Polyester-imide enameled copper round wire for automatic winding magnetic ring

Abstract

The utility model belongs to the field of enameled wire, especially a polyester imine enameled copper round wire of automatic winding magnetic ring, in view prior art's bending process can reduce the structural strength of enamelled wire, cause the problem of enameled wire outer layer breakage, present the following scheme, including magnetic ring, the outer wall of magnetic ring is wrapped with enameled wire, the enamelled wire is composed of copper wire and enameled layer, the enameled layer is from inside to outside and is composed of polyester imine main part, reinforcing net, support layer and smooth layer, wherein, in the automatic winding process, the reinforcing net resists the stress deformation of bending to enhance the structural strength, the smooth layer reduces the friction coefficient to reduce the outer layer breakage, in the utility model, through the oblique interlaced woven reinforcing net, the overall trend of enameled wire in the winding process can be adapted, the stress deformation produced by the high-speed winding of the winding machine is effectively resisted, and meanwhile the smooth layer greatly reduces the friction coefficient in the winding process of enameled wire, which has a good protection effect on enameled wire.

Description

Technical Field

[0001] This utility model relates to the field of enameled wire technology, and in particular to a polyesterimide enameled copper round wire for automatically winding magnetic rings. Background Technology

[0002] Polyesterimide enameled copper round wire is a round wire with high-purity electrolytic copper as the conductor and an outer layer coated with polyesterimide resin insulating varnish. It belongs to the H-class heat-resistant conductor and is widely used in motor windings, high-temperature transformers, precision electronic components, automotive motors and power tools.

[0003] During the process of winding polyesterimide enameled copper round wire into a magnetic ring, the enameled wire needs to be continuously wound. In order to achieve better winding, the enameled wire will be bent multiple times before winding. During the bending process, the structural strength of the enameled wire will be reduced, causing damage to the outer layer of the enameled wire. Utility Model Content

[0004] The purpose of this invention is to address the shortcomings of existing technologies where bending reduces the structural strength of the enameled wire and causes damage to the outer layer of the enameled wire. This invention proposes a polyesterimide enameled copper round wire with an automatically wound magnetic ring.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: A polyesterimide enameled copper round wire for automatically winding magnetic rings includes a magnetic ring, the outer wall of which is wrapped with enameled wire, the enameled wire being composed of copper wire and an enameled layer, the enameled layer being composed of a polyesterimide body, a reinforcing mesh, a support layer and a smoothing layer from the inside out; During the automatic winding process, the reinforcing mesh resists bending stress deformation to enhance structural strength, and the smooth layer reduces the coefficient of friction to reduce damage to the outer layer.

[0006] In one possible design, the reinforcing mesh is woven from a first oblique braided strip and a second oblique braided strip, and the first oblique braided strip and the second oblique braided strip are woven at an oblique 45-degree angle. This weaving method forms a mesh reinforcement in both the radial and axial directions, effectively resisting the stress deformation generated by the high-speed winding of the winding machine.

[0007] In one possible design, an adhesive is provided between the polyesterimide body and the support layer, and the reinforcing mesh is located within the adhesive; The adhesive is used to anchor the layers, ensuring the bonding stability of the reinforcing mesh.

[0008] In one possible design, multiple support strips are integrally formed within the support layer, the support layer is made of PVC material, and the support strips are composed of PVC and PE materials; Among them, the support strip improves the support of the enameled wire and reduces bending deformation.

[0009] In one possible design, the support strip has an arc-shaped cross-section and is equidistantly distributed along the axial direction of the enameled wire; The curved cross-section disperses bending stress and reduces the risk of breakage.

[0010] In one possible design, the smooth layer comprises PTFE micropowder; Among them, PTFE micro powder reduces the coefficient of friction of enameled wire and reduces winding friction loss.

[0011] In one possible design, the thickness of the smooth layer is 3 μm, and the particle size of the PTFE powder is 5 μm; The optimized thickness and particle size configuration reduces the friction coefficient to below 0.08.

[0012] In one possible design, the polyesterimide body is coated on the outside of the copper wire and is formed by a dip-coating process of polyesterimide resin. The polyesterimide body provides Class H insulation and maintains insulation integrity during bending.

[0013] In one possible design, the reinforcing mesh is made of aramid fibers; Among them, aramid fibers enhance toughness and adapt to the overall orientation of the enameled wire during the winding process.

