Electrically insulated conductor

Abstract

Exemplary embodiments of an electrically insulated conductor are disclosed. In an exemplary embodiment, the electrically insulated conductor includes a conductive core and one or more non-conductive layers. The one or more non-conductive layers are parallel to the length of the conductive core and / or include adhered ends that extend longitudinally at least partially along its length. The one or more non-conductive layers are at least partially along the perimeter of the conductive core.

Description

Technical Field

[0001] The present disclosure generally relates to electrically insulated conductors.

Background Art

[0002] This section provides background information related to the present disclosure that is not necessarily prior art. Electric vehicles are currently commonly used and are expected to see a significant increase in their use in the future. The electric motors used in electric vehicles may be driven by a pulse width modulation (PWM) inverter.

Brief Description of the Drawings

[0003] The drawings described herein are for illustrative purposes only of selected embodiments and are not intended to show all possible implementations nor to limit the scope of the present disclosure.

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[0004] Detailed Description Exemplary embodiments will be described in more detail below with reference to the accompanying drawings. The electric vehicle industry is transitioning to silicon carbide (SiC) and gallium nitride (GaN) inverter technologies to increase the DC voltage applied to stator windings, but the effects of dv / dt and the associated rise times are not well understood or recognized. As recognized here, as the DC voltage and current applied to the stator windings increase, the electrical stress on the electrical insulation system increases. If the increase in electrical stress (between phases and between turns) is not addressed, the operating life of the electrical insulator and the electric motor may be shortened.

[0005] Exemplary embodiments of electrically insulated conductors have been developed and / or disclosed herein that are configured to extend the life due to electrical stress (between phases and between turns) compared to the prior art and reduce the amount of insulating material for wire wrapping. Conventional corona-resistant insulation solutions may be strong enough to address the increase in DC voltage and current applied to stator windings, but conventional corona-resistant insulation solutions tend to be relatively costly and not economical.

[0006] In an exemplary embodiment disclosed herein, an insulator can be provided that specifically targets high electric field regions on magnet wire (e.g., copper, aluminum, stainless steel, alloys thereof, other metals, other electrical conductors, etc.) in a winding driven by a converter device (e.g., a stator winding in an electric motor or other power electronics device). The magnet wire can be insulated with a corona-resistant film without significantly increasing the overall cross-sectional area of the magnet wire. For example, the corona-resistant film can include a thin corona-resistant film that includes copper and a single-sided fluoropolymer coating that is thermally bondable to itself. Alternatively, other electrical insulating materials that are preferably relatively thin, have good dielectric strength, and are coated using a single-sided adhesive system that is functionalized for dv / dt resistance and corona resistance can also be used. The electrical insulating material can include a functionalized dielectric layer designed for in-plane thermal conductivity and / or partial discharge resistance. The electrical insulating material can have a multi-layer structure that includes at least one or more dielectric layers. The at least one or more dielectric layers can include one or more of enamel (or other polymer coatings), corona-resistant enamel, adhesion promoters, varnishes, extruded polymers, polymer films, and / or polymers functionalized with inorganic particles. The multi-layer structure can include one or more semiconductor layers configured to assist, for example, in reducing dielectric breakdown due to corona induction.

[0007] The exemplary embodiments disclosed herein can provide or include one or more (but not necessarily any or all) of the following advantageous effects or features, such as improved efficiency, reduced operating temperature, increased power density, increased motor voltage, dv / dt tolerance, tolerance to SiC / GaN inverters, increased copper filling amount, extended operating life and reliability, and / or increased partial discharge inception voltage (PDIV). By using a corona-resistant film (e.g., a single-layer film, a multilayer structure, etc.), fewer insulating materials (e.g., less than 1 / 8 of the material, etc.) can be used in the exemplary embodiments disclosed herein compared to conventional insulation methods. The exemplary embodiments can include a high copper filling rate and can improve the efficiency of an electric motor. When the efficiency of an electric motor is improved, the driving range can be extended even with the same battery pack or a smaller battery pack, and the cost of the battery pack per electric vehicle can be reduced. The exemplary embodiments disclosed herein can also basically bring high efficiency and design freedom to the original equipment manufacturer (OEM). In the exemplary embodiments, the corona-resistant film can be adhered using one or more means such as a fluoropolymer (e.g., perfluoroalkoxy alkane (PFA), fluorinated ethylene propylene (FEP), etc.) and / or polyimide having a specific Tg (glass transition temperature) of 220 to 400 degrees Celsius (°C) under cured enamel, and may be cured by applying a commercially available KAPTON (registered trademark) film. Regarding the design freedom, the exemplary embodiments can enable reduction of slot dimensions, increase of copper content with the same slot dimensions, miniaturization of the package, insulation of 3D printed coils, and / or dielectric barriers for distributed electrical windings.

