A high-strength triple-insulated wire

Abstract

This invention discloses a high-strength triple-insulated wire, comprising a conductor core, the outer surface of which is wrapped with a first insulation layer, and the outer surface of the first insulation layer is wrapped with a second insulation layer. In this invention, a polyetheretherketone (PEEK) reinforcing layer between the conductor core and the first insulation layer, with its high tensile strength and long-term temperature resistance, solves the problem of weak resistance to external forces in conventional triple-insulated wires. A wear-resistant coating (nano-alumina modified epoxy resin) on the outer surface of the third insulation layer forms a dual wear-resistant protection system with the third insulation layer (polytetrafluoroethylene), significantly improving the surface wear resistance compared to conventional insulated wires. During installation, the coating resists frictional damage caused by dragging. Furthermore, the tape-type adhesive surface and release paper design reduce vibration friction by quickly fixing the wire, further reducing the probability of wear and significantly extending the service life of the insulated wire.

Description

Technical Field

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

[0002] Triple-insulated wire, also known as double-insulated wire, is a high-performance insulated conductor newly developed internationally in recent years. This conductor has three insulation layers, with the core wire in the middle. The first layer is a golden-yellow polyamide film; the second layer is a highly insulating painted coating; and the third (outermost) layer is a transparent fiberglass layer. Triple-insulated wire is suitable for cutting-edge technology and defense applications, used in the manufacture of windings for micro-motors and high-frequency transformer windings for miniaturized switching power supplies. Its advantages include high insulation strength (it can withstand a safe voltage of 3000VAC between any two layers), no need for a barrier layer to ensure a safe margin, and no need for insulating tape layers between electrodes; it also has high current density. High-frequency transformers wound with it can be half the size of those wound with enameled wire.

[0003] However, existing conventional triple-insulated wires have weak resistance to external forces and are easily damaged by pulling during long-term use. They cannot meet the high durability requirements of industrial automation, aerospace and other scenarios. Installation dragging and corrosion in harsh environments such as chemical and papermaking industries can easily lead to surface damage of the insulation wire, affecting insulation performance and even causing short circuits. The insulation wire heats up under current load. In high-power equipment and dense wiring scenarios, inadequate heat dissipation will increase power loss and may even cause fires.

[0004] To address this issue, a high-strength triple-insulated wire is proposed, which possesses the advantages of high strength, wear resistance, and rapid heat conduction, thereby solving the problems mentioned in the background technology. Utility Model Content

[0005] The purpose of this invention is to address the shortcomings of existing technologies by proposing a high-strength triple-insulated wire.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a high-strength triple-insulated wire, comprising a conductor core, the outer surface of which is wrapped with a first insulation layer, the outer surface of which is wrapped with a second insulation layer, the outer surface of which is wrapped with a third insulation layer, the outer surface of which is coated with a wear-resistant coating, the surface of which is coated with a tape adhesive, and release paper is attached to the tape adhesive. A reinforcing layer made of polyetheretherketone is installed between the conductor core and the first insulation layer.

[0007] As a further description of the above technical solution: the thickness of the reinforcing layer is between 10 and 2000 micrometers, and the length of the reinforcing layer is adapted to the length of the conductor core.

[0008] As a further description of the above technical solution: the first insulating layer, the second insulating layer and the third insulating layer have the same length, and the lengths of the first insulating layer, the second insulating layer and the third insulating layer match the length of the conductor core.

[0009] As a further description of the above technical solution: the tape adhesive surface covers the surface of the wear-resistant coating, and the length of the tape adhesive surface matches the length of the third insulating layer, and the size of the release paper matches the size of the tape adhesive surface.

[0010] As a further description of the above technical solution: the thickness range of the first insulating layer is 10-30 micrometers, the thickness range of the second insulating layer is 10-30 micrometers, and the thickness range of the third insulating layer is 10-50 micrometers.

[0011] As a further description of the above technical solution: the gaps between the multi-strand strands of the conductor core are filled with graphene thermal conductive paste, and the graphene thermal conductive paste is composed of a silicon-based paste of graphene particles.

