An enameled wire for an alternator

Abstract

This utility model discloses an enameled wire for an AC generator, belonging to the field of AC generator technology. It solves the problem that the surface enamel film on existing enameled wires is easily damaged during winding, causing the wires to fail to meet various environmental testing requirements. The wire includes an enameled wire body, which comprises a conductive element and an enamel film surrounding the conductive element. The enamel film, in the radial direction of the conductive element, sequentially includes a base coat, a base coat, and a surface coat, with the base coat thickness being 5% of the enamel film thickness. This utility model changes the stator enameled wire's enamel film from two layers to three layers, adding a base coat to improve the adhesion of the enameled wire, reduce enamel film damage during winding, and ultimately meet various environmental testing requirements, ensuring the reliability of the generator product and guaranteeing continuous and normal power supply to the vehicle's electrical components.

Description

Technical Field

[0001] This utility model relates to the field of AC motor technology, specifically to an enameled wire for AC generators. Background Technology

[0002] The stator enameled wire in existing AC generators often includes a base enamel film and a top enamel film. The base enamel film and the top enamel film are made of polyesterimide and polyesteramineimide, respectively. The top enamel film has higher wear resistance and corrosion resistance than the base enamel film, thus serving as the core protective layer.

[0003] However, in the actual stator production process, the enameled wire needs to be wound, which can easily damage the surface enamel film on the wire. As the surface enamel film, which is the core protective layer, is damaged, the exposed underlying enamel film will be quickly worn or corroded, thus failing to meet the requirements of various environmental tests, such as high leakage current and failure to pass the salt spray test. As a result, the generator produced is prone to wire corrosion and breakage during actual use (especially in saline areas), causing the alternator to fail to generate electricity normally and fail to supply power to the vehicle's electrical appliances. Utility Model Content

[0004] To address the aforementioned problems in the prior art, this utility model provides an enameled wire for an AC generator, which solves the problem that the surface enamel film on existing enameled wires is easily damaged during winding, causing the enameled wires to fail to meet the requirements of various environmental tests.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows:

[0006] An enameled wire for an alternator is provided, comprising an enameled wire body, the enameled wire body including a conductive element and an enamel film surrounding the conductive element, the enamel film comprising, in the radial direction of the conductive element, a base layer, a base layer and a top layer, the thickness of the base layer being 5% of the thickness of the enamel film.

[0007] The beneficial effects of this solution are as follows: Changing the stator enameled wire coating from two layers to three layers by adding a base coat increases processing costs. However, the layered design of the base coat, top coat, and top coat optimizes the coating performance. The base coat, as a foundation layer, not only improves adhesion between the coating and conductive components, but also ensures that even if the top coat is damaged, the base coat is also protected against wear and corrosion. Furthermore, the base coat serves as a final wear- and corrosion-resistant protective layer, thus meeting the requirements of various environmental tests, ensuring the reliability of the generator product, guaranteeing continuous and normal power supply to the vehicle's electrical components, and improving the overall product qualification rate. Setting the base coat thickness to 5% of the coating thickness ensures adhesion without excessively increasing the overall thickness, maintaining the flexibility and electrical properties of the enameled wire.

[0008] Furthermore, the thickness of the base layer is 40% to 50% of the paint film thickness. As an intermediate layer, the base layer not only ensures electrical performance but also provides a good foundation for the top layer.

[0009] Furthermore, the static friction coefficient of the outer wall surface of the surface layer is less than or equal to 0.06. A low static friction coefficient can reduce frictional damage to the surface layer during winding.

[0010] Furthermore, the diameter of the conductive component is 1.089mm to 1.100mm, and the thickness of the enamel film is greater than or equal to 0.034mm. This high dimensional accuracy ensures the reliability and stability of the enameled wire performance, thereby guaranteeing the reliability and stability of the generator's output performance. The conductive component diameter of 1.089mm to 1.1mm ensures that its current-carrying capacity and resistivity are within a reasonable range, meeting the current transmission requirements of the AC generator.

[0011] Furthermore, the diameter of the enameled wire body is less than or equal to 1.164 mm. A smaller diameter can reduce eddy current losses and improve generator efficiency.

[0012] Furthermore, the ratio of the maximum to the minimum thickness of the varnish film in the circumferential direction is less than or equal to 1.5. Generally speaking, the more uniform the varnish film, the better, that is, the closer the maximum to the minimum thickness is to 1, the better. However, the setting of 1.5 is a result that takes into account the balance between the actual operating conditions of the generator and the production process of the varnish film of the enameled wire, and can take both into account.

[0013] Furthermore, the materials for the undercoat, base coat, and top coat are polyesteramide imide, polyesterimide, and polyesteramide imide, respectively. The main function of the polyesteramide imide undercoat is to improve adhesion, while also serving as the final wear-resistant and corrosion-resistant protective layer. The polyesterimide top coat is designed to improve the flexibility of the paint film, and it also continues to serve as the core heat-resistant and wear-resistant protective layer.

[0014] Furthermore, the conductive component is made of copper. Attached Figure Description

[0015] Figure 1 This is a schematic cross-sectional view of the enameled wire used in an AC generator;

[0016] The components are: 1. Conductive components; 2. Underlayer; 3. Base layer; 4. Top layer. Detailed Implementation

[0017] The specific embodiments of this utility model are described below to enable those skilled in the art to understand this utility model. However, it should be understood that this utility model is not limited to the scope of the specific embodiments. For those skilled in the art, as long as various changes are within the spirit and scope of this utility model as defined and determined by the appended claims, these changes are obvious. All utility model creations utilizing the concept of this utility model are within the scope of protection.

