Conductor core and enameled wire

Abstract

The application discloses a kind of conductor core and enameled wire, the conductor core is single root structure, its section is plum blossom shape, the plum blossom shape is by multiple circular arc smooth connection, it is alternately enclosed to form;Enameled wire includes the conductor core and the enameled layer of the conductor core outside covering;By setting the plum blossom section of conductor core, using multiple sets of symmetrical circular arc increases the heat dissipation area, can form air guide channel along the axial direction of conductor core and realize high-efficiency heat dissipation;Compared with traditional circular enameled wire conductor core, under the premise of same conductive performance, can obviously save conductor raw material, and the effect of saving material is remarkable.

Description

Technical Field

[0001] This invention relates to the field of enameled wire technology, specifically to a conductor core and enameled wire, which is applicable to fields such as motor windings, high-density wiring, power transmission and electronic equipment, and is especially suitable for scenarios such as new energy vehicle motors and automated equipment where there are high requirements for the heat dissipation, material saving and space utilization of enameled wires. Background Technology

[0002] Enamelled wire is a core conductive component in products such as motors, transformers, and electronic components, and is widely used in various fields including industry, agriculture, transportation, and electronic communications. Currently, most commercially available enamelled wire conductors have a circular cross-section. This type of enamelled wire has several shortcomings in practical applications, particularly in terms of heat dissipation and material conservation, as detailed below:

[0003] 1. High material loss: Circular cross-section enameled wire has a larger cross-sectional area for the same conductivity requirements, resulting in excessive loss of raw materials such as copper. When bundled, there are a lot of gaps between the conductors, requiring more enameled wire to meet conductivity requirements in the same installation space, further increasing material usage and production costs. This does not conform to the current industry trend of cost reduction, efficiency improvement, and green energy saving, especially against the backdrop of rising copper prices, where the need for material conservation is even more urgent.

[0004] 2. Poor heat dissipation performance: The surface area of ​​circular cross-section enameled wire is small, and the ratio of perimeter to area is low, resulting in poor heat dissipation efficiency. At the same time, when circular enameled wire is bundled, the gap distribution is uneven, and heat is easy to accumulate. Under long-term high-load operation, the enameled layer is prone to aging and peeling, which not only shortens the service life of the enameled wire, but also reduces the operational stability of motors and electronic equipment. The heat dissipation problem is even more prominent under harsh operating conditions such as motors of new energy vehicles and power systems of low-altitude flight equipment.

[0005] 3. Low space utilization: When circular cross-section enameled wires are bundled together, the porosity is high. It is impossible to integrate more core wires under the same cross-sectional area, which makes it difficult to meet the high-density wiring requirements in small spaces such as motor windings and electronic equipment, thus limiting the miniaturization and lightweight development of equipment.

[0006] In existing technologies, some enameled wires adopt irregular cross-section designs, but these are mostly limited to flat, elliptical, or similar circular structures, which cannot effectively solve the defects of traditional circular cross-sections in terms of heat dissipation and material saving. Among them, flat enameled wires suffer from uneven heat dissipation and poor flexibility, while elliptical enameled wires have limited material saving effects. Neither can achieve simultaneous optimization of heat dissipation and material saving.

[0007] Therefore, developing a conductor core and enameled wire with good heat dissipation performance, high material utilization rate, significant material saving effect and reasonable structure has become an urgent need in the field of enameled wire technology, and is also the key to promoting the development of the enameled wire industry towards green and energy-saving. Summary of the Invention

[0008] The purpose of this invention is to overcome the shortcomings of the prior art, improve the heat dissipation performance and material utilization of enameled wire, enhance the structural rationality of enameled wire, and provide a conductor core and enameled wire.

[0009] To achieve the above objectives, the present invention adopts the following technical solution:

[0010] A conductor core, wherein the conductor core is a single-strand structure with a cross-section in the shape of a plum blossom, the plum blossom shape being formed by multiple segments of circular arcs smoothly connected end to end and alternately enclosing each other.

[0011] By setting a conductor core with a plum blossom-shaped cross section and using multiple sets of symmetrical arcs to increase the heat dissipation area, an air flow channel can be formed along the conductor core axis to achieve efficient heat dissipation. At the same time, compared with traditional round enameled wire conductor cores, under the premise of the same conductivity, it can significantly save conductor raw materials, resulting in significant material saving effect.

[0012] Preferably, the plum blossom-shaped cross section includes multiple convex arc lobes and multiple concave arc portions, wherein the convex arc lobes are arc-shaped protrusions and the concave arc portions are arc-shaped depressions, and the convex arc lobes and concave arc portions are alternately and evenly arranged.

[0013] Preferably, the centers of the multiple convex arc lobes are the same.

[0014] Preferably, the conductor core is made of copper, aluminum, copper-clad aluminum, or silver-copper alloy.