[0008] Conventionally, in order to cope with an increase in DC voltage and current applied to the stator winding, the thickness of the insulator may be significantly increased. However, as the thickness of the insulator increases, the copper filling rate decreases, thereby reducing the efficiency. In contrast, the exemplary embodiments disclosed herein can provide an economical approach for enhancing reliability and realizing e-mobility market trends such as aerospace e-mobility applications where stress can be extremely high. For example, an exemplary embodiment may include a conductive core in which the insulator is provided only partially (e.g., not on all sides), thereby reducing the insulating material in embodiments where it is not necessary to completely wrap the conductive core / wire with the insulator.

[0009] The exemplary embodiments disclosed herein are not limited to being used only in the electric motors of electric vehicles. The exemplary embodiments disclosed herein can be used in a wide range of electronic devices such as aircraft, ships, industrial, automotive and other power electronics devices, electric motors driven by pulse width modulation inverters, high switching frequency converters that provide high dv / dt signals, traction motors for e-mobility applications, and other windings driven by converter devices.

[0010] In an exemplary embodiment, the electrically insulated conductor includes a conductive core and one or more non-conductive layers and / or insulating layers. The one or more non-conductive layers include adhered ends that are parallel to the length of the conductive core and / or extend longitudinally at least partially along its length. The one or more non-conductive layers are at least partially along the periphery of the conductive core.

[0011] In an exemplary embodiment, an electrically insulated conductor for a winding driven by a converter device includes a conductive core and one or more non-conductive layers and / or insulating layers. The one or more non-conductive layers extend longitudinally at least partially along the length of the conductive core. The one or more non-conductive layers may be non-uniform and / or asymmetric longitudinally at least partially along the periphery of the conductive core. Alternatively, the one or more non-conductive layers may be symmetric longitudinally at least partially along the periphery of the conductive core. The one or more non-conductive layers are configured to target one or more predetermined high electric field regions along the conductive core within the winding. At least a portion of the one or more non-conductive layers is disposed in or near one or more predetermined high electric field regions along the conductive core within a winding (such as a stator winding of an electric motor or other power electronics device) driven by the converter device.

[0012] In an exemplary embodiment, the one or more non-conductive layers include an end or edge that is at least partially adhered along at least one side of the conductive core. In an exemplary embodiment, the one or more non-conductive layers are wound longitudinally at least partially along the periphery of the conductive core. The one or more non-conductive layers may be wound completely around the conductive core. The one or more non-conductive layers may be wound completely around the conductive core with at least one overlap, such that at least one portion of the one or more non-conductive layers overlaps at least one other portion of the one or more non-conductive layers. The one or more non-conductive layers may be wound completely around the conductive core with a plurality of overlaps, such that a plurality of portions of the one or more non-conductive layers overlap a plurality of other portions of the one or more non-conductive layers.

[0013] In an exemplary embodiment, the one or more non-conductive layers are wound at least partially along the periphery of the conductive core and substantially perpendicular to the length of the conductive core. In an exemplary embodiment, one or more non-conductive layers are heterogeneous and / or asymmetric at least partially along the periphery of the conductive core. In other exemplary embodiments, one or more non-conductive layers are symmetric at least partially along the periphery of the conductive core.

[0014] In an exemplary embodiment, one or more non-conductive layers are configured to electrically insulate a conductive core in order to target one or more predetermined high electric field regions along the conductive core within a winding driven by a converter device (such as a stator winding of an electric motor or a power electronics device). At least a portion of the one or more non-conductive layers is disposed in or near one or more predetermined high electric field regions along the conductive core within the stator winding, such as an inter-turn region of the conductive core.

