Novel high-temperature-resistant and high-strength electromagnetic wire

Abstract

The utility model relates to the technical field of electromagnetic wire, especially to a novel high temperature and high strength electromagnetic wire, including electromagnetic wire main part, the electromagnetic wire main part includes the conductor core layer, high temperature resistant insulating layer, high strength fiber reinforced layer and outer protective layer that set gradually from inside to outside, the outside of conductor core layer is tightly wrapped with high temperature resistant insulating layer, high strength fiber reinforced layer sets up in high temperature resistant insulating layer outside, adopts high modulus fiber and is woven, the high temperature resistant insulating layer is wrapped with outer protective layer, the utility model discloses through the innovative design electromagnetic wire main part structure, adopts multiple groups of stranding core wire in the conductor core layer and optimizes internal insulation, selects nanometer composite ceramic material and adds nano particle to high temperature resistant insulating layer, the high strength fiber reinforced layer uses multilayer cross -woven and embeds steel wire ring, and outer protective layer adopts multilayer composite structure. Each layer is closely matched, and the high temperature and high strength performance of electromagnetic wire is improved significantly, and the stable operation of equipment is guaranteed.

Description

Technical Field

[0001] This utility model relates to the field of electromagnetic wire technology, and in particular to a novel high-temperature resistant and high-strength electromagnetic wire. Background Technology

[0002] In numerous fields such as electrical engineering, electronic equipment, aerospace, and new energy vehicles, electromagnetic wire plays a crucial role as a key basic material. With the rapid development of these fields, the performance requirements for electromagnetic wire are also increasing.

[0003] Traditional electromagnetic wires are prone to softening, aging, or even failure of their insulation layer under high-temperature environments, leading to a significant decrease in insulation performance and potential safety hazards such as short circuits. This makes them unsuitable for high-temperature operating scenarios. Furthermore, in applications requiring the application to withstand significant mechanical stress, such as the vibration environment of aerospace equipment or the frequent start-stop cycles of electric motors in new energy vehicles, traditional electromagnetic wires lack sufficient strength and are prone to breakage and wear, severely impacting equipment reliability and lifespan.

[0004] Moreover, existing electromagnetic wires are often structurally simple and lack effective reinforcement and protection measures. For example, the structural design of the conductor core layer is not reasonable enough, resulting in low current transmission efficiency and limited internal insulation performance; the bonding between the layers is not tight enough, with tiny gaps, which affect the overall performance and stability of the electromagnetic wire.

[0005] Furthermore, with the advancement of technology, higher demands are being placed on the versatility of electromagnetic wires. They not only need excellent high-temperature resistance and high strength, but also good wear resistance and corrosion resistance to adapt to complex and changing working environments. Utility Model Content

[0006] To address some of the problems existing in the prior art, this utility model provides a novel high-temperature resistant and high-strength electromagnetic wire. This utility model innovatively designs the main structure of the electromagnetic wire, employing multiple stranded core wires and optimizing internal insulation in the conductor core layer; the high-temperature resistant insulation layer uses nano-composite ceramic material with added nanoparticles; the high-strength fiber reinforcement layer utilizes multi-layer cross-braiding with built-in steel wire rings; and the outer protective layer adopts a multi-layer composite structure. The close cooperation of each layer significantly improves the high-temperature resistance and high-strength performance of the electromagnetic wire, ensuring stable equipment operation.

[0007] To achieve the above objectives, this utility model provides a novel high-temperature resistant and high-strength electromagnetic wire, comprising an electromagnetic wire body. The electromagnetic wire body includes a conductor core layer, a high-temperature resistant insulation layer, a high-strength fiber reinforcement layer, and an outer protective layer arranged sequentially from the inside to the outside. The conductor core layer is tightly wrapped with the high-temperature resistant insulation layer. The high-strength fiber reinforcement layer is disposed outside the high-temperature resistant insulation layer and is woven from high-modulus fibers. The high-temperature resistant insulation layer is wrapped with the outer protective layer.

[0008] As a further improvement of this utility model, in order to improve the conductivity and temperature resistance of the conductor core layer, effectively prevent short circuits between conductors, and enhance the overall high temperature resistance, the conductor core layer adopts a multi-group structure. The conductor core layer includes several groups of conductor core wires. The conductor core wires adopt a multi-strand twisted metal wire structure. An internal insulation layer is provided between adjacent conductor core wires. The external surface of the internal insulation layer is coated with a ceramic coating.

