An enameled wire with good wear resistance

Abstract

The utility model discloses a kind of enameled wire with good wear resistance, related to enameled wire technical field, including take-up reel and enameled wire body, enameled wire body is wound on the take-up reel, wear-resistant matrix layer is arranged on the outside of high-temperature-resistant protective layer, transition layer is wrapped inside surface layer, the outside of transition layer is provided with surface layer. In the utility model, through wear-resistant layer structure, excellent wear resistance is realized, wear-resistant matrix layer provides solid foundation, transition layer enhances the bonding force between layers, the fluoride coating of surface layer has excellent wear resistance, corrosion resistance and low friction coefficient characteristics, significantly improves the wear resistance of enameled wire in complex environment, in addition, the outer surface of surface layer is also coated with anticorrosive layer formed by silicon carbide-based anticorrosive paint, further protects enameled wire from the erosion of corrosive medium, thereby omnidirectionally enhances the wear resistance of enameled wire, prolongs its service life.

Description

Technical Field

[0001] This utility model relates to the field of enameled wire technology, specifically to an enameled wire with good wear resistance. Background Technology

[0002] Enameled wire is a type of electrical wire with one or more layers of insulating coating on its conductor surface. Specifically, it involves coating the conductor portion of a bare wire (usually made of a high-purity, highly conductive metal such as copper or aluminum) with one or more layers of insulating varnish, followed by baking, cooling, and other processes to form an insulated wire. Due to its unique structure and properties, enameled wire plays a crucial role in electrical equipment, primarily used for the conversion of electromagnetic energy, such as electrical energy into kinetic energy or heat energy. It is an indispensable material for motors, electrical appliances, electrical instruments, electrical devices, and household appliances.

[0003] During the winding process and equipment operation, the existing enameled wire must withstand the combined stress of mechanical tension, dynamic bending and high-frequency vibration friction for a long time. Under repeated deformation and friction, its insulation layer gradually undergoes micro-wear (such as surface scratches and coating peeling), resulting in a step-like reduction in insulation thickness. Once the insulation layer is completely worn through, the conductor will be directly exposed between adjacent turns or metal parts, which can easily cause inter-turn short circuits or leakage faults. In severe cases, it may cause equipment burnout or even safety accidents.

[0004] For example, the patented high-temperature reinforced enameled wire with authorization announcement number CN212392045U has a certain degree of wear resistance in the polyimide enamel layer. However, under the combined stress of long-term mechanical tension, dynamic bending and high-frequency vibration friction, its wear resistance is still limited. This may lead to the gradual wear of the insulation layer, which in turn may cause electrical faults.

[0005] Therefore, it is necessary to invent a type of enameled wire with good wear resistance to solve the above problems. Utility Model Content

[0006] The purpose of this invention is to provide an enameled wire with good wear resistance to solve the problem of poor wear resistance leading to gradual wear of the insulation layer and subsequent electrical faults.

[0007] To achieve the above objectives, this utility model provides the following technical solution: a wear-resistant enameled wire, comprising a take-up spool and an enameled wire body, wherein the enameled wire body is wound on the take-up spool, the enameled wire body comprising a metal conductor, an antioxidant layer and a flame-retardant layer, an insulating layer is disposed outside the flame-retardant layer, a mesh support layer and a corrugated support tube are disposed outside the insulating layer, a high-temperature resistant protective layer is disposed outside the corrugated support tube, and a wear-resistant layer structure is disposed outside the high-temperature resistant protective layer, the wear-resistant layer structure comprising a wear-resistant substrate layer, a transition layer and a surface layer, the wear-resistant substrate layer being disposed outside the high-temperature resistant protective layer, the transition layer being wrapped inside the surface layer, and the surface layer being disposed outside the transition layer.

[0008] Preferably, the metal conductor is made of high-purity oxygen-free copper, and the outer side of the metal conductor is coated with an antioxidant layer, which is a tin-plated metal layer. The low oxygen content of oxygen-free copper inhibits grain boundary corrosion, extends the conductor's lifespan, and together with the subsequent antioxidant layer, forms a dual protection system.