[0015] In an exemplary embodiment, one or more non-conductive layers include at least one functionalized dielectric layer designed for in-plane thermal conductivity and / or partial discharge resistance. For example, an exemplary embodiment may include a thermal substrate as disclosed in U.S. Patent Application Publication No. 2021 / 0111097, which is hereby incorporated by reference in its entirety. In such an exemplary embodiment, the thermal substrate includes a multilayer film including a first outer layer, a core layer, and a second outer layer. The first outer layer includes a first thermoplastic polyimide. The core layer includes a polyimide. The second outer layer includes a second thermoplastic polyimide. A first conductive layer is adhered to the first outer layer of the multilayer film. A second conductive layer is adhered to the second outer layer of the multilayer film. The multilayer film has a total thickness in the range of 5 micrometers (μm) to 150 micrometers (μm). The first outer layer, the core layer, and the second outer layer each include a thermally conductive filler. The first conductive layer and the second conductive layer each have a thickness in the range of 250 micrometers (μm) to 3000 micrometers (μm).

[0016] In an exemplary embodiment, one or more non-conductive layers include a multilayer structure. The multilayer structure may include at least one dielectric layer including one or more of enamel, adhesion promoter, varnish, extruded and / or engineering polymer, polymer film, and / or a polymer film functionalized with inorganic and / or organic particles such as corona resistance, foamability. The multilayer structure may include at least one dielectric layer including one or more enamels including one or more types of varnish. The types of varnish may include polyimide, polyamideimide, polyesterimide, and / or combinations thereof, and / or the types of varnish may be functionalized with inorganic and / or organic particles such as corona resistance, foamability. The multilayer structure may include one or more semiconductor layers configured to assist, for example, in reducing dielectric breakdown due to corona induction.

[0017] In an exemplary embodiment, the electrically insulated conductor includes an adhesive for adhering one or more non-conductive layers. The adhesive may be one that can maintain a relative temperature index of at least about 180 degrees Celsius. The adhesive may be one that can adhere to conductive surfaces, metal surfaces, and polymer surfaces.

[0018] In an exemplary embodiment, the electrically insulated conductor includes a polymer surface (such as enamel or other polymer coating, etc.) along at least a portion of the conductive core. One or more non-conductive layers cover at least a portion of the polymer surface, and the covered portion of the polymer surface is between the conductive core and one or more non-conductive layers. The polymer surface may include at least one region not covered by one or more non-conductive layers, and that region is generally disposed between at least two spaced-apart discontinuous portions of one or more non-conductive layers. Alternatively, one or more non-conductive layers may cover the entire polymer surface. The polymer surface may extend along the entire circumference of the conductive core.

[0019] In an exemplary embodiment, one or more non-conductive layers include enamel or other polymer coating. In an exemplary embodiment, the one or more non-conductive layers include a first non-conductive layer. The electrically insulated conductor includes a second non-conductive layer that extends longitudinally at least partially along the length of the conductive core and includes an enamel (or other polymer coating) that extends at least partially around the conductive core.

[0020] In an exemplary embodiment, the conductive core has a cross-sectional shape that is substantially rectangular, circular, oval, diamond-shaped, or rounded rectangular, or other cross-sectional shape having at least one side. The electrically insulated conductor has a cross-sectional shape that is substantially rectangular, circular, oval, diamond-shaped, or rounded rectangular, or other cross-sectional shape in which at least one side is defined jointly by the conductive core and the one or more non-conductive layers. However, in other exemplary embodiments, the conductive core and / or the electrically insulated conductor may be configured differently and may have different cross-sectional shapes than those disclosed in this paragraph.

[0021] In an exemplary embodiment, the conductive core includes magnet wire. The magnet wire can include copper wire, aluminum wire, stainless steel wire, copper alloy wire, other magnet wire, wire made from other metals, or wire made from other metal alloys.

[0022] In an exemplary embodiment, the conductive core includes wire of copper, aluminum, or stainless steel having a cross-sectional shape that is substantially rectangular, circular, oval, diamond-shaped, or rounded rectangular, or other cross-sectional shape having at least one side. However, in other exemplary embodiments, the conductive core may have a different configuration, such as including a different conductive material and / or having a cross-sectional shape different from that disclosed in this paragraph.

[0023] In an exemplary embodiment, the one or more non-conductive layers are wound at least partially around the conductive core, and no portion of the one or more non-conductive layers overlaps and covers another portion of the one or more non-conductive layers.

[0024] In an exemplary embodiment, one or more non-conductive layers are wound around the entire circumference of the conductive core, and only the first and second longitudinal edges or ends on both sides of the one or more non-conductive layers overlap, and the other portions of the one or more non-conductive layers do not overlap with other portions of the one or more non-conductive layers. The first and second longitudinal edges or ends can be straight, linear, or non-linear (e.g., S-shaped, zigzag-shaped, interleaved pattern, etc.). Thus, the exemplary embodiment is not limited to non-conductive layers having only straight or linear edges or ends.