[0012] This utility model has the following beneficial effects:

[0013] In this invention, a polyetheretherketone (PEEK) reinforcing layer between the conductor core and the first insulation layer solves the problem of weak resistance to external forces in conventional triple-insulated wires due to its high tensile strength and long-term temperature resistance. A dual wear-resistant protection system is formed by the wear-resistant coating (nano-alumina modified epoxy resin) on the outer surface of the third insulation layer and the third insulation layer (polytetrafluoroethylene), significantly improving the surface wear resistance compared to conventional insulated wires. During installation, the coating resists frictional damage caused by dragging. Furthermore, the tape-type adhesive surface and release paper design reduce vibration friction by quickly fixing the wire, further reducing the probability of wear and significantly extending the service life of the insulated wire. By filling the gaps between the multiple strands of the conductor core with graphene thermal conductive paste, the heat dissipation bottleneck of the air gaps between traditional multi-strand conductors is solved. In high-power equipment and dense wiring scenarios, this effectively reduces power loss. Simultaneously, the total thickness of the three insulation layers is controlled within a reasonable range to avoid excessive thickness hindering heat dissipation. Heat can be quickly conducted to the insulation layer and dissipated into the environment through the thermal conductive paste, fundamentally solving the fire hazard caused by untimely heat dissipation. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of a high-strength triple-insulated wire according to the present invention;

[0015] Figure 2 This is a cross-sectional view of a high-strength triple-insulated wire according to the present invention;

[0016] Figure 3 This is a three-dimensional diagram of the third insulation layer (without release paper installed).

[0017] Legend:

[0018] 1. Conductor core; 2. First insulation layer; 3. Second insulation layer; 4. Third insulation layer; 5. Reinforcing layer; 6. Tape adhesive surface; 7. Release paper; 8. Wear-resistant coating; 9. Graphene thermal paste. Detailed Implementation

[0019] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0020] According to an embodiment of the present invention, a high-strength triple-insulated wire is provided.

[0021] The present invention will now be further described in conjunction with the accompanying drawings and specific embodiments, such as... Figure 1-3As shown, a high-strength triple-insulated wire according to an embodiment of the present invention includes a conductor core 1, the outer surface of the conductor core 1 is wrapped with a first insulation layer 2, the outer surface of the first insulation layer 2 is wrapped with a second insulation layer 3, the outer surface of the second insulation layer 3 is wrapped with a third insulation layer 4, the outer surface of the third insulation layer 4 is coated with a wear-resistant coating 8, the surface of the third insulation layer 4 is coated with a tape adhesive surface 6, and release paper 7 is pasted on the tape adhesive surface 6. A reinforcing layer 5 made of polyetheretherketone (PEEK) is installed between the conductor core 1 and the first insulation layer 2. The conductor core 1, as the core carrier for current transmission, is made of high-purity copper or copper alloy to ensure excellent conductivity. The first insulation layer 2, which is tightly wrapped on its outer surface, is made of modified polyimide material, which has both insulation and a certain degree of flexibility, and can initially isolate the conductor from the electrical connection with the external environment. The second insulation layer 3 outside the insulation layer 2 is made of cross-linked polyethylene. The cross-linking treatment of the molecular structure improves the temperature resistance, and it can work stably in an environment from -40℃ to 125℃. The outermost third insulation layer 4 is made of polytetrafluoroethylene. Its extremely low coefficient of friction and chemical corrosion resistance provide basic protection for the overall structure. The outer surface of the third insulation layer 4 is coated with a wear-resistant coating 8 (made of nano-alumina modified epoxy resin). The coating thickness is controlled at 5-10 micrometers. Through the strengthening effect of nanoparticles, the surface wear resistance is improved by more than 40%. At the same time, the surface of the third insulation layer 4 is provided with a tape adhesive surface 6 (the width is 1 / 3 of the wire diameter). The adhesive surface is made of high temperature resistant pressure-sensitive adhesive. The release paper 7 (silicone paper material) pasted on it can be quickly peeled off when fixing the wiring, which facilitates the bonding and fixing of the wire to the mounting base and reduces friction loss caused by vibration. In addition, a reinforcing layer 5 made of polyetheretherketone (PEEK) is innovatively installed between the conductor core 1 and the first insulation layer 2. This material has a long-term service temperature of 260°C and extremely high tensile strength (up to 90MPa), which can effectively disperse external forces and improve the tensile strength of the overall structure.

