Enameled wire with a corona-resistant composite coating structure

Abstract

This invention discloses an enameled wire with a corona-resistant composite coating structure, comprising a conductor. The outer wall of the conductor is sequentially provided with a first insulating layer, a second insulating layer, a third insulating layer, a fourth insulating layer, a fifth insulating layer, and a weather-resistant protective outer layer. The weather-resistant protective outer layer contains microencapsulated repair agent particles, which are either siloxane or epoxy resin. These microencapsulated repair agent particles are uniformly distributed within the coating matrix, and the particle size is 5μm-50μm. The first, third, and fifth insulating layers constitute the main corona-resistant structure. This invention, by setting a weather-resistant protective outer layer with uniformly embedded microencapsulated repair agent particles within the coating matrix, ensures a fast repair response and wide coverage, while avoiding impact on the outer layer's mechanical strength. It actively repairs damage triggered by high temperatures or mechanical friction, thus improving service life.

Description

Technical Field

[0001] This utility model relates to the field of corona-resistant enameled wire technology, and in particular to an enameled wire with a corona-resistant composite coating structure. Background Technology

[0002] Corona-resistant enameled wire is a special type of electromagnetic wire with excellent corona resistance. By coating the conductor with a special insulating varnish layer, it can effectively suppress corona discharge under high-frequency pulse voltage, improving the insulation performance and operational reliability of electrical equipment. However, with the continuous development of the manufacturing industry of new energy vehicle motors, engines, etc., the continuous changes in the application environment, and the continuous progress of technology, special enameled wires with high current resistance, voltage resistance, and corona resistance are needed in more and more occasions. Existing enameled wires can no longer meet the requirements. For this reason, the authorized publication number CN207409287U discloses "a corona-resistant enameled wire". This solution adopts a multi-layer composite structure of polyamide-imide varnish and nano-polyester-imide varnish. Compared with commercially available enameled wires with two insulation layers, its voltage breakdown capacity is increased by about 3000V and its high-frequency pulse resistance is improved by 1.5 times. At the same time, it has better solvent resistance, heat resistance, and transmission oil resistance, and can be used in new energy vehicle motors, variable frequency motors, traction motors, and other products.

[0003] However, this solution does not have self-healing capabilities. It cannot repair minor corona damage, eventually leading to breakdown. Over time, the insulation performance deteriorates, resulting in a reduced service life. Therefore, a corona-resistant composite coating structure for enameled wire is proposed. Utility Model Content

[0004] The purpose of this invention is to address the shortcomings of existing technologies by proposing a corona-resistant composite coating structure for enameled wire.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: an enameled wire with a corona-resistant composite coating structure, comprising a conductor, wherein the outer wall of the conductor is sequentially provided with a first insulation layer, a second insulation layer, a third insulation layer, a fourth insulation layer, a fifth insulation layer, and a weather-resistant protective outer layer, wherein the weather-resistant protective outer layer is embedded with microencapsulated repair agent particles, wherein the microencapsulated repair agent particles are siloxane or epoxy resin. Through the design of multiple insulation layers and a self-healing weather-resistant layer, the corona resistance and environmental adaptability of the enameled wire are significantly improved.

[0006] As a further description of the above technical solution:

[0007] The microencapsulated repair agent particles of the weather-resistant protective outer layer are uniformly distributed in the coating matrix. The particle size is 5μm-50μm. The uniformly distributed microcapsules can release the repair agent when the coating is damaged, automatically repairing micro-cracks and extending the service life.

[0008] As a further description of the above technical solution:

[0009] The first, third, and fifth insulating layers constitute the corona-resistant main structure. The superimposed design of the three corona-resistant materials effectively disperses electric field stress, suppresses partial discharge, and improves overall insulation performance.

[0010] As a further description of the above technical solution:

[0011] Both the first and third insulating layers are made of high-adhesion polyamide-imide varnish, specifically ELANTAS' TONGMID596. This high-adhesion material ensures that the insulating layer is tightly bonded to the conductor and other coatings, preventing delamination or peeling.

[0012] As a further description of the above technical solution:

[0013] The fifth insulating layer is made of high heat-resistant polyamide-imide varnish, specifically ELANTAS' Allotherm 602L-A, whose high-temperature resistance allows the enameled wire to maintain stable electrical and mechanical properties even under high-temperature conditions.

[0014] As a further description of the above technical solution:

[0015] The second and fourth insulating layers constitute a flexible buffer structure. Both the second and fourth insulating layers are made of nano-polyesterimide varnish. The flexible buffer layer can absorb mechanical stress and reduce the risk of the insulating layer cracking due to bending or vibration.

[0016] As a further description of the above technical solution:

[0017] The conductor is a copper wire with a circular cross-section and a diameter of 0.8 mm. The standardized circular copper conductor balances conductivity and coating uniformity, making it suitable for high-frequency and high-power applications.