[0025] In an exemplary embodiment, one or more non-conductive layers are wound around the entire circumference of the conductive core, and the one or more non-conductive layers include first and second longitudinal edges or ends on both sides, and they abut against each other without any portion of the one or more non-conductive layers being overlapped and covered by another portion of the one or more non-conductive layers.

[0026] In an exemplary embodiment, one or more non-conductive layers are wound along a range less than the entire circumference of the conductive core, and the one or more non-conductive layers include first and second longitudinal edges or ends on both sides, and they are spaced apart from each other and discontinuous, and the spaced-apart first and second longitudinal edges or ends define a gap therebetween that extends longitudinally at least partially along the length of the conductive core.

[0027] In an exemplary embodiment, one or more non-conductive layers are wound around the entire circumference of the conductive core, and the one or more non-conductive layers include first and second longitudinal edges or ends on both sides that abut against each other, and the abutting first and second longitudinal edges or ends define a longitudinal seam therebetween that extends longitudinally at least partially along the length of the conductive core.

[0028] In an exemplary embodiment, one or more non-conductive layers may include first and second longitudinal edges or ends that are linear, linear, or non-linear (e.g., S-shaped, zigzag, interleaved pattern, etc.). Thus, the exemplary embodiments are not limited to non-conductive layers having only linear or linear edges or ends.

[0029] In an exemplary embodiment, one or more non-conductive layers are wound around the entire circumference of a conductive core, and the one or more non-conductive layers include first and second longitudinal edges or ends on both sides that overlap each other, and the overlapping first and second longitudinal edges or ends define overlapping seams that extend at least partially along the length of the conductive core therebetween.

[0030] In an exemplary embodiment, the conductive core includes a plurality of sides that define a perimeter. One or more non-conductive layers are wound so as to extend longitudinally along at least two of the plurality of sides of the conductive core.

[0031] In an exemplary embodiment, one or more non-conductive layers are wound so as to extend longitudinally along each of the plurality of sides of the conductive core. In an exemplary embodiment, the conductive core includes a plurality of sides that define a perimeter. One or more non-conductive layers are wound so as to extend longitudinally along less than all of the plurality of sides of the conductive core.

[0032] In an exemplary embodiment, the conductive core includes a plurality of sides that define a perimeter. One or more non-conductive layers are disposed along only one of the plurality of sides of the conductive core. In an exemplary embodiment, the conductive core includes a plurality of sides that define a perimeter. One or more non-conductive layers are spirally wrapped with a polymer film (e.g., an adhesive, etc.). Also, an electrically insulated conductor includes a second one or more non-conductive layers disposed along only one side of the conductive core or along a plurality of sides.

[0033] In an exemplary embodiment, the conductive core includes a plurality of sides that define a perimeter. One or more non-conductive layers are disposed along only one side, or along a plurality of sides, of the conductive core, and the electrically insulated conductor includes one or more additional non-conductive layers helically wound with a polymer film (e.g., an adhesive, etc.).

[0034] In an exemplary embodiment, one or more non-conductive layers are configured to electrically insulate the conductive core for use in a distributed electrical winding. One or more non-conductive layers are configured to provide a dielectric barrier to a distributed electrical winding defined by an electrically insulated conductor.

[0035] In an exemplary embodiment, the electrically insulated conductor is configured to withstand a voltage stress of 1.6 Kv PK 20 KHz for at least about 15 - 20 hours. An exemplary embodiment includes a winding (e.g., a stator winding for an electric motor or other power electronics device) driven by a converter device that includes an electrically insulated conductor as disclosed herein. One or more non-conductive layers of the electrically insulated conductor are disposed along and in the vicinity of one or more predetermined high electric field regions along the conductive core within the winding.

[0036] Also disclosed is an exemplary method of manufacturing an electrically insulated conductor for a winding (e.g., a stator winding of an electric motor or power electronics device) driven by a converter device. In an exemplary embodiment, the method includes adhesively bonding an end or edge of one or more non-conductive layers parallel to and / or longitudinally along at least a portion of the length of the conductive core. One or more non-conductive layers are at least partially along the perimeter of the conductive core and are configured to target one or more predetermined high electric field regions along the conductive core within a winding driven by a converter device.

