Enameled copper flat wire for new energy automobile driving motor

Abstract

The utility model discloses an enameled copper flat wire for a driving motor of a new energy automobile, which comprises a copper wire and an outer cladding layer, the copper wire is uniformly filled in the outer cladding layer, the outer cladding layer comprises an inner insulating layer, an elastic layer, a strengthening layer, a flame-retardant layer and a wear-resistant sleeve layer, the copper wire is wrapped by the inner insulating layer, the elastic layer is arranged on the outer layer of the inner insulating layer, and the wear-resistant sleeve layer is arranged on the outer layer of the strengthening layer. A reinforcing layer is arranged on the outer side of the elastic layer, the flame-retardant layer is arranged between the reinforcing layer and the wear-resistant sleeve layer, and the surface of the wear-resistant sleeve layer is uniformly coated with a protective coating. According to the utility model, through the design of the mylar tape, the elastic layer and the reinforcing layer, the mylar tape has good tensile strength and can prevent the copper wire from loosening, the elastic layer has elasticity and flexibility and can ensure that the cable can still maintain good electrical performance under the action of external forces such as bending and stretching, and finally the reinforcing layer can further improve the strength of the cable, so that the service life of the cable is prolonged. Damage to the cable caused by long-term vibration of a motor or a vehicle is avoided, and the shock resistance of the cable is effectively improved.

Description

Technical Field

[0001] The utility model relates to the technical field of enameled copper wire design, in particular to an enameled copper flat wire for a new energy vehicle drive motor. Background Art

[0002] The enameled copper flat wire used in new energy vehicle drive motors is a special conductive material. It plays a vital role in the drive motors of new energy vehicles. It is mostly composed of two parts: conductor and insulation. At the same time, the flat wire design can fill the space more fully in the motor stator cross-section, thereby improving the slot fill rate of the motor. Compared with traditional round wire motors, the slot fill rate of flat wire motors can be increased by more than 20%, which helps to improve the output power and torque of the motor.

[0003] The applicant found that the enameled copper flat wire for motors often needs to work with the motor for a long time, so its external insulation layer may be damaged, for example, by external moisture or corrosive gas, fire on the outside of the motor, long-term wear and tear, and insufficient strength due to vibration damage leading to cracking, which may then cause a safety accident of power leakage.

[0004] Therefore, the applicant proposed an enameled copper flat wire for a new energy vehicle drive motor to solve the problem. Utility Model Content

[0005] The utility model provides an enameled copper flat wire for a new energy vehicle driving motor, which solves the problems raised in the above background by optimizing its own strength, wear resistance, corrosion resistance, flame retardancy and high temperature resistance.

[0006] In order to solve the above technical problems, the utility model provides an enameled copper flat wire for a new energy vehicle drive motor, comprising a copper conductor and an outer sheath, the copper conductor is evenly filled inside the outer sheath, the outer sheath comprises an inner insulating layer, an elastic layer, a strengthening layer, a flame retardant layer and a wear-resistant sleeve, the inner insulating layer wraps the copper conductor and the outer layer is provided with an elastic layer, a strengthening layer is provided on the outside of the elastic layer, the flame retardant layer is arranged between the strengthening layer and the wear-resistant sleeve, and the surface of the wear-resistant sleeve is evenly coated with a protective coating.

[0007] As a preferred technical solution of the utility model, the elastic layer is made of insulating elastic rubber, and the reinforcement layer is made of carbon fiber through a weaving process.

[0008] As a preferred technical solution of the utility model, the flame retardant layer is composed of a flame retardant rubber layer and a flame retardant coating. The flame retardant coating is coated on the outside of the flame retardant rubber layer. The flame retardant rubber layer is made of mica tape and is located on the outer layer of the strengthening layer. The flame retardant coating is located on the inner layer of the wear-resistant sleeve layer.

[0009] As a preferred technical solution of the utility model, a high temperature resistant heat insulating layer is further provided on the inner side of the flame retardant adhesive layer, and the high temperature resistant heat insulating layer is in close contact with the strengthening layer and is made of polyimide.

[0010] As a preferred technical solution of the utility model, the wear-resistant sleeve layer includes a polyurethane layer, and the contact layer between the polyurethane layer and the flame-retardant coating is provided with an outer insulating coating.

[0011] As a preferred technical solution of the utility model, the protective coating consists of an anti-corrosion coating and a lubricating coating. The anti-corrosion coating is coated on the surface of the polyurethane layer and is made of epoxy resin, and the lubricating coating is coated on the surface of the anti-corrosion coating and is made of corrosion-resistant lubricating oil.

[0012] As a preferred technical solution of the utility model, a layer of Mylar tape for improving the insulation effect is wound around the outside of the copper wire, and the Mylar tape is in close contact with the inner insulation layer.