[0009] Preferably, the antioxidant layer is wrapped with a flame-retardant layer, which is made of modified flame-retardant polyolefin material. The flame-retardant layer is tightly bonded to the insulating layer, which can prevent the flame from spreading to the metal conductor and at the same time alleviate the damage of thermal stress to the internal structure.

[0010] Preferably, the mesh support layer is made by weaving high-strength fibers into a tubular metal mesh using a braiding machine, and the mesh shape can be rhomboid. The mesh support layer can suppress the deformation of the enameled wire body under bending or vibration and improve fatigue resistance.

[0011] Preferably, a corrugated support tube is fitted on the outside of the mesh support layer. The corrugated support tube is a corrugated plastic sleeve. The corrugated support tube is coaxially fitted with the mesh support layer. The corrugated plastic sleeve absorbs mechanical vibration energy through axial expansion and contraction, disperses stress concentration, and protects the internal mesh support layer from dynamic load damage.

[0012] Preferably, the wear-resistant substrate layer, transition layer, and surface layer are arranged in a coaxial composite structure from the inside out. The wear-resistant substrate layer is made of modified epoxy resin, the transition layer is nylon varnish, and the surface layer is a fluoride coating, which effectively improves the wear resistance of the enameled wire body.

[0013] Preferably, the wear-resistant layer structure further includes an anti-corrosion layer, which is coated on the outer surface of the surface layer. The anti-corrosion layer is a silicon carbide-based anti-corrosion coating. The anti-corrosion layer protects the surface layer of the enameled wire body from corrosion by corrosive media and extends the service life of the enameled wire body in harsh environments.

[0014] The technical effects and advantages provided by this utility model in the above technical solution are as follows:

[0015] 1. This utility model achieves excellent wear resistance through a wear-resistant layer structure. The wear-resistant substrate layer provides a solid foundation, the transition layer enhances the bonding force between the layers, and the fluoride coating on the surface layer has excellent wear resistance, corrosion resistance, and low coefficient of friction, which significantly improves the wear resistance of the enameled wire in complex environments. In addition, a silicon carbide-based anti-corrosion coating is applied to the outer surface of the surface layer to form an anti-corrosion layer, which further protects the enameled wire from the erosion of corrosive media, thereby comprehensively enhancing the wear resistance of the enameled wire and extending its service life.

[0016] 2. In this utility model, the design of fitting a corrugated support tube on the outside of the mesh support layer provides excellent mechanical support and vibration absorption capacity for the enameled wire. The mesh support layer suppresses the deformation of the enameled wire under bending or vibration, improving its fatigue resistance. The corrugated support tube absorbs mechanical vibration energy through axial expansion and contraction, disperses stress concentration, and effectively protects the internal mesh support layer. This unique support structure enables the enameled wire to maintain good performance in complex working environments, improving its reliability and stability. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of the overall structure of this utility model;

[0018] Figure 2 This is a cross-sectional three-dimensional structural diagram of the enameled wire body of this utility model;

[0019] Figure 3 This is a schematic diagram of the left-side cross-section of the enameled wire body of this utility model;

[0020] Figure 4 This is a cross-sectional three-dimensional structural diagram of the wear-resistant layer structure of this utility model.

[0021] Explanation of reference numerals in the attached figures:

[0022] 1. Take-up reel; 2. Enamelled wire body; 201. Metal conductor; 202. Antioxidant layer; 203. Flame retardant layer; 3. Insulation layer; 4. Mesh support layer; 5. Corrugated support tube; 6. High-temperature resistant protective layer; 7. Wear-resistant layer structure; 701. Wear-resistant substrate layer; 702. Transition layer; 703. Surface layer; 704. Anti-corrosion layer. Detailed Implementation

[0023] To enable those skilled in the art to better understand the technical solution of this utility model, the present utility model will be further described in detail below with reference to the accompanying drawings.