[0037] In an exemplary embodiment, the method includes winding one or more non-conductive layers at least partially along the periphery of a conductive core, whereby the one or more non-conductive layers are at least partially along the periphery of the conductive core either heterogeneous and / or asymmetric, or the one or more non-conductive layers are symmetric at least partially along the periphery of the conductive core. At least a portion of the one or more non-conductive layers is disposed in or near one or more predetermined high electric field regions along the conductive core in a winding driven by a converter device.

[0038] In an exemplary embodiment, the method includes disposing an electrically insulated conductor within the winding such that at least a portion of the one or more non-conductive layers is located in or near one or more predetermined high electric field regions along the conductive core in a winding driven by a converter device.

[0039] In an exemplary embodiment, the method includes selectively applying one or more non-conductive layers at least partially along the length of the conductive core, thereby enabling a reduction in the use of environmentally sustainable non-conductive materials.

[0040] In an exemplary embodiment, the method includes selectively applying fragments of one or more non-conductive layers at indexed positions spaced along the length of the conductive core. In an exemplary embodiment, the method includes manufacturing an electrically insulated conductor as disclosed herein.

[0041] In an exemplary embodiment, a system is configured to perform a method of manufacturing an electrically insulated conductor as disclosed herein. Exemplary embodiments are provided so that this disclosure is sufficient and fully conveys the scope to those skilled in the art. To provide a complete understanding of the embodiments of this disclosure, numerous specific details are shown, such as examples of specific components, devices, and methods. It will be apparent to those skilled in the art that specific details need not be used, that exemplary embodiments can be embodied in many different forms, and that neither should be construed as limiting the scope of the disclosure. In some exemplary embodiments, well-known processes, well-known device structures, and well-known technologies are not described in detail. Further, the advantages and improvements that can be achieved in one or more exemplary embodiments of this disclosure are provided for illustrative purposes only, and the exemplary embodiments of this disclosure do not limit the scope of this disclosure because they may or may not provide all of the above advantages and improvements and still be within the scope of this disclosure.

[0042] The specific numerical dimensions and values, specific materials, and / or specific shapes disclosed in this specification are, in essence, illustrative and not intended to limit the scope of the present disclosure. The disclosure in this specification of specific values and ranges of values for a given parameter does not exclude other values and ranges of values that may be useful in one or more of the examples disclosed herein. Further, it is contemplated that any two specific values of a given parameter described herein may define the endpoints of a range of values suitable for the given parameter (the disclosure of the first and second values of a given parameter may be construed as disclosing that any value between the first and second values can be used for the given parameter). For example, if parameter X is illustrated herein as having value A and also as having value Z, it is contemplated that parameter X may have a range of values from about A to about Z. Similarly, the disclosure of two or more ranges of values of a parameter (whether such ranges are nested, overlapping, or distinct) is contemplated to encompass all possible combinations of ranges of values that may be claimed using the endpoints of the disclosed ranges. For example, if parameter X is illustrated herein as having values in the ranges of 1 to 10, or 2 to 9, or 3 to 8, it is also contemplated that parameter X may have other ranges of values including 1 to 9, 1 to 8, 1 to 3, 1 to 2, 2 to 10, 2 to 8, 2 to 3, 3 to 10, and 3 to 9.

[0043] The terms used in this specification are for the purpose of describing particular exemplary embodiments only and are not intended to be limiting. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprising", "including", and "having" are inclusive and thus specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. Method steps, processes, and operations described herein should not be construed as necessarily requiring their performance in the particular order described or illustrated, unless specifically specified as an order of performance. It is also to be understood that additional or alternative steps may be employed.

[0044] When an element or layer is described as being "on", "engaged to", "connected to", or "coupled to" another element or layer, it can be directly on, engaged to, connected to, or coupled to that other element or layer, or intervening elements or layers that may be present. In contrast, when an element is described as being "directly on", "directly engaged to", "directly connected to", or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like manner (e.g., "between" and "directly between", "adjacent" and "directly adjacent", etc.). As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0045] When applied to a value, the term "about" indicates that a calculation or measurement allows for some slight inaccuracy in the value (by an approach to the accuracy of the value, being nearly or reasonably close to the value; approximately). If for any reason the inaccuracy provided by "about" is not understood in this ordinary sense in the relevant art, "about" as used herein indicates at least the variations that can arise from the normal methods of measuring or using such parameters. For example, the terms "generally", "about", and "substantially" may be used herein to mean within manufacturing tolerances. Alternatively, for example, the term "about" as used herein, when used in changing the amounts of the components or reactants of the present invention, refers to the variations that can occur through inadvertent error in these procedures; through differences in the manufacture, source, or purity of the components used to make the composition or to carry out the method, in typical measurement and handling procedures such as when making concentrates or solutions in the real world; the term "about" also encompasses different amounts due to different equilibrium conditions of the compositions resulting from a particular initial mixture. Whether or not modified by the term "about", the claims include the equivalent amounts of the quantity.

