Composite enameled copper round wire

Abstract

The utility model discloses a kind of composite enameled copper round wire, including copper conductor, the outer layer of copper conductor is equipped with composite insulating layer, the outer layer of composite insulating layer is equipped with shielding braid, the outer layer of shielding braid is equipped with composite flame-retardant layer, the outer layer of composite flame-retardant layer is equipped with protective layer.The utility model is triggered self-formation porcelain reaction by composite flame-retardant layer design, ceramic silicon rubber outer layer can form dense ceramic hard shell quickly when high temperature, oxygen and heat exchange are completely isolated, when ceramic silicon rubber outer layer is cracked or notched when fire is powerful, composite flame retardant will be exposed to take effect, dilute combustible gas concentration, while promote carbon layer expansion, form dense heat insulation layer, realize the composite effect of gas phase flame-retardant and condensed phase flame-retardant, finally silica gel heat insulation inner layer can play good heat insulation effect, avoid high temperature to produce too big influence inside, very practical.

Description

Technical Field

[0001] This utility model relates to the field of copper round wire design technology, and in particular to a composite enameled copper round wire. Background Technology

[0002] Enameled copper round wire is a common type of electromagnetic wire, consisting of a copper conductor covered with an insulating enamel layer. It is widely used in electrical equipment such as motors, transformers, and inductors. Its components consist of an inner conductor and an outer insulating layer.

[0003] Through in-depth research and technical comparison, the applicant discovered that the current trend of electrical equipment evolving towards higher density, miniaturization, and extreme operating conditions places more stringent demands on the flame-retardant performance of enameled copper round wires. In existing technologies, to meet safety requirements in complex electromagnetic environments, composite outer layer structures have become the mainstream technical approach to improve the flame-retardant properties of enameled copper round wires. For example, the polyimide high-temperature composite enameled copper round wire disclosed in patent number CN222653693U uses a flame-retardant polyolefin matrix material for its flame-retardant layer. Thanks to its excellent thermal oxidation stability (long-term temperature resistance exceeding 200℃) and low heat release rate, it effectively suppresses the risk of thermal degradation and dripping of the insulation layer under high-temperature conditions. However, this type of solution still suffers from a technical bottleneck due to its singular flame-retardant mechanism: its flame-retardant effectiveness mainly relies on the intrinsic thermal stability of the polyolefin matrix, and its suppression of flame spread is still limited to the realm of physical insulation, making it difficult to synergistically leverage the combined effects of gas-phase flame retardancy (inhibiting free radical chain reactions) and condensed-phase flame retardancy (enhancing the density of the char layer).

[0004] Therefore, the applicant proposed a composite enameled copper round wire to solve the problem. Utility Model Content

[0005] This invention provides a composite enameled copper round wire, which solves the problems mentioned in the background.

[0006] To solve the above-mentioned technical problems, this utility model provides a composite enameled copper round wire, including a copper conductor, a composite insulation layer on the outer layer of the copper conductor, a shielding braided layer on the outer layer of the composite insulation layer, a composite flame-retardant layer on the outer layer of the shielding braided layer, and a protective layer on the outer layer of the composite flame-retardant layer. The composite flame-retardant layer includes a silicone heat-insulating inner layer and a ceramicized silicone rubber outer layer. The inner wall of the ceramicized silicone rubber outer layer has an arc-shaped notch, and the arc-shaped notch is uniformly filled with a compound flame retardant. The silicone heat-insulating inner layer is disposed on the outer layer of the shielding braided layer, and the ceramicized silicone rubber outer layer is disposed on the inner layer of the protective layer.

[0007] Preferably, the inner wall of the ceramicized silicone rubber outer layer is provided with a ring of protrusions, which are embedded in the grooves on the surface of the silicone heat insulation inner layer.

[0008] Preferably, the outer side of the ceramicized silicone rubber outer layer is further provided with a flame-retardant coating, which is made of organosilicon-modified acrylic resin.