[0022] Please refer to Figure 2The thickness of reinforcing layer 5 ranges from 10 to 2000 micrometers, and its length is matched to the length of conductor core 1. The thickness of reinforcing layer 5 is strictly controlled within this range, taking into full account the needs of different application scenarios: for aerospace and other applications with extremely high lightweight requirements, an ultra-thin reinforcing layer 5 of 10-50 micrometers can be used to control overall weight while meeting strength requirements; for industrial robots and other applications requiring frequent bending, a thicker reinforcing layer 5 of 500-1000 micrometers is used to improve fatigue resistance by increasing material thickness; in some extreme heavy-duty scenarios (such as deep-sea exploration equipment), even a 2000-micrometer reinforcing layer 5 can be used, combined with the hydrolysis resistance of PEEK material itself, to ensure the structural stability of the wire under long-term high-voltage conditions. Simultaneously, the length of reinforcing layer 5 is perfectly matched to the length of conductor core 1, achieving full-length reinforcement from core to insulation layer, avoiding weak points caused by the absence of reinforcing layer 5 in certain areas, and completely solving the problem of conventional wires being prone to breakage during tensile stress.

[0023] Please refer to Figure 2 The first insulation layer 2, the second insulation layer 3, and the third insulation layer 4 are of the same length, and their lengths match the length of the conductor core 1. This equal-length design, precisely matching the length of the conductor core 1, eliminates the risk of exposed ends. In traditional triple-insulated wire production, inconsistent insulation layer lengths can easily lead to stepped exposures at the ends, causing localized electric field concentration. This design, through a precise extrusion molding process, ensures that the three insulation layers are flush with the ends of the conductor core 1. Combined with subsequent end sealing, this can control partial discharge to below 5pC. Simultaneously, the equal-length design ensures more uniform stress distribution across the insulation layers: when the wire is bent, the three insulation layers deform synchronously, avoiding shear stress caused by length differences and significantly increasing the number of bends (from the conventional 500 times to over 3000 times). In addition, this structure facilitates automated processing. In subsequent processes such as cutting and welding, a unified positioning reference can be used to ensure processing accuracy and reduce the defect rate in the production process.

[0024] Please refer to Figure 2 and Figure 3The adhesive tape 6 covers the surface of the wear-resistant coating 8, and its length matches the length of the third insulation layer 4. The size of the release paper 7 matches the size of the adhesive tape 6. The adhesive tape 6 covers the surface of the wear-resistant coating 8 in a centered manner, and its length perfectly matches the length of the third insulation layer 4, ensuring that it can be fixed throughout the entire cabling process. The width of the adhesive tape is set to 1 / 3 of the wire diameter, which ensures sufficient adhesive strength (peel strength ≥5N / cm) while preventing adhesive overflow and contamination of other components. The size of the release paper 7 strictly corresponds to the adhesive tape 6, with the edge deviation controlled within ±0.5mm, which can completely cover the adhesive surface to prevent dust adhesion and avoid residue during peeling. This design is particularly suitable for high-density cabling scenarios (such as server racks), which can quickly fix the cable routing through the adhesive tape, reduce friction and collision between cables, and reduce the labor cost of binding and fixing.

[0025] Please refer to Figure 1 and Figure 2 The thickness of the first insulating layer 2 is between 10-30 micrometers, the thickness of the second insulating layer 3 is between 10-30 micrometers, and the thickness of the third insulating layer 4 is between 10-50 micrometers. The thickness parameters of each insulating layer have been optimized by balancing electrical and mechanical properties: the thickness of the first insulating layer 2 is controlled between 10-30 micrometers. As an insulating layer that directly contacts the conductor, its thickness must meet the basic insulation requirements (breakdown voltage ≥3kV). If it is too thin, pinhole defects are likely to occur, and if it is too thick, thermal resistance will increase. The second insulating layer 3 is also designed with a thickness of 10-30 micrometers. As an auxiliary insulating layer, it forms a synergistic insulation system with the first insulating layer 2, thereby improving the overall pulse withstand voltage capability to over 10kV. The thickness of the third insulating layer 4 is slightly increased to 10-50 micrometers. In addition to its insulating function, it also undertakes the structural support function. The thicker thickness, combined with the polytetrafluoroethylene material, can provide physical protection for the inner insulating layer and resist external mechanical impact. The total thickness of the three insulating layers is controlled between 30 and 110 micrometers to ensure insulation strength while avoiding heat dissipation obstruction due to excessive thickness.