[0046] The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers, and / or sections, but these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms can only be used to distinguish one element, component, region, layer, or section from another region, layer, or section. The terms "first", "second", etc. as used herein, and other numerical terms, do not mean an order or sequence unless clearly indicated by the context. Thus, a first element, component, region, layer, or section can be referred to as a second element, component, region, layer, or section without departing from the teachings of the exemplary embodiments.

[0047] Spatially relative terms such as "inner", "outer", "lower", "down", "lower side", "upper", "upper side", etc. may be used herein to facilitate the description of the relationship of one element or function to another element or function as shown in the figures. Spatially relative terms may be intended to encompass different directions of the device in use or operation in addition to the directions shown in the figures. For example, if the device in the figure is turned over, an element described as "under" or "lower" of another element or function will be "above" the other element or function. Thus, examples of the term "under" may encompass both upward and downward directions. The device may be otherwise oriented (rotated 90 degrees or in other directions), and the spatially relative descriptors used herein may be interpreted accordingly.

[0048] The foregoing description of the embodiments has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. The individual elements, intended or described uses, or features of a particular embodiment will, in most cases, not be limited to that particular embodiment, but, where applicable, are interchangeable and may be used in the selected embodiment even if not specifically shown or described. The same can be modified in many ways. Such modifications should not be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims

1. An electrically insulated conductor comprising: a conductive core having a length and a circumference; and one or more non-conductive layers including an adhered end portion that is parallel to the length of the conductive core and / or extends longitudinally at least partially along the length, wherein the one or more non-conductive layers are at least partially along the circumference of the conductive core, the electrically insulated conductor.

2. The one or more non-conductive layers are configured to electrically insulate the conductive core in order to target one or more predetermined high electric field regions along the conductive core within a winding driven by a converter device, so that at least a part of the one or more non-conductive layers is located in or near the one or more predetermined high electric field regions such as the inter-turn region of the conductive core along the conductive core within the winding, the electrically insulated conductor according to claim 1.

3. The one or more non-conductive layers are heterogeneous and / or asymmetric at least partially along the circumference of the conductive core, or the one or more non-conductive layers are symmetric at least partially along the circumference of the conductive core, the electrically insulated conductor according to claim 1 or 2.

4. An electrically insulated conductor for a winding driven by a converter device, the electrically insulated conductor comprising: a conductive core having a length and a circumference; and one or more non-conductive layers extending longitudinally at least partially along the length of the conductive core, wherein the one or more non-conductive layers are heterogeneous and / or asymmetric at least partially along the circumference of the conductive core, or the one or more non-conductive layers are symmetric at least partially along the circumference of the conductive core, the one or more non-conductive layers are configured to target one or more predetermined high electric field regions along the conductive core within a winding driven by an inverter device, and at least a part of the one or more non-conductive layers is located in or near the one or more predetermined high electric field regions along the conductive core within the winding driven by the inverter device, the electrically insulated conductor.

5. The one or more non-conductive layers include an end portion that is at least partially adhered along at least one side of the conductive core, the electrically insulated conductor according to any one of claims 1 to 4.

6. The electrically insulated conductor according to any one of claims 1 to 5, wherein the one or more non-conductive layers are wound longitudinally at least partially along the circumference of the conductive core.

7. The electrically insulated conductor according to claim 4, wherein the one or more non-conductive layers are wound completely around the conductive core.

8. The electrically insulated conductor according to claim 7, wherein the one or more non-conductive layers are wound completely around the conductive core with at least one overlap, and at least one part of the one or more non-conductive layers overlaps with at least one other part of the one or more non-conductive layers.

9. The electrically insulated conductor according to claim 8, wherein the one or more non-conductive layers are wound completely around the conductive core with a plurality of overlaps, and a plurality of parts of the one or more non-conductive layers overlap with a plurality of other parts of the one or more non-conductive layers.