[0009] As a further improvement of this utility model, in order to help fill the tiny gap between the two and reduce stress concentration caused by the difference in thermal expansion coefficients, a transition layer is also provided between the high-temperature resistant insulation layer and the conductor core layer. The transition layer is made of thermally conductive silicone grease and is used to fill the tiny gap between the conductor core layer and the high-temperature resistant insulation layer.

[0010] As a further improvement of this utility model, in order to enhance the overall strength and tear resistance of the fiber reinforcement layer and protect the electromagnetic wire from mechanical damage, the high-strength fiber reinforcement layer adopts a multi-layer cross-woven structure, with the fiber directions of each layer arranged in a cross pattern.

[0011] As a further improvement of this utility model, in order to ensure the flexibility of the electromagnetic wire, facilitate bending and installation, provide good wear resistance and scratch resistance, and protect the electromagnetic wire from corrosion by external environmental factors, the outer protective layer adopts a multi-layer composite structure, the inner layer of the outer protective layer is an elastomer material, and the outer layer of the outer protective layer is a hard wear-resistant coating.

[0012] As a further improvement of this utility model, in order to improve the high temperature resistance and electrical insulation performance of the insulation layer, and further enhance the hardness and wear resistance of the insulation layer, the high temperature resistant insulation layer is made of nano-composite ceramic insulation material, and nano-sized alumina particles are uniformly dispersed in the high temperature resistant insulation layer.

[0013] As a further improvement of this utility model, in order to enhance the tensile strength and bending resistance of the electromagnetic wire and provide additional mechanical support so that it can withstand greater external forces without breaking or deforming, a steel wire ring is provided inside the high-strength fiber reinforcement layer. The steel wires are arranged in a circular ring at equal intervals inside the high-strength fiber reinforcement layer, and several steel wire rings are arranged in parallel.

[0014] When this invention is in operation, the current first passes through the conductor core layer. The conductor core layer adopts a multi-structure, containing several sets of multi-strand twisted metal wire conductor cores. Adjacent conductor cores are separated by an internal insulation layer, and the exterior of the internal insulation layer is coated with a ceramic coating. This not only ensures the stability of current transmission but also enhances the insulation performance inside the conductor core layer.

[0015] During current transmission, the conductor core layer generates heat. At this point, the transition layer between the conductor core layer and the high-temperature resistant insulation layer plays a crucial role. Made of thermally conductive silicone grease, the transition layer effectively fills the tiny gaps between the two, accelerating heat conduction and rapidly transferring the heat generated by the conductor core layer away, preventing heat buildup that could affect the performance of the electromagnetic wire.

[0016] The high-temperature resistant insulation layer is made of nano-composite ceramic insulating material, in which nano-sized alumina particles are uniformly dispersed. This gives it excellent high-temperature resistance and insulation properties, enabling it to work stably in high-temperature environments, effectively preventing current leakage and ensuring the safe operation of the electromagnetic wire.

[0017] The high-strength fiber reinforcement layer employs a multi-layered cross-woven structure, with fibers in each layer intersecting each other, and internally containing equally spaced and parallel steel wire rings. This structure significantly enhances the overall strength and tensile strength of the electromagnetic wire, making it less prone to deformation or breakage under external forces and enabling it to adapt to complex working environments.

[0018] The outer protective layer adopts a multi-layer composite structure. The inner layer is an elastomer material, which plays a role in buffering and protection. The outer layer is a hard wear-resistant coating, which can effectively resist external friction and wear, protect the internal structure from damage, and extend the service life of the electromagnetic wire.

[0019] The beneficial effects of this utility model are as follows:

[0020] Excellent high temperature resistance

[0021] The high-temperature resistant insulation layer is made of nano-composite ceramic insulating material, in which nano-sized alumina particles are uniformly dispersed. This unique material composition endows the insulation layer with excellent high-temperature resistance, enabling it to maintain stable insulation performance in high-temperature environments, effectively preventing current leakage, and significantly improving the safe and reliable operation of the electromagnetic wire under high-temperature conditions.

[0022] The high-strength fiber reinforcement layer employs a multi-layered cross-woven structure, with the fiber directions of each layer intersecting, significantly enhancing the overall strength and stability of the fiber layer. Simultaneously, the internally arranged, equally spaced, parallel steel wire rings further improve the tensile and compressive strength of the electromagnetic wire. This structural design allows the electromagnetic wire to better withstand stress under external forces, reducing the likelihood of deformation or breakage and significantly improving its mechanical strength.