[0013] Compared with the related art, the enameled copper flat wire for new energy vehicle drive motor provided by the utility model has the following beneficial effects:

[0014] 1. The utility model provides an enameled copper flat wire for a new energy vehicle driving motor. In terms of self-strength optimization, the Mylar tape, the elastic layer and the strengthening layer are designed. The Mylar tape has good tensile strength and can prevent the copper wire from loosening, while the elastic layer has elasticity and flexibility, ensuring that the cable can still maintain good electrical performance under external forces such as bending and stretching. Finally, the strengthening layer can further improve the strength of the cable, avoid damage to the cable caused by long-term vibration of the motor or vehicle, and effectively improve the anti-seismic ability of the cable;

[0015] 2. The utility model provides an enameled copper flat wire for a new energy vehicle driving motor. In terms of fire resistance optimization, a flame retardant layer is designed. When the outside is on fire, the wear-resistant sleeve layer will be damaged. At this time, the flame retardant adhesive layer is made of mica tape with excellent flame retardant performance, and the flame retardant coating is used to further enhance the flame retardant effect. The high temperature resistant heat insulation layer can play a heat insulation effect, avoiding excessive heat from the external fire source to cause damage to the interior, thereby effectively improving the flame retardant ability of the cable;

[0016] 3. The utility model provides an enameled copper flat wire for new energy vehicle drive motors. In terms of wear-resistant and corrosion-resistant optimized design, the cable surface has excellent wear-resistant and corrosion-resistant properties through a wear-resistant sleeve and a protective coating, and enhanced insulation, reduced friction and wear, thereby effectively enhancing the ability to resist external wear and corrosion damage, improving production efficiency and extending the service life of the cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a schematic diagram of the overall three-dimensional structure of the utility model;

[0018] Figure 2 It is a schematic diagram of the overall front cross-sectional structure of the utility model;

[0019] Figure 3 This is a schematic diagram of the connection structure of the elastic layer and the strengthening layer of the utility model;

[0020] Figure 4 This is a schematic diagram of the layered structure of the flame retardant layer of the utility model;

[0021] Figure 5 This is a schematic diagram of the layered structure of the protective coating of the utility model;

[0022] Figure 6 It is a schematic diagram of the wear-resistant sleeve structure of the utility model.

[0023] Numbers in the figure: 1. Copper conductor; 2. Outer sheath; 3. Inner insulation layer; 4. Elastic layer; 5. Reinforcement layer; 6. Flame retardant layer; 61. Flame retardant rubber layer; 62. Flame retardant coating; 63. High temperature resistant insulation layer; 7. Wear-resistant sleeve layer; 71. Polyurethane layer; 72. Outer insulation coating; 8. Protective coating; 81. Anti-corrosion coating; 82. Lubricating coating; 9. Mylar tape. DETAILED DESCRIPTION

[0024] The technical solutions in the embodiments of the utility model will be clearly and completely described below in conjunction with the drawings in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, rather than all of the embodiments; based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without making creative work are within the scope of protection of the utility model.

[0025] Depend on Figure 1-Figure 6 It is given that the utility model includes a copper conductor 1 and an outer sheath 2, the copper conductor 1 is uniformly filled inside the outer sheath 2, the outer sheath 2 includes an inner insulating layer 3, an elastic layer 4, a reinforcing layer 5, a flame retardant layer 6 and a wear-resistant sleeve 7, the inner insulating layer 3 wraps the copper conductor 1 and the outer layer is provided with an elastic layer 4, the outer side of the elastic layer 4 is provided with a reinforcing layer 5, the flame retardant layer 6 is arranged between the reinforcing layer 5 and the wear-resistant sleeve 7, and the surface of the wear-resistant sleeve 7 is uniformly coated with a protective coating 8.

[0026] The elastic layer 4 is made of insulating elastic rubber, and the reinforcing layer 5 is made of carbon fiber through a weaving process. By designing the elastic layer 4 and the reinforcing layer 5, the elastic layer 4 is made of insulating elastic rubber to enhance insulation, and it has elasticity and flexibility, can withstand certain external force deformation and restore its original state, ensuring that the cable can still maintain good electrical properties under external forces such as bending and stretching. At the same time, the reinforcing layer 5 is woven with carbon fiber, which can further improve the cable strength and avoid breakage of various structures inside the outer layer 2. It also has good insulation to avoid damage to the cable caused by long-term vibration of the motor or vehicle.

[0027] The flame retardant layer 6 is composed of a flame retardant adhesive layer 61 and a flame retardant coating 62. The flame retardant coating 62 is coated on the outside of the flame retardant adhesive layer 61. The flame retardant adhesive layer 61 is made of mica tape and is located on the outer layer of the reinforcement layer 5. The flame retardant coating 62 is located on the inner layer of the wear-resistant sleeve 7. A high-temperature resistant heat-insulating layer 63 is also provided on the inner side of the flame retardant adhesive layer 61. The high-temperature resistant heat-insulating layer 63 is tightly attached to the reinforcement layer 5 and is made of polyimide. By designing the flame retardant layer 6, when the outside world is on fire, the wear-resistant sleeve 7 will be damaged. At this time, the flame retardant adhesive layer 61 is made of mica tape and has excellent flame retardant properties. The flame retardant coating 62 further enhances the flame retardant effect, and the high-temperature resistant heat-insulating layer 63 can have a heat-insulating effect to prevent the internal damage caused by excessive heat from the external fire source, thereby effectively improving the flame retardant ability of the cable.