[0014] In this application, the enameled wire is wound onto a magnetic ring using an automatic magnetic winding machine. The main body of the enameled wire consists of copper wire and an enameled layer, with the enameled layer covering the outer wall of the copper wire. The enameled layer is composed of a polyesterimide main body, a reinforcing mesh, a support layer, a waterproof layer, a heat dissipation layer, and a smoothing layer, arranged sequentially from the inside out. The polyesterimide main body provides insulation. The reinforcing mesh is woven from a first oblique braided strip and a second oblique braided strip. The reinforcing mesh is bonded between the polyesterimide main body and the support layer with adhesive, ensuring the stability of the reinforcing mesh bonding and improving the toughness of the enameled wire. The support strip is integrally formed within the support layer, improving the support of the enameled wire. The waterproof layer is located outside the support layer for waterproofing. The heat dissipation layer is located outside the waterproof layer for heat dissipation. The smoothing layer is located outside the heat dissipation layer to improve the smoothness of the enameled wire, reducing friction during the winding process and thus reducing wear on the enameled wire.

[0015] Beneficial effects: In this utility model, the polyesterimide enameled copper round wire for automatically winding magnetic rings adopts a first oblique braided strip and a second oblique braided strip fiber cross braiding process at 45° for the reinforcing mesh layer, and achieves interlayer anchoring with an adhesive bonding layer. This structure forms a mesh reinforcement in both the radial and axial directions, effectively resisting the stress deformation generated by the high-speed winding of the winding machine and reducing the wire breakage rate. In this invention, the polyesterimide enameled copper round wire for automatically winding magnetic rings effectively reduces the coefficient of friction and reduces winding friction loss through an outer smooth PTFE micro powder coating; a middle heat dissipation layer of silicone rubber constructs a heat dissipation channel to reduce the temperature during continuous operation; and an inner waterproof layer of PU material provides a hydrophobic barrier to ensure stable operation in humid environments. In this invention, the reinforcing mesh, which is woven in an oblique interlacing pattern, can adapt to the overall direction of the enameled wire during the winding process, effectively resisting the stress deformation generated by the high-speed winding of the winding machine. At the same time, the smooth layer greatly reduces the coefficient of friction of the enameled wire during the winding process, thus playing a good protective role for the enameled wire. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of a polyesterimide enameled copper round wire structure for automatically winding magnetic rings, as proposed in this utility model.

[0017] Figure 2 This is a schematic diagram of the structure of a polyesterimide enameled copper round wire for automatically winding magnetic rings, as proposed in this utility model.

[0018] Figure 3 This is a cross-sectional view of a polyesterimide enameled copper round wire reinforcing mesh for automatically winding magnetic rings, as proposed in this utility model.

[0019] In the diagram: 1. Magnetic ring; 2. Enameled wire; 3. Smooth layer; 4. Heat dissipation layer; 5. Waterproof layer; 6. Support layer; 7. Support strip; 8. Adhesive; 9. Reinforcing mesh; 10. Polyesterimide body; 11. Copper wire; 12. First oblique braided strip; 13. Second oblique braided strip; 14. Enameled layer. Detailed Implementation

[0020] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments.

[0021] Example 1: Refer to Figure 1 A polyesterimide enameled copper round wire with an automatically wound magnetic ring is disclosed. This wire, used in the field of enameled wire, comprises a magnetic ring 1 using a standard ferrite core, with a sandblasted surface to enhance adhesion. The enameled wire 2 is wound onto the outer wall of the magnetic ring 1 at a constant tension of 300 revolutions per minute using an automatic magnetic winding machine. The copper wire 11 of the enameled wire 2 is selected from annealed copper round wire with a diameter of 0.5 mm, and its outer surface is degreased and cleaned before entering the coating process.

[0022] Reference Figure 1The polyesterimide substrate 10 is formed by a dip-coating process: copper wire 11 is passed through a molten polyesterimide varnish bath at 180°C at a speed of 2 m / min, the coating thickness is controlled to be 15 μm, and then cured in a 280°C oven to form a basic insulation layer. The reinforcing mesh 9 is then laminated immediately before the polyesterimide substrate 10 has completely cooled.

[0023] Reference Figure 2 and Figure 3 The reinforcing mesh 9 is made of aramid fibers, with the first oblique braided strip 12 and the second oblique braided strip 13 interlaced at a 45° angle, and the mesh density is 120 mesh. The adhesive 8 is an epoxy-modified polyurethane adhesive, which is evenly applied to the surface of the polyesterimide body 10 using a dual-head coating device, with the coating amount controlled at 20 g / m². 2 The reinforcing mesh 9 is pressed into the adhesive layer 8 by tension rollers, so that the woven strips are embedded into the adhesive layer to a depth of 40%, and then cured by hot air at 150℃ to form an interlayer anchoring structure.