[0023] Excellent electrical performance

[0024] The conductor core layer employs a multi-layered structure, containing several sets of multi-stranded metal conductor cores. An internal insulation layer separates adjacent conductor cores, and this inner insulation layer is coated with a ceramic layer. This design not only ensures the stability of current transmission but also enhances the insulation performance of the conductor core layer, effectively reducing current loss and electromagnetic interference, and improving the electrical transmission efficiency and quality of the electromagnetic wire.

[0025] Good heat dissipation

[0026] A transition layer made of thermally conductive silicone grease is placed between the conductor core layer and the high-temperature resistant insulation layer. This transition layer fills the tiny gap between the two layers, accelerating heat conduction. During operation, the heat generated in the conductor core layer can be quickly transferred away through the transition layer, preventing heat accumulation inside the wire and thus reducing its operating temperature. This further improves the wire's high-temperature resistance and operational reliability.

[0027] Excellent protective capabilities

[0028] The outer protective layer adopts a multi-layer composite structure. The inner layer is an elastomer material that acts as a buffer and protector, absorbing external impacts. The outer layer is a hard, wear-resistant coating that effectively resists external friction and wear, protecting the internal layers from damage. This dual-protection design greatly improves the electromagnetic wire's resistance to external damage, enabling it to maintain good performance in complex and harsh working environments. Attached Figure Description

[0029] To facilitate understanding by those skilled in the art, the present invention will be further described below with reference to the accompanying drawings:

[0030] Figure 1 This is a structural diagram of the present invention.

[0031] The structure consists of: 1. Conductor core layer; 2. High-temperature resistant insulation layer; 3. High-strength fiber reinforcement layer; 4. Outer protective layer; 5. Conductor core wire; 6. Inner insulation layer; 7. Ceramic coating; 8. Transition layer; and 9. Steel wire ring. Detailed Implementation

[0032] To enable those skilled in the art to better understand the technical solutions in this application, the following description is provided in conjunction with the appendix. Figure 1 The present invention will be further described below. The following embodiments are only used to illustrate the technical solution of the present invention more clearly, and should not be used to limit the protection scope of the present invention.

[0033] like Figure 1The present invention discloses a novel high-temperature resistant and high-strength electromagnetic wire, comprising an electromagnetic wire body, wherein the electromagnetic wire body comprises, from the inside out, a conductor core layer 1, a high-temperature resistant insulation layer 2, a high-strength fiber reinforcement layer 3, and an outer protective layer 4. The conductor core layer 1 is tightly wrapped with the high-temperature resistant insulation layer 2. The high-strength fiber reinforcement layer 3 is disposed outside the high-temperature resistant insulation layer 2 and is woven from high-modulus fibers. The high-temperature resistant insulation layer 2 is wrapped with the outer protective layer 4.

[0034] The conductor core layer 1 adopts a multi-group structure. The conductor core layer 1 includes several groups of conductor core wires 5. The conductor core wires 5 adopt a multi-strand twisted metal wire structure. An internal insulation layer 6 is provided between adjacent conductor core wires 5. The external surface of the internal insulation layer 6 is coated with a ceramic coating 7.

[0035] A transition layer 8 is provided between the high-temperature resistant insulating layer 2 and the conductor core layer 1. The transition layer 8 is made of thermally conductive silicone grease and is used to fill the tiny gaps between the conductor core layer 1 and the high-temperature resistant insulating layer 2.

[0036] The high-strength fiber reinforcement layer 3 adopts a multi-layer cross-woven structure, with the fiber directions of each layer arranged in a cross pattern.

[0037] The outer protective layer 4 adopts a multi-layer composite structure, the inner layer of the outer protective layer 4 is an elastomer material, and the outer layer of the outer protective layer 4 is a hard wear-resistant coating.

[0038] The high-temperature resistant insulation layer 2 is made of nano-composite ceramic insulation material, and nano-sized alumina particles are uniformly dispersed in the high-temperature resistant insulation layer 2.

[0039] The high-strength fiber reinforcement layer 3 has steel wire rings 9 inside. The steel wires are arranged in a circular shape and equidistantly inside the high-strength fiber reinforcement layer 3, and the steel wire rings 9 are arranged in parallel.