[0028] The wear-resistant sleeve 7 includes a polyurethane layer 71, and the contact layer between the polyurethane layer 71 and the flame-retardant coating 62 is provided with an outer insulating coating 72. By designing the wear-resistant sleeve 7, the polyurethane layer 71 has good wear resistance and can resist external friction and mechanical damage. At the same time, it also has excellent elasticity and toughness and can adapt to the bending and stretching of the cable during movement. The outer insulating coating 72 cooperates with the inner insulating layer 3 to enhance the insulation performance of the cable and prevent problems such as current leakage or short circuit.

[0029] The protective coating 8 is composed of an anti-corrosion coating 81 and a lubricating coating 82. The anti-corrosion coating 81 is coated on the surface of the polyurethane layer 71 and is made of epoxy resin. The lubricating coating 82 is coated on the surface of the anti-corrosion coating 81 and is made of corrosion-resistant lubricating oil. Through the protective coating 8, moisture, corrosive gas and other environments will lead to the risk of corrosion. Therefore, the anti-corrosion coating 81 is added to the surface to improve the corrosion resistance of the wire and extend its service life. The main function of the lubricating coating 82 is to improve the sliding performance of the cable during the winding process, reduce friction and wear, thereby improving production efficiency and extending the service life of the cable without affecting other performances of the cable.

[0030] A layer of Mylar tape 9 is wound around the outside of the copper conductor 1 to improve the insulation effect, and the Mylar tape 9 is in close contact with the inner insulation layer 3. By adding a layer of Mylar tape 9 on the outside of the copper conductor 1, the Mylar tape 9 has good tensile strength, which can prevent the copper conductor 1 from loosening, further ensuring the stability of the insulating wrapping layer. At the same time, the Mylar tape 9 also has an insulating effect, further enhancing the safety performance.

[0031] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device.

[0032] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. An enameled copper rectangular wire for a new energy vehicle driving motor, comprising a copper conductor (1) and an outer sheath (2), characterized in that: The copper conductor (1) is uniformly filled inside the outer sheath (2); the outer sheath (2) comprises an inner insulating layer (3), an elastic layer (4), a strengthening layer (5), a flame retardant layer (6) and a wear-resistant sleeve layer (7); the inner insulating layer (3) wraps the copper conductor (1) and is provided with an elastic layer (4) on the outer layer; a strengthening layer (5) is provided on the outer side of the elastic layer (4); the flame retardant layer (6) is provided between the strengthening layer (5) and the wear-resistant sleeve layer (7); and the surface of the wear-resistant sleeve layer (7) is uniformly coated with a protective coating (8).

2. The enameled rectangular copper wire for a new energy vehicle drive motor according to claim 1, characterized in that: The elastic layer (4) is made of insulating elastic rubber, and the reinforcement layer (5) is made of carbon fiber through a weaving process.

3. The enameled rectangular copper wire for a new energy vehicle drive motor according to claim 1, characterized in that: The flame retardant layer (6) is composed of a flame retardant adhesive layer (61) and a flame retardant coating (62), wherein the flame retardant coating (62) is coated on the outside of the flame retardant adhesive layer (61), the flame retardant adhesive layer (61) is made of mica tape and is located on the outer layer of the reinforcement layer (5), and the flame retardant coating (62) is located on the inner layer of the wear-resistant sleeve layer (7).

4. The enameled rectangular copper wire for a new energy vehicle drive motor according to claim 3, characterized in that: A high temperature resistant heat insulating layer (63) is also provided on the inner side of the flame retardant adhesive layer (61); the high temperature resistant heat insulating layer (63) is in close contact with the strengthening layer (5) and is made of polyimide.

5. The enameled rectangular copper wire for a new energy vehicle driving motor according to claim 3, characterized in that: The wear-resistant sleeve layer (7) comprises a polyurethane layer (71), and the contact layer between the polyurethane layer (71) and the flame-retardant coating (62) is provided with an outer insulating coating (72).

6. The enameled rectangular copper wire for a new energy vehicle driving motor according to claim 5, characterized in that: The protective coating (8) is composed of an anti-corrosion coating (81) and a lubricating coating (82); the anti-corrosion coating (81) is coated on the surface of the polyurethane layer (71) and is made of epoxy resin; the lubricating coating (82) is coated on the surface of the anti-corrosion coating (81) and is made of corrosion-resistant lubricating oil.

7. The enameled rectangular copper wire for a new energy vehicle driving motor according to claim 1, characterized in that: The copper conductor (1) is externally wound with a layer of Mylar tape (9) for improving the insulation effect, and the Mylar tape (9) is in close contact with the inner insulation layer (3).

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