[0009] Preferably, the protective layer includes an insulating soft sleeve disposed on the outside of the composite flame-retardant layer, the insulating soft sleeve being made of modified polyimide, the surface of the insulating soft sleeve being coated with a wear-resistant layer, and the surface of the wear-resistant layer being coated with a waterproof layer. The abrasion-resistant layer is made of polyurethane, while the waterproof layer is made of acrylic emulsion.

[0010] Preferably, the shielding braided layer is a hybrid structure formed by glass fiber and metal wire; After the shielding braided layer is woven, it is impregnated with flame-retardant resin for reinforcement.

[0011] Preferably, the composite insulating layer includes a primer coated on the surface of the copper conductor, an insulating varnish layer is coated on the surface of the primer, and an epoxy resin coating is coated on the outer wall of the insulating varnish layer.

[0012] Compared with related technologies, the composite enameled copper round wire provided by this utility model has the following beneficial effects: 1. This utility model utilizes a composite flame-retardant layer design. The ceramicized silicone rubber outer layer triggers a self-ceramic reaction at high temperatures, rapidly forming a dense ceramic shell that completely isolates oxygen and heat exchange. When a powerful fire causes cracks or gaps in the ceramicized silicone rubber outer layer, the compounded flame retardant is exposed and takes effect, diluting the concentration of flammable gases and promoting the expansion of the char layer to form a dense heat-insulating layer. This achieves a combined effect of gas-phase and condensed-phase flame retardancy. Finally, the silicone heat-insulating inner layer provides excellent heat insulation, preventing excessive impact of high temperatures on the interior, resulting in better flame-retardant performance and making it highly practical.

[0013] 2. This utility model designs a protective layer that serves as a protective composite flame-retardant layer. The insulating soft sleeve provides external mechanical protection and enhances the insulation effect, while the polyurethane wear-resistant layer has excellent mechanical properties such as resistance to metal scratches, further enhancing the protective effect. The acrylic emulsion forms a dense hydrophobic film through three-dimensional network cross-linking, providing waterproof functionality, thus comprehensively improving the protective effect.

[0014] 3. The shielding braided layer in this utility model integrates electromagnetic shielding, mechanical protection and flame retardant reinforcement through a mixed braided skeleton of glass fiber and metal wire and flame retardant resin impregnation. Compared with the traditional single shielding function, it is more effective. When the composite flame retardant layer is damaged by mechanical impact during a fire, resulting in a protection gap, it can also provide a certain flame retardant effect and buy time for protection. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall three-dimensional structure of the present invention; Figure 2 This is a schematic diagram of the overall front view of the present invention; Figure 3 This is a schematic diagram of the composite flame-retardant layer structure of this utility model; Figure 4 This is a schematic diagram of the layered structure of the protective layer of this utility model; Figure 5 This is a schematic diagram of the shielding braided layer structure of this utility model.

[0016] The following are the labeling elements in the diagram: 1. Copper conductor; 2. Composite insulation layer; 21. Primer; 22. Insulating varnish layer; 23. Epoxy resin coating; 3. Shielding braided layer; 31. Glass fiber; 32. Metal wire; 4. Composite flame retardant layer; 41. Silicone thermal insulation inner layer; 42. Ceramicized silicone rubber outer layer; 43. Arc-shaped notch; 44. Compound flame retardant; 45. Protrusion; 46. Flame retardant coating; 5. Protective layer; 51. Insulating soft sleeve; 52. Wear-resistant layer; 53. Waterproof layer. Detailed Implementation

[0017] 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. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.

[0018] Depend on Figures 1-5 The present invention includes a copper conductor 1, an outer layer of a composite insulation layer 2, an outer layer of a shielding braided layer 3, an outer layer of a composite flame-retardant layer 4, and an outer layer of a protective layer 5. The composite flame-retardant layer 4 includes a silicone heat-insulating inner layer 41 and a ceramicized silicone rubber outer layer 42. The inner wall of the ceramicized silicone rubber outer layer 42 has a ring of arc-shaped notches 43, which are uniformly filled with a compound flame retardant 44. The silicone heat-insulating inner layer 41 is disposed on the outer layer of the shielding braided layer 3, and the ceramicized silicone rubber outer layer 42 is disposed on the inner layer of the protective layer 5. The inner wall of the ceramicized silicone rubber outer layer 42 has a ring of protrusions 45, which are embedded in the grooves on the surface of the silicone heat-insulating inner layer 41. A flame-retardant coating 46 is also disposed on the outer side of the ceramicized silicone rubber outer layer 42. The flame-retardant coating 46 is made of organosilicon modified acrylic resin.