[0015] Preferably, the silver-copper alloy contains 88% to 95% copper and 5% to 12% silver.

[0016] Preferably, the surface of the conductor core has a dense layer formed after annealing in an inert gas environment.

[0017] Preferably, the conductor core has a through hole.

[0018] An enameled wire includes the conductor core and an enameled layer covering the outside of the conductor core.

[0019] Preferably, the coating layer is made of modified polyurethane paint or polyimide paint.

[0020] Preferably, the thickness of the enameled layer is 0.0008mm-0.0025mm.

[0021] This invention improves the heat dissipation performance and material utilization of enameled wire by using a plum blossom-shaped cross-section conductor core. The alternating and uniform distribution of convex and concave arc sections ensures a symmetrical and uniform plum blossom structure with balanced stress distribution. Compared to traditional circular enameled wire conductor cores, with the same conductivity and similar cross-sectional diameter, the surface area of ​​the plum blossom-shaped conductor core is significantly increased, resulting in a significant improvement in heat dissipation efficiency. Simultaneously, the cross-sectional area is significantly reduced, leading to a substantial reduction in material usage and outstanding material savings. The concave arc design not only allows multiple enameled wires to be bundled together in an interlaced manner, significantly reducing porosity and improving space utilization, but also forms airflow channels, accelerating heat convection, improving heat conduction efficiency, and achieving highly efficient heat dissipation. Furthermore, it significantly reduces the skin effect of high-frequency power supplies or AC power. Moreover, compared to flat, elliptical, and other near-circular enameled wires, the plum blossom-shaped structure of this invention has a simpler processing technology, lower mold costs, and significantly improved structural rationality. Attached Figure Description

[0022] The present invention will now be described in further detail with reference to the accompanying drawings:

[0023] Figure 1 This is a schematic diagram of the structure of Example 1;

[0024] Figure 2 This is a cross-sectional schematic diagram of Example 1;

[0025] Figure 3 This is a cross-sectional schematic diagram of Example 2. Detailed Implementation

[0026] Example 1

[0027] like Figure 1 and Figure 2 As shown, the present invention provides a conductor core, which is a single-strand structure with a cross-section in the shape of a plum blossom. The plum blossom shape is formed by multiple segments of circular arcs that are smoothly connected end to end and alternately enclosed.

[0028] The quincunx-shaped cross-section comprises multiple convex arc segments and multiple concave arc segments. The convex arc segments are arc-shaped protrusions, and the concave arc segments are arc-shaped depressions, with the convex and concave arc segments evenly arranged alternately. The concave arc segments, by curving inwards towards the center, not only allow multiple enameled wires to be bundled together and interlocked, reducing the porosity, but also enable the integration of more core wires within the same installation space, improving space utilization. This is suitable for high-density wiring requirements in confined spaces such as motor windings and electronic equipment. Furthermore, it forms an airflow channel, accelerating heat convection, improving heat transfer efficiency, and achieving efficient heat dissipation. Simultaneously, the improved space utilization allows for more compact internal wiring, indirectly reducing the amount of material used in the equipment casing to achieve auxiliary material savings. Moreover, compact wiring does not impede heat convection, avoiding heat dissipation obstruction caused by dense wiring. In addition, compared to flat, elliptical, or other near-circular enameled wires, the quincunx-shaped cross-section of this application has a simpler processing technology, lower mold costs, and eliminates the need for a stranding process, avoiding single-wire stretching losses during stranding.

[0029] In this embodiment, the plum blossom-shaped cross-section is composed of nine alternating and uniformly distributed convex arc segments and nine concave arc segments. The convex arc segment of the plum blossom-shaped conductor core, with a maximum diameter of 1 mm, has a single arc length of 0.21456 mm, and the concave arc segment has a single arc length of 0.15586 mm, resulting in a total arc length of 3.33374 mm and a conductor core cross-sectional area of ​​0.67629 mm². The smooth transition between the convex and concave arc segments, compared to a traditional circular enameled wire conductor core (1 mm diameter, 3.14159 mm circumference, and 0.78539 mm² area), increases the surface area (longitudinal surface area) of the plum blossom-shaped conductor core by more than 6% under the same conductivity conditions (e.g., the same conductivity), saving more than 13% of raw materials such as copper, demonstrating significant material-saving effects. Furthermore, it significantly reduces the skin effect of high-frequency power supplies or alternating current. Through a reasonable ratio of convex to concave arc lengths, the plum blossom-shaped structure is symmetrical and uniform, with a balanced stress distribution.

[0030] In another embodiment, the quincunx-shaped cross-section can be configured to include 10-13 convex arc segments and 10-13 concave arc segments. The arc angles and radii of the convex and concave arc segments can be the same or different.