[0024] This utility model provides, for example Figure 1-4The enameled wire shown includes a take-up spool 1 and an enameled wire body 2. The enameled wire body 2 is wound on the take-up spool 1. The enameled wire body 2 includes a metal conductor 201, an antioxidant layer 202 and a flame-retardant layer 203. An insulation layer 3 is provided on the outside of the flame-retardant layer 203. A mesh support layer 4 and a corrugated support tube 5 are provided on the outside of the insulation layer 3. A high-temperature resistant protective layer 6 is provided on the outside of the corrugated support tube 5. An wear-resistant layer structure 7 is provided on the outside of the high-temperature resistant protective layer 6.

[0025] The metal conductor 201 is made of high-purity oxygen-free copper with a purity of ≥99.97%. The outer side of the metal conductor 201 is coated with an antioxidant layer 202, which is a tin-plated metal layer. The antioxidant layer 202 is wrapped with a flame-retardant layer 203, which is made of modified flame-retardant polyolefin material. The flame-retardant layer 203 is tightly bonded to the insulating layer 3.

[0026] In this embodiment, the metal conductor 201, made of high-purity oxygen-free copper, has a low oxygen content that can inhibit grain boundary corrosion, ensure the stability of the conductivity of the enameled wire body 2 during long-term use, reduce problems such as increased resistance caused by conductor corrosion, and extend the service life of the enameled wire body 2. In addition, the tin-plated metal layer, as an antioxidant layer 202, forms a protective film on the surface of the metal conductor 201, effectively isolating oxygen and moisture, preventing the metal conductor 201 from being oxidized, and further enhancing the stability and reliability of the metal conductor 201. Furthermore, the flame-retardant layer 203, made of modified flame-retardant polyolefin material, has good flame-retardant properties. When the enameled wire body 2 encounters a fire source, the flame-retardant layer 203 can prevent the spread of flames and protect the internal metal conductor 201 from high-temperature damage.

[0027] The mesh support layer 4 is made by weaving high-strength fibers into a tubular metal mesh using a weaving machine, and the mesh shape can be diamond-shaped. A corrugated support tube 5 is fitted on the outside of the mesh support layer 4. The corrugated support tube 5 is a corrugated plastic sleeve and is coaxially fitted with the mesh support layer 4.

[0028] In this embodiment, a tubular metal mesh sleeve woven from high-strength fibers serves as the mesh support layer 4. Its diamond-shaped mesh structure ensures a certain degree of flexibility while effectively suppressing the deformation of the enameled wire body 2 under bending or vibration. When the enameled wire body 2 is subjected to external force, the mesh support layer 4 can disperse stress and enhance the fatigue resistance of the enameled wire body 2. In addition, the corrugated support tube 5 can further enhance the flexibility of the enameled wire body 2 and improve its reliability in complex working environments.

[0029] The wear-resistant layer structure 7 includes a wear-resistant substrate layer 701, a transition layer 702, and a surface layer 703. The wear-resistant substrate layer 701 is disposed on the outside of the high-temperature protective layer 6. The transition layer 702 is wrapped inside the surface layer 703. The surface layer 703 is disposed on the outside of the transition layer 702. The wear-resistant substrate layer 701, the transition layer 702, and the surface layer 703 are arranged in a coaxial composite structure from the inside to the outside. The wear-resistant substrate layer 701 is made of modified epoxy resin, the transition layer 702 is nylon paint, and the surface layer 703 is a fluoride coating. The wear-resistant layer structure 7 also includes an anti-corrosion layer 704, which is coated on the outer surface of the surface layer 703. The anti-corrosion layer 704 is a silicon carbide-based anti-corrosion coating.

[0030] In this embodiment, the wear-resistant matrix layer 701, made of modified epoxy resin, provides a solid wear-resistant foundation for the enameled wire body 2. It has good mechanical properties and adhesion, and can firmly adhere to the outside of the high-temperature protective layer 6, withstand a certain amount of friction and wear, and protect the internal structure from external physical damage. The nylon paint, as a transition layer 702, plays a good transition and bonding role between the wear-resistant matrix layer 701 and the surface layer 703. It can enhance the bonding force between the layers, make the wear-resistant layer structure 7 more stable, prevent the peeling phenomenon between the layers, and improve the overall performance of the enameled wire. Furthermore, the surface layer 703 can significantly reduce the frictional resistance of the enameled wire body 2 during use and reduce wear. At the same time, the anti-corrosion layer 704 further enhances the anti-corrosion performance of the enameled wire body 2. It can prevent corrosive media from penetrating into the interior of the enameled wire body 2 and improve the service life of the enameled wire body 2 in harsh environments.