[0040] When this invention is in operation, the current first passes through the conductor core layer 1. The conductor core layer 1 adopts a multi-structure, containing several sets of multi-strand twisted metal wire conductor cores 5. Adjacent conductor cores 5 are separated by an internal insulation layer 6, and the internal insulation layer 6 is coated with a ceramic coating 7. This not only ensures the stability of current transmission but also enhances the insulation performance inside the conductor core layer 1.

[0041] During current transmission, the conductor core layer 1 generates heat. At this time, the transition layer 8 between the conductor core layer 1 and the high-temperature resistant insulating layer 2 plays an important role. The transition layer 8 is made of thermally conductive silicone grease, which can effectively fill the tiny gap between the two, accelerate heat conduction, and quickly transfer the heat generated by the conductor core layer 1 away, avoiding heat accumulation that could affect the performance of the electromagnetic wire.

[0042] The high-temperature resistant insulation layer 2 is made of nano-composite ceramic insulating material, in which nano-sized alumina particles are uniformly dispersed. This gives it excellent high-temperature resistance and insulation performance, enabling it to work stably in high-temperature environments, effectively preventing current leakage and ensuring the safe operation of the electromagnetic wire.

[0043] The high-strength fiber reinforcement layer 3 adopts a multi-layer cross-woven structure, with the fiber directions of each layer intersecting each other, and also contains parallel steel wire rings 9 arranged in a circular pattern at equal intervals. This structure greatly enhances the overall strength and tensile strength of the electromagnetic wire, making it less prone to deformation or breakage under external forces, and enabling it to adapt to complex working environments.

[0044] The outer protective layer 4 adopts a multi-layer composite structure. The inner layer is an elastomer material, which plays a role in buffering and protection. The outer layer is a hard wear-resistant coating, which can effectively resist external friction and wear, protect the internal structure from damage, and extend the service life of the electromagnetic wire.

[0045] This utility model is not limited to the above embodiments. Based on the technical solutions disclosed in this utility model, those skilled in the art can make some substitutions and modifications to some of the technical features without creative labor, and these substitutions and modifications are all within the protection scope of this utility model.

Claims

1. A novel high-temperature resistant and high-strength electromagnetic wire, comprising an electromagnetic wire body, characterized in that, The main body of the electromagnetic wire includes a conductor core layer (1), a high-temperature resistant insulation layer (2), a high-strength fiber reinforcement layer (3), and an outer protective layer (4) arranged sequentially from the inside to the outside. The conductor core layer (1) is tightly wrapped with the high-temperature resistant insulation layer (2). The high-strength fiber reinforcement layer (3) is arranged outside the high-temperature resistant insulation layer (2) and is woven from high-modulus fibers. The high-temperature resistant insulation layer (2) is wrapped with the outer protective layer (4). The high-strength fiber reinforcement layer (3) adopts a multi-layer cross-woven structure, with the fiber directions of each layer arranged in a cross pattern. The outer protective layer (4) adopts a multi-layer composite structure, the inner layer of the outer protective layer (4) is an elastomer material; the outer layer of the outer protective layer (4) is a hard wear-resistant coating. The high-temperature resistant insulation layer (2) is made of nano-composite ceramic insulation material, and nano-sized alumina particles are uniformly dispersed in the high-temperature resistant insulation layer (2).

2. The novel high-temperature resistant and high-strength electromagnetic wire according to claim 1, characterized in that, The conductor core layer (1) adopts a multi-group structure. The conductor core layer (1) includes several groups of conductor core wires (5). The conductor core wires (5) adopt a multi-strand twisted metal wire structure. An internal insulation layer (6) is provided between adjacent conductor core wires (5). The external surface of the internal insulation layer (6) is coated with a ceramic coating (7).

3. The novel high-temperature resistant and high-strength electromagnetic wire according to claim 1, characterized in that, A transition layer (8) is provided between the high-temperature resistant insulation layer (2) and the conductor core layer (1). The transition layer (8) is made of thermally conductive silicone grease and is used to fill the tiny gap between the conductor core layer (1) and the high-temperature resistant insulation layer (2).

4. The novel high-temperature resistant and high-strength electromagnetic wire according to claim 1, characterized in that, The high-strength fiber reinforcement layer (3) is provided with steel wire rings (9). The steel wires are arranged in a circular shape and equidistantly inside the high-strength fiber reinforcement layer (3), and the steel wire rings (9) are arranged in parallel.

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