[0024] Reference Figure 2 and Figure 3 The support layer 6 is made of PVC and PE blended granules (7:3 ratio), which is extruded onto the outside of the reinforcing mesh 9 at 185℃ using a 45mm extruder, with an extrusion thickness of 0.1mm. The support strips 7 are extruded synchronously with the support layer 6 through 12 micro-channels embedded in the die head. Each support strip 7 has a semi-circular cross-section (80μm in diameter) and is equidistantly distributed along the axial direction of the enameled wire 2 with a spacing of 0.8mm.

[0025] Reference Figure 2 The waterproof layer 5 uses a two-component PU coating, which is sprayed onto the surface of the support layer 6 using a precision metering pump. The wet film thickness is 50μm, and it is cross-linked into a film under 80℃ hot air circulation. The heat dissipation layer 4 is formed by slit coating of liquid silicone rubber (containing 30% aluminum nitride thermally conductive filler). The coating thickness is 80μm, and the thermal conductivity reaches 1.2W / m·K after curing at 120℃.

[0026] Reference Figure 2 The smooth layer 3 is prepared by mixing PTFE micro powder (5μm particle size) and fluorocarbon resin in a 1:4 ratio to form a suspension, which is then applied to the surface of the heat dissipation layer 4 using an electrostatic spraying process with a spraying voltage of 50kV, ultimately forming a 3μm thick coating. The dynamic friction coefficient of the enameled wire 2 surface was measured to be reduced to 0.08 using a friction coefficient tester.

[0027] Example 2: Reference Figure 1 An improvement upon Example 1: During the winding process, the pressure of the guide wheel of the automatic winding machine was set to 0.5N, and the enameled wire 2 was wound at a linear speed of 22m / min. After 200 bending tests (radius of curvature 3mm), the enameled layer 14 showed no cracking; under 85% humidity, the insulation resistance value remained >10GΩ; and after continuous operation with a 5A current for 8 hours, the wire temperature was ≤65℃.

[0028] The accompanying drawings in this application are for illustrative purposes only. The dimensions and shapes of the components shown are not actual limitations but are merely schematic representations. In actual implementation, the components can be reasonably configured and adjusted according to specific needs and actual conditions.

[0029] The above description is only a preferred embodiment of the present utility model, but the protection scope of the present utility model is not limited thereto. Any equivalent substitutions or changes made by those skilled in the art within the technical scope disclosed in the present utility model, based on the technical solution and the inventive concept of the present utility model, should be included within the protection scope of the present utility model.

Claims

1. A polyesterimide enameled copper round wire for automatically winding a magnetic ring, comprising a magnetic ring (1), characterized in that, The outer wall of the magnetic ring (1) is wrapped with enameled wire (2), which is composed of copper wire (11) and enameled layer (14). The enameled layer (14) is composed of polyesterimide body (10), reinforcing mesh (9), support layer (6) and smooth layer (3) from the inside to the outside. The reinforcing mesh (9) is woven from a first oblique braided strip (12) and a second oblique braided strip (13), and the first oblique braided strip (12) and the second oblique braided strip (13) are woven at an oblique 45-degree angle. An adhesive (8) is provided between the polyesterimide body (10) and the support layer (6), and the reinforcing mesh (9) is located within the adhesive (8).

2. The polyesterimide enameled copper round wire for automatically winding magnetic rings according to claim 1, characterized in that, The support layer (6) has multiple support strips (7) integrally formed inside it. The support layer (6) is made of PVC material, and the support strips (7) are composed of PVC material and PE material.

3. The polyesterimide enameled copper round wire for automatically winding magnetic rings according to claim 2, characterized in that, The support bar (7) has an arc-shaped cross section and is equidistantly distributed along the axial direction of the enameled wire (2).

4. The polyesterimide enameled copper round wire for automatically winding magnetic rings according to claim 1, characterized in that, The smooth layer (3) contains PTFE micropowder.

5. The polyesterimide enameled copper round wire for automatically winding magnetic rings according to claim 4, characterized in that, The thickness of the smooth layer (3) is 3 μm, and the particle size of the PTFE micro powder is 5 μm.

6. The polyesterimide enameled copper round wire for automatically winding magnetic rings according to claim 1, characterized in that, The polyesterimide body (10) is wrapped around the outside of the copper wire (11) and is formed by dip coating process of polyesterimide resin.

7. The polyesterimide enameled copper round wire for automatically winding magnetic rings according to claim 1, characterized in that, The reinforcing mesh (9) is made of aramid fiber.

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