[0031] Working principle of this utility model:

[0032] Refer to the instruction manual appendix Figure 1-4 When using this utility model, firstly, when the enameled wire body 2 is connected to other electrical equipment or components, the metal conductor 201 generates heat due to the current passing through it. The antioxidant layer 202 forms a protective film on the surface of the metal conductor 201, effectively isolating oxygen and moisture. Moreover, the antioxidant layer 202 itself is relatively thin, so it has little impact on the heat dissipation of the metal conductor 201 and continues to play an anti-oxidation role. When the enameled wire body 2 encounters a fire source, the flame retardant layer 203 can prevent the flame from spreading, protect the internal metal conductor 201 from high temperature damage, and at the same time alleviate the damage of thermal stress to the internal structure. The insulation layer 3 usually has a certain heat resistance and can withstand a certain temperature when the metal conductor 201 dissipates heat. At the same time, the synergistic effect of the mesh support layer 4 and the corrugated support tube 5 inside the enameled wire body 2 can effectively enhance the fatigue resistance of the enameled wire body 2. Finally, the wear-resistant layer structure 7 provides a solid wear-resistant foundation for the enameled wire body 2, which can withstand a certain amount of friction and wear, and protect the internal structure from external physical damage.

[0033] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0034] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A type of enameled wire with good wear resistance, comprising a take-up spool (1) and an enameled wire body (2), characterized in that: The take-up reel (1) is wound with an enameled wire body (2). The enameled wire body (2) includes a metal conductor (201), an antioxidant layer (202), and a flame-retardant layer (203). An insulation layer (3) is provided on the outside of the flame-retardant layer (203). A mesh support layer (4) and a corrugated support tube (5) are provided on the outside of the insulation layer (3). A high-temperature resistant protective layer (6) is provided on the outside of the corrugated support tube (5). A wear-resistant layer structure (7) is provided on the outside of the high-temperature resistant protective layer (6). The wear-resistant layer structure (7) includes a wear-resistant substrate layer (701), a transition layer (702), and a surface layer (703). The wear-resistant substrate layer (701) is provided on the outside of the high-temperature resistant protective layer (6). The transition layer (702) is wrapped inside the surface layer (703). The surface layer (703) is provided on the outside of the transition layer (702).

2. The enameled wire with good wear resistance according to claim 1, characterized in that: The metal conductor (201) is made of high-purity oxygen-free copper, and the outer side of the metal conductor (201) is coated with an antioxidant layer (202), which is a tin-plated metal layer.

3. The enameled wire with good wear resistance according to claim 2, characterized in that: The antioxidant layer (202) is wrapped with a flame retardant layer (203), which is made of modified flame retardant polyolefin material and is tightly bonded to the insulating layer (3).

4. The enameled wire with good wear resistance according to claim 1, characterized in that: The mesh support layer (4) is made by weaving high-strength fibers into a tubular metal mesh using a weaving machine, and the mesh shape can be rhomboid.

5. The enameled wire with good wear resistance according to claim 4, characterized in that: The mesh support layer (4) is fitted with a corrugated support tube (5) on the outside. The corrugated support tube (5) is a corrugated plastic sleeve and is coaxially fitted with the mesh support layer (4).

6. The enameled wire with good wear resistance according to claim 1, characterized in that: The wear-resistant substrate layer (701), transition layer (702) and surface layer (703) are arranged in a coaxial composite structure from the inside to the outside. The wear-resistant substrate layer (701) is made of modified epoxy resin, the transition layer (702) is nylon paint, and the surface layer (703) is a fluoride coating.

7. The enameled wire with good wear resistance according to claim 1, characterized in that: The wear-resistant layer structure (7) also includes an anti-corrosion layer (704), which is coated on the outer surface of the surface layer (703) and is a silicon carbide-based anti-corrosion coating.

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