[0018] In the actual stator production process, the enameled wire needs to be wound, which easily damages the surface enamel film, the core protective layer. This causes the enameled wire to lose its high corrosion resistance and wear resistance, failing to meet environmental test requirements, such as high leakage current and failure to pass salt spray tests. Consequently, generators produced in this way are prone to wire corrosion and breakage when used in saline areas. To solve this problem, this application provides an enameled wire for AC generators. By changing the enamel film of the stator enameled wire from two layers to three layers by adding a base coat 2, although this increases processing costs, it improves the overall product qualification rate of the generator. The base coat 2, as a base layer, not only helps improve the adhesion between the enamel film and the conductive component 1, but also ensures that even if the surface layer 4 is damaged, the base coat 3 will also be worn or corroded. The base coat 2 also serves as a final wear-resistant and corrosion-resistant protective layer, thus meeting the requirements of various environmental tests, ensuring the reliability of the generator product, and guaranteeing continuous and normal power supply to the vehicle's electrical components.

[0019] The structure of an enameled wire for an alternator can be referenced. Figure 1 It includes an enameled wire body, which includes a conductive element 1 and an enamel film surrounding the conductive element 1. The enamel film, in the radial direction of the conductive element 1, sequentially includes a base layer 2, a base layer 3, and a top layer 4. The thickness of the base layer 2 is 5% of the enamel film thickness, the thickness of the base layer 3 is 40% to 50% of the enamel film thickness, and thus the thickness of the top layer 4 is 45% to 55% of the enamel film thickness.

[0020] In this embodiment, the conductive component 1 is made of copper, and the base coat 2, base coat 3, and top coat 4 are made of polyesteramide imide, polyesterimide, and polyesteramide imide, respectively. The main function of the polyesteramide imide base coat 2 is to improve adhesion, while also serving as the final wear-resistant and corrosion-resistant protective layer. The polyesterimide top coat 4 is designed to improve the flexibility of the paint film, and it still serves as the core heat-resistant and wear-resistant protective layer.

[0021] Specifically, the diameter of conductive component 1 is 1.089mm to 1.100mm, and the thickness of the enamel film is greater than or equal to 0.034mm. The total diameter of the enameled wire body is less than or equal to 1.164mm. High dimensional accuracy ensures the reliability and stability of the enameled wire's performance, thereby guaranteeing the reliability and stability of the generator's output performance. The diameter of conductive component 1, ranging from 1.089mm to 1.1mm, ensures that its current-carrying capacity and resistivity are within a reasonable range, meeting the current transmission requirements of the AC generator.

[0022] To balance the actual operating performance of the generator with the difficulty of the enameled wire coating production process, the ratio of the maximum to minimum thickness of the coating in the circumferential direction is less than or equal to 1.5. From the perspective of generator use, a more uniform coating is better, meaning the ratio of the maximum to minimum thickness should be as close to 1 as possible. However, the more uniform the coating, the more difficult the enameled wire coating process becomes. The difficulty of the enameled wire coating process is mainly related to the number of coating passes and the coating speed. Specifically, regarding the number of coating passes, to achieve a more uniform coating of the same thickness, the amount of coating applied each time will be reduced, thus increasing the number of coating passes. Regarding the coating speed, with the same amount of coating applied each time, a higher coating speed results in a more uniform coating. The value of 1.5 in this embodiment is a result that comprehensively considers both the number of coating passes and the coating speed.

[0023] As a further embodiment, the static friction coefficient of the outer wall surface of the surface layer 4 is less than or equal to 0.06. A low static friction coefficient can reduce frictional damage to the surface layer 4 during winding. To achieve this effect, a lubricant, such as polytetrafluoroethylene or molybdenum disulfide, can be added to the material of the surface layer 4. Alternatively, a paraffin lubricating layer can be applied to the surface layer 4, or a silicone oil coating or a fluorinated coating can be applied.

[0024] Although the specific embodiments of the utility model have been described in detail with reference to the accompanying drawings, this should not be construed as limiting the scope of protection of this patent. Various modifications and variations that can be made by those skilled in the art without inventive effort within the scope described in the claims still fall within the scope of protection of this patent.

Claims

1. An enameled wire for an alternator, characterized by, The device includes an enameled wire body, which includes a conductive element (1) and an enamel film surrounding the conductive element (1). The enamel film includes, in the radial direction of the conductive element (1), a base layer (2), a base layer (3), and a top layer (4). The thickness of the base layer (2) is 5% of the thickness of the enamel film. The ratio of the maximum thickness to the minimum thickness of the paint film in the circumferential direction is less than or equal to 1.

5.

2. The enameled wire for an alternator according to claim 1, characterized by, The thickness of the bottom layer (3) is 40% to 50% of the thickness of the paint film.

3. The enameled wire for an alternator according to claim 1, characterized by, The static friction coefficient of the outer wall of the surface layer (4) is less than or equal to 0.

06.

4. The enameled wire for an alternator according to claim 1, characterized by, The diameter of the conductive element (1) is 1.089 mm to 1.100 mm, and the thickness of the paint film is greater than or equal to 0.034 mm.

5. The enameled wire for an alternator according to claim 1, characterized by, The diameter of the enameled wire body is less than or equal to 1.164 mm.

6. The enameled wire for an alternator according to claim 1, characterized in that, The materials of the base layer (2), the base layer (3), and the top layer (4) are polyesterimide, polyesterimide, and polyesterimide, respectively.

7. The enameled wire for an alternator according to claim 1, characterized by, The conductive component (1) is made of copper.

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