[0019] As described above, through the design of the composite flame-retardant layer 4, after the external fire breaks through the protective layer 5, the ceramicized silicone rubber outer layer 42 triggers a self-ceramic reaction at high temperatures, which can quickly form a dense ceramic hard shell (compressive strength > 8MPa), completely isolating oxygen and heat exchange. When the fire is strong enough to cause cracks or gaps in the ceramicized silicone rubber outer layer 42, the compounded flame retardant 44 will be exposed and take effect. The compounded flame retardant 44 can be obtained by compounding a phosphorus-based flame retardant (such as ammonium polyphosphate APP) with a nitrogen-based flame retardant (such as melamine cyanurate MCA). During combustion, the phosphorus-based flame retardant... The compound decomposes to generate phosphoric acid, which catalyzes the formation of the char layer; nitrogen compounds release non-flammable gases (such as NH3 and N2), diluting the concentration of flammable gases, while promoting the expansion of the char layer to form a dense heat insulation layer, achieving a combined effect of gas-phase flame retardancy and condensed-phase flame retardancy. Finally, the silicone heat insulation inner layer 41 can play a good heat insulation role, avoiding excessive impact of high temperature on the interior, which is very practical. The protrusion 45 makes the connection stability between the silicone heat insulation inner layer 41 and the ceramicized silicone rubber outer layer 42 better, and the two cannot rotate, making the position of the compounded flame retardant 44 more stable.

[0020] The protective layer 5 includes an insulating sleeve 51 disposed on the outside of the composite flame retardant layer 4. The insulating sleeve 51 is made of modified polyimide. The surface of the insulating sleeve 51 is coated with an abrasion-resistant layer 52. The surface of the abrasion-resistant layer 52 is coated with a waterproof layer 53. The abrasion-resistant layer 52 is made of polyurethane, while the waterproof layer 53 is made of acrylic emulsion.

[0021] As described above, the protective layer 5 is designed to protect the composite flame-retardant layer 4, the insulating soft sleeve 51 can provide external mechanical protection and enhance the insulation effect, while the polyurethane wear-resistant layer 52 has excellent mechanical properties such as resistance to metal scratches, enhances the protective effect, and has a waterproof function. The acrylic emulsion forms a dense hydrophobic film through three-dimensional network cross-linking, which comprehensively improves the protective effect.

[0022] The shielding braided layer 3 is a hybrid structure formed by glass fiber 31 and metal wire 32. After the shielding braided layer 3 is woven, it is impregnated with flame retardant resin for reinforcement treatment.

[0023] As described above, the shielding braided layer 3 integrates electromagnetic shielding, mechanical protection, and flame retardant reinforcement through a mixed braided skeleton of glass fiber 31 and metal wire 32 and flame retardant resin impregnation. This is more effective than the traditional single shielding function. It can also provide a certain flame retardant effect when the composite flame retardant layer 4 is damaged by mechanical impact during a fire, resulting in a protective gap. Note that the ratio of glass fiber 31 to metal wire 32 should be adjusted according to the actual application and is not limited here.

[0024] The composite insulation layer 2 includes a primer 21 coated on the surface of the copper conductor 1, an insulating varnish layer 22 coated on the surface of the primer 21, and an epoxy resin coating 23 coated on the outer wall of the insulating varnish layer 22.

[0025] As described above, the composite insulation layer 2 uses a traditional primer 21 and insulating varnish layer 22 to provide insulation protection for the copper conductor 1. In addition, an epoxy resin coating 23 is provided, which has the advantages of high mechanical strength and good temperature resistance, providing protection for the primer 21 and insulating varnish layer 22. It remains rigid at high temperatures (such as the motor operating temperature of 105°C) and inhibits the creep of the insulation layer.