[0026] Please refer to Figure 2The conductor core 1 is constructed with multi-strand stranded conductors, and the gaps between these strands are filled with graphene thermal conductive paste 9. This paste 9 is composed of a silicon-based paste made from graphene particles. The conductor core 1 employs a multi-strand stranded structure (7-19 strands), with the gaps between the strands filled with graphene thermal conductive paste 9. This paste is made by mixing graphene particles (5-10 micrometers in diameter, 20% addition) with a silicon-based paste (thermal conductivity 0.8 W / m•K), and after uniform stirring, forms a thixotropic paste. The filling process is completed using specialized dispensing equipment to ensure complete penetration of the paste into all gaps, forming a thermally conductive pathway after curing. The core function of this design is to reduce contact thermal resistance: conventional multi-strand conductors have air gaps between the strands (thermal conductivity only 0.026 W / m•K), severely hindering heat transfer; while the thermal conductivity of graphene thermal conductive paste 9 can reach 3.5 W / m•K, enabling rapid conduction of heat from the conductor's interior to the outer insulation structure. Actual tests show that after filling with thermal paste, the surface temperature of the wire at rated current decreases by 15-20℃, and the current carrying capacity increases by 20%, effectively solving the heat dissipation problem in dense wiring scenarios.

[0027] Working principle:

[0028] In use, the conductor core 1 serves as the core skeleton, providing basic structural support. The outer PEEK reinforcing layer 5 disperses external forces through the material's high tensile strength (90MPa). When the wire is stretched or bent, the reinforcing layer 5 evenly transfers stress to the overall structure, preventing breakage caused by localized stress concentration. Simultaneously, the reinforcing layer 5 is designed to be the same length as the conductor core 1, ensuring balanced stress along the entire length from the core to the insulation layer, forming a continuous strength support network. The third insulation layer 4 (polytetrafluoroethylene) reduces basic frictional loss due to its low coefficient of friction (0.04-0.1), while the outer wear-resistant coating 8 enhances surface hardness (pencil hardness above 2H) through the reinforcement of nanoparticles, resisting scratches and wear. During wiring and fixing, after peeling off the release paper 7, the adhesive tape 6 bonds the wire to the mounting base, avoiding relative friction caused by vibration. This triple mechanism works together to build a wear-resistant protective barrier. The heat generated when current passes through the conductor core 1 is partly conducted to the surface by the conductor itself, and partly rapidly diffused through the graphene thermal paste 9 between the strands. The thermal conductive pathways formed by the graphene particles gather the heat between the strands to the conductor surface, and then transfer it to the external environment through the insulation layers (first insulation layer 2, second insulation layer 3, and third insulation layer 4). Since the thermal conductivity of the thermal paste is more than 130 times that of air, the heat dissipation path is significantly shortened. Combined with the thin design of the insulation layers, rapid heat dissipation is achieved, ensuring the temperature stability of the wire under high loads.

[0029] Finally, it should be noted that the above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Although the present utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A high strength three-layer insulated wire comprising a conductor core (1) characterized in that: The outer surface of the conductor core (1) is covered with a first insulation layer (2), and the outer surface of the first insulation layer (2) is covered with a second insulation layer (3). The outer surface of the second insulation layer (3) is covered with a third insulation layer (4), and the outer surface of the third insulation layer (4) is coated with a wear-resistant coating (8). The surface of the third insulation layer (4) is coated with a tape adhesive surface (6), and release paper (7) is pasted on the tape adhesive surface (6). A reinforcing layer (5) made of polyether ether ketone is installed between the conductor core (1) and the first insulation layer (2).

2. The high strength three-layer insulated wire of claim 1, wherein: The thickness of the reinforcing layer (5) is between 10 and 2000 micrometers, and the length of the reinforcing layer (5) is adapted to the length of the conductor core (1).

3. The high strength three-layer insulated wire of claim 1, wherein: The first insulating layer (2), the second insulating layer (3) and the third insulating layer (4) have the same length, and the lengths of the first insulating layer (2), the second insulating layer (3) and the third insulating layer (4) match the length of the conductor core (1).

4. The high strength, three-layer insulated wire of claim 1, wherein: The tape adhesive surface (6) covers the surface of the wear-resistant coating (8), and the length of the tape adhesive surface (6) matches the length of the third insulating layer (4), and the size of the release paper (7) matches the size of the tape adhesive surface (6).

5. The high strength, three-layer insulated wire of claim 1, wherein: The thickness of the first insulating layer (2) is between 10 and 30 micrometers, the thickness of the second insulating layer (3) is between 10 and 30 micrometers, and the thickness of the third insulating layer (4) is between 10 and 50 micrometers.

6. The high strength, three-layer insulated wire of claim 1, wherein: The gaps between the stranded conductors of the conductor core (1) are filled with graphene thermal paste (9), and the graphene thermal paste (9) is made of silicon-based paste of graphene particles.

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