[0018] This utility model has the following beneficial effects:

[0019] Compared with existing technologies, the enameled wire with this corona-resistant composite coating structure has a weather-resistant outer layer. The microencapsulated repair agent particles of the weather-resistant outer layer are uniformly embedded in the coating matrix, ensuring the repair response speed and coverage, while avoiding affecting the mechanical strength of the outer layer. When the temperature is high or mechanical friction is triggered, it actively repairs damage and improves service life. Attached Figure Description

[0020] Figure 1 This is a three-dimensional structural diagram of an enameled wire with a corona-resistant composite coating structure proposed in this utility model;

[0021] Figure 2 This is a cross-sectional view of an enameled wire with a corona-resistant composite coating structure proposed in this utility model.

[0022] Legend:

[0023] 1. Conductor; 2. First insulating layer; 3. Second insulating layer; 4. Third insulating layer; 5. Fourth insulating layer; 6. Fifth insulating layer; 7. Weather-resistant protective outer layer. Detailed Implementation

[0024] 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.

[0025] Reference Figures 1 to 2 This utility model provides an enameled wire with a corona-resistant composite coating structure, comprising a conductor 1, which is a copper wire with a circular cross-section and a diameter of 0.8 mm. The standardized circular copper conductor balances conductivity and coating uniformity, making it suitable for high-frequency and high-power applications. The outer wall of the conductor 1 is sequentially provided with a first insulating layer 2, a second insulating layer 3, a third insulating layer 4, a fourth insulating layer 5, a fifth insulating layer 6, and a weather-resistant protective outer layer 7. The first insulating layer 2, the third insulating layer 4, and the fifth insulating layer 6 constitute the main corona-resistant structure. The stacked design of the three corona-resistant materials effectively disperses electric field stress, suppresses partial discharge, and improves overall insulation performance. The fifth insulating layer 6 is made of high-heat-resistant polyamide-imide varnish. The heat-resistant polyamide-imide varnish is ELANTAS' Allotherm 602L-A. Its high-temperature resistance allows the enameled wire to maintain stable electrical and mechanical properties even in high-temperature environments. The first insulation layer 2 and the third insulation layer 4 are both made of ultra-adhesive polyamide-imide varnish, which is ELANTAS' TONGMID 596. The high-adhesion material ensures that the insulation layer is tightly bonded to the conductor and other coatings, avoiding delamination or peeling problems. The second insulation layer 3 and the fourth insulation layer 5 form a flexible buffer structure. The second insulation layer 3 and the fourth insulation layer 5 are both made of nano-polyester-imide varnish. The flexible buffer layer can absorb mechanical stress and reduce the risk of insulation layer cracking due to bending or vibration.

[0026] The weather-resistant outer layer 7 contains microencapsulated repair agent particles, which are either siloxane or epoxy resin. These particles are uniformly distributed within the coating matrix, with a particle size of 5μm-50μm. This uniform embedding ensures fast repair response and coverage while avoiding impact on the outer layer's mechanical strength. It actively repairs damage under high temperatures or mechanical friction, thus extending service life.

[0027] Working principle: The microencapsulated repair agent particles of the weather-resistant outer layer 7 are uniformly embedded in the coating matrix, ensuring repair response speed and coverage, while avoiding affecting the mechanical strength of the outer layer. When the temperature is high or mechanical friction is triggered, it actively repairs damage and improves service life.

[0028] 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 corona-resistant composite coating structure for enameled wire, comprising a conductor (1), characterized in that: The outer wall of the conductor (1) is provided with a first insulating layer (2), a second insulating layer (3), a third insulating layer (4), a fourth insulating layer (5), a fifth insulating layer (6) and a weather-resistant protective outer layer (7) in sequence. The weather-resistant protective outer layer (7) is embedded with microencapsulated repair agent particles, which are siloxane or epoxy resin.

2. The enameled wire with a corona-resistant composite coating structure according to claim 1, characterized in that: The microencapsulated repair agent particles of the weather-resistant protective outer layer (7) are uniformly distributed in the coating matrix, and the particle size is 5μm-50μm.

3. The enameled wire with a corona-resistant composite coating structure according to claim 1, characterized in that: The first insulating layer (2), the third insulating layer (4) and the fifth insulating layer (6) constitute the corona-resistant main structure.

4. The enameled wire with a corona-resistant composite coating structure according to claim 1, characterized in that: The first insulating layer (2) and the third insulating layer (4) are both made of super-adhesion polyamide-imide paint, and the super-adhesion polyamide-imide paint is ELANTAS' TONGMID596.

5. The enameled wire with a corona-resistant composite coating structure according to claim 1, characterized in that: The fifth insulating layer (6) is made of high heat-resistant polyamide-imide varnish, which is ELANTAS' Allotherm 602L-A.

6. The enameled wire with a corona-resistant composite coating structure according to claim 1, characterized in that: The second insulating layer (3) and the fourth insulating layer (5) constitute a flexible buffer structure. The material of the second insulating layer (3) and the fourth insulating layer (5) is nano-polyesterimide paint.

7. The enameled wire with a corona-resistant composite coating structure according to claim 1, characterized in that: The conductor (1) is a copper wire with a circular cross-section and a diameter of 0.8 mm.

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