[0031] The conductor core is made of copper, aluminum, copper-clad aluminum, or silver-copper alloy. In silver-copper alloys, the copper content is 88%–95%, and the silver content is 5%–12%.

[0032] In this embodiment, the conductor core is made of silver-copper alloy, wherein the copper content is 92% and the silver content is 8%.

[0033] The surface of the conductor core has a dense layer formed after annealing in an inert gas environment. By setting this dense layer, the flexibility of the conductor core and the adhesion of the enamel film can be improved while ensuring conductivity, thus preventing the enameled wire from being scrapped due to enamel film peeling. In addition, the dense layer formed by annealing can also reduce the resistance loss of the conductor core, reduce heat sources, and further improve heat dissipation efficiency.

[0034] The conductor core has a through hole to reduce the skin effect during high-frequency current transmission, saving material and not significantly affecting conductivity.

[0035] This invention improves the heat dissipation performance and material utilization of enameled wire by setting a conductor core with a plum blossom-shaped cross-section. The alternating and uniform distribution of convex and concave arc sections ensures a symmetrical and uniform plum blossom structure with balanced stress distribution. Compared to traditional circular enameled wire conductor cores, with the same conductivity and similar cross-sectional diameter, the surface area of ​​the plum blossom-shaped conductor core of this invention is significantly increased, resulting in a significant improvement in heat dissipation efficiency. Simultaneously, the cross-sectional area is significantly reduced, leading to a substantial reduction in material usage and outstanding material savings. The concave arc design not only allows multiple enameled wires to be bundled together in an interlaced manner, significantly reducing porosity and improving space utilization, but also forms airflow channels, accelerating heat convection and improving heat conduction efficiency for highly efficient heat dissipation. Furthermore, compared to flat, elliptical, and other near-circular enameled wires, the plum blossom-shaped structure of this invention has a simpler processing technology, lower mold costs, and significantly improved structural rationality. Compared to traditional circular enameled wires, the plum blossom-shaped enameled wire of this embodiment has superior anti-interference capabilities and flexibility, making it suitable for scenarios involving frequent dragging, high temperature, and high load, such as new energy vehicle motors, photovoltaic equipment, and lifting equipment.

[0036] Example 2

[0037] The difference from Embodiment 1 is that in this embodiment, the centers of the multiple convex arc lobes are the same. For example... Figure 3 As shown. By setting the centers of multiple convex arc segments to be the same, the complexity of the manufacturing process is reduced.

[0038] Example 3

[0039] The difference from Example 1 is that this example provides an enameled wire, including the conductor core of Example 1 or Example 2 and an enameled layer covering the conductor core. The cross-section of the enameled wire is also quincunx-shaped. The enameled layer tightly covers the conductor core, forming a uniform and dense insulating protective layer. The enameled layer uses modified polyurethane varnish or polyimide varnish, with a thickness of 0.0008mm-0.0025mm. A uniform and dense varnish film is formed through precise coating and segmented drying processes (baking temperature 3.8 to 4.5). The operating temperature range is -40℃ to +150℃. It has good high-temperature resistance, corona resistance, and wear resistance, and is suitable for use under high load and high temperature conditions. It can delay the aging of the enameled layer, extend the service life of the enameled wire, reduce replacement losses, and achieve material saving.

[0040] The above are merely preferred embodiments of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope defined in the claims.

Claims

1. A conductor core, characterized in that, The conductor core is a single-strand structure with a plum blossom-shaped cross-section, which is formed by multiple segments of arcs smoothly connected end to end and alternately enclosing each other.

2. The conductor core according to claim 1, characterized in that, The plum blossom-shaped cross section includes multiple convex arc lobes and multiple concave arc portions. The convex arc lobes are arc-shaped protrusions, and the concave arc portions are arc-shaped depressions. The convex arc lobes and concave arc portions are alternately and evenly arranged.

3. The conductor core according to claim 2, characterized in that, The centers of the multiple convex arc lobes are the same.

4. The conductor core according to claim 1, characterized in that, The conductor core is made of copper, aluminum, copper-clad aluminum, or silver-copper alloy.

5. The conductor core according to claim 1, characterized in that, The silver-copper alloy contains 88%–95% copper and 5%–12% silver.

6. The conductor core according to claim 1, characterized in that, The surface of the conductor core has a dense layer formed after annealing in an inert gas environment.

7. The conductor core according to claim 1, characterized in that, The conductor core has a through hole.

8. An enameled wire, characterized in that, It includes the conductor core as described in any one of claims 1-7 and the enameled layer covering the outside of the conductor core.

9. The enameled wire according to claim 8, characterized in that, The coating layer is made of modified polyurethane paint or polyimide paint.

10. The enameled wire according to claim 8, characterized in that, The thickness of the enameled layer is 0.0008mm-0.0025mm.

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