear resistance, fire resistance, and insulation, thereby improving the safety performance during use.
Claims
1. A copper clad aluminium composite enameled wire core comprising a composite core mechanism (1), wherein: The outer side of the composite wire core mechanism (1) is provided with a wire core protection mechanism (2), the composite wire core mechanism (1) comprises a plurality of hollow copper wires (11), the inner cavity of each of the plurality of hollow copper wires (11) is fixedly installed with a solid aluminum wire (12), the top of each of the plurality of hollow copper wires (11) is provided with a positioning clamping groove one (111), the bottom of each of the plurality of hollow copper wires (11) is provided with a positioning clamping plate one (112), the left side of each of the plurality of hollow copper wires (11) is provided with a positioning clamping groove two (113), the right side of each of the plurality of hollow copper wires (11) is fixedly installed with a positioning clamping plate two (114), the positioning clamping plate one (112) at the bottom of the upper hollow copper wire (11) among the vertically adjacent hollow copper wires (11) is clamped with the positioning clamping groove one (111) provided at the top of the lower hollow copper wire (11), and the positioning clamping groove two (113) at the left side of the right hollow copper wire (11) among the horizontally adjacent hollow copper wires (11) is clamped with the positioning clamping plate two (114) at the right side of the left hollow copper wire (11).
2. A copper clad aluminum composite enameled wire core as claimed in claim 1, wherein: The wire core protection mechanism (2) comprises a wear-resistant layer (21), the inner wall of the wear-resistant layer (21) is fixedly installed with a fireproof layer (22), the inner wall of the fireproof layer (22) is fixedly installed with an insulating layer (23), and the composite wire core mechanism (1) is located in the inner cavity of the insulating layer (23).