[0026] Working principle: When the cable faces fire, mechanical damage, or electromagnetic interference, the outer protective layer 5 resists metal scratches and external friction through the polyurethane wear-resistant layer 52, the modified polyimide insulating soft sheath 51 buffers the impact and isolates moisture, and the acrylic waterproof layer 53 forms a dense hydrophobic film to block moisture penetration; when the protective layer 5 is damaged at high temperature, the ceramicized silicone rubber outer layer 42 of the composite flame retardant layer 4 quickly forms a ceramicized hard shell, blocking oxygen and heat exchange. If the ceramic layer is damaged by external force, the embedded phosphorus-nitrogen composite flame retardant particles 44 are immediately exposed, and the cracks are filled through a dual mechanism of phosphoric acid catalytic carbonization and inert gas expansion, while the silicone... The inner heat-insulating layer 41 blocks residual heat; the glass fiber 31 and metal wire braided structure of the middle shielding braid 3 shields electromagnetic interference and delays flame spread through flame-retardant resin impregnation; the inner composite insulation layer 2 uses primer 21 to enhance conductor adhesion, the insulating varnish layer 22 to achieve basic electrical insulation, and the epoxy resin coating 23 maintains rigidity at high temperatures to inhibit insulation layer creep, ultimately achieving multi-level synergistic protection from mechanical protection, flame blocking, electromagnetic shielding to electrical insulation, ensuring stable operation of the copper conductor 1 in extreme environments. It is worth noting that the compounded flame retardant 44 can be microencapsulated to improve its compatibility with the matrix material.

[0027] 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.

[0028] 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 composite enameled copper round wire, comprising a copper conductor (1), characterized in that: The outer layer of the copper conductor (1) is provided with a composite insulation layer (2), the outer layer of the composite insulation layer (2) is provided with a shielding braided layer (3), the outer layer of the shielding braided layer (3) is provided with a composite flame retardant layer (4), and the outer layer of the composite flame retardant layer (4) is provided with a protective layer (5). The composite flame retardant layer (4) includes a silicone heat insulation inner layer (41) and a ceramicized silicone rubber outer layer (42). The inner wall of the ceramicized silicone rubber outer layer (42) is provided with an arc-shaped notch (43), and the arc-shaped notch (43) is uniformly filled with a compound flame retardant (44). The silicone heat insulation inner layer (41) is disposed on the outer layer of the shielding braided layer (3), and the ceramicized silicone rubber outer layer (42) is disposed on the inner layer of the protective layer (5).

2. The composite enameled copper round wire according to claim 1, characterized in that, The inner wall of the ceramicized silicone rubber outer layer (42) is provided with a ring of protrusions (45), which are embedded in the grooves on the surface of the silicone heat insulation inner layer (41).

3. The composite enameled copper round wire according to claim 2, characterized in that, The outer side of the ceramicized silicone rubber outer layer (42) is also provided with a flame-retardant coating (46), which is made of silicone-modified acrylic resin.

4. The composite enameled copper round wire according to claim 2, characterized in that, The protective layer (5) includes an insulating soft sleeve (51) disposed on the outside of the composite flame retardant layer (4). The insulating soft sleeve (51) is made of modified polyimide. The surface of the insulating soft sleeve (51) is coated with a wear-resistant layer (52). The surface of the wear-resistant layer (52) is coated with a waterproof layer (53). The abrasion-resistant layer (52) is made of polyurethane, while the waterproof layer (53) is made of acrylic emulsion.

5. The composite enameled copper round wire according to claim 1, characterized in that, The shielding braided layer (3) is a hybrid structure formed by glass fiber (31) and metal wire (32); After the shielding braided layer (3) is woven, it is impregnated with flame-retardant resin for reinforcement treatment.

6. The composite enameled copper round wire according to claim 1, characterized in that, The composite insulation layer (2) includes a primer (21) coated on the surface of the copper conductor (1), an insulating varnish layer (22) coated on the surface of the primer (21), and an epoxy resin coating (23) coated on the outer wall of the insulating varnish layer (22).

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