10. The electrically insulated conductor according to any one of claims 1 to 9, wherein the one or more non-conductive layers are wound at least partially along the circumference of the conductive core and substantially perpendicular to the length of the conductive core.

11. The electrically insulated conductor according to any one of claims 1 to 10, wherein the one or more non-conductive layers include at least one functionalized dielectric layer designed for in-plane thermal conductivity and / or partial discharge resistance.

12. The electrically insulated conductor according to any one of claims 1 to 11, wherein the one or more non-conductive layers include a multilayer structure.

13. The multilayer structure includes at least one dielectric layer including one or more of enamel, adhesion promoter, varnish, extrusion and / or engineering polymer, polymer film, and / or polymer film functionalized with inorganic and / or organic particles such as corona resistance and foamability, of the electrically insulated conductor according to any one of claims 1 to 12.

14. The multilayer structure includes at least one dielectric layer including one or more enamels including one or more varnishes, wherein the one or more varnishes include polyimide, polyamideimide, polyesterimide, and / or combinations thereof, and / or The one or more varnishes of the electrically insulated conductor according to claim 13 are functionalized with inorganic and / or organic particles such as corona resistance and foamability.

15. The multi-layer structure includes one or more semiconductor layers, the electrically insulated conductor according to claim 11 or 14.

16. The electrically insulated conductor according to any one of claims 1 to 15 includes an adhesive for bonding the one or more non-conductive layers.

17. The adhesive of the electrically insulated conductor according to claim 16 is capable of adhesive bonding to a conductive surface, a metal surface, and a polymer surface.

18. The electrically insulated conductor includes a polymer surface along at least a part of the conductive core, the one or more non-conductive layers cover at least a part of the polymer surface, and the covered part of the polymer surface is between the conductive core and the one or more non-conductive layers, the electrically insulated conductor according to any one of claims 1 to 17.

19. The polymer surface includes at least one region not covered by the one or more non-conductive layers, and the at least one region is generally disposed between at least two separated and discontinuous portions of the one or more non-conductive layers, the electrically insulated conductor according to claim 18.

20. The one or more non-conductive layers cover the entire polymer surface, the electrically insulated conductor according to claim 18.

21. The polymer surface extends along the entire circumference of the conductive core, the electrically insulated conductor according to claim 18.

22. The one or more non-conductive layers include enamel, the electrically insulated conductor according to any one of claims 1 to 17.

23. The one or more non-conductive layers include a first non-conductive layer, The electrically insulated conductor includes a second non-conductive layer including enamel that extends longitudinally along at least a part of the length of the conductive core and extends at least partially around the conductive core, the electrically insulated conductor according to any one of claims 1 to 17.

24. The conductive core has a substantially rectangular, circular, elliptical, diamond-shaped, or rounded rectangular cross-sectional shape, or another cross-sectional shape having at least one side, and / or The electrically insulated conductor has a cross-sectional shape that is substantially rectangular, circular, elliptical, rhombic, or rounded rectangular, or another cross-sectional shape in which at least one side is defined jointly by the conductive core and the one or more non-conductive layers. An electrically insulated conductor according to any one of claims 1 to 23. **Claim 25** An electrically insulated conductor according to any one of claims 1 to 24, wherein the conductive core includes a magnet wire. **Claim 26** An electrically insulated conductor according to any one of claims 1 to 25, wherein the conductive core includes a wire of copper, aluminum, or stainless steel having a cross-sectional shape that is substantially rectangular, circular, elliptical, rhombic, or rounded rectangular, or another cross-sectional shape having at least one side. **Claim 27** An electrically insulated conductor according to any one of claims 1 to 26, wherein the one or more non-conductive layers are wound at least partially along the periphery of the conductive core, and no portion of the one or more non-conductive layers overlaps and covers another portion of the one or more non-conductive layers. **Claim 28** An electrically insulated conductor according to any one of claims 1 to 26, wherein the one or more non-conductive layers are wound along the entire periphery of the conductive core, and only the first and second longitudinal ends on both sides of the one or more non-conductive layers overlap, and the other portions of the one or more non-conductive layers do not overlap another portion of the one or more non-conductive layers. **Claim 29** An electrically insulated conductor according to any one of claims 1 to 26, wherein the one or more non-conductive layers are wound along the entire periphery of the conductive core, and the one or more non-conductive layers include first and second longitudinal ends on both sides, and they abut against each other without any portion of the one or more non-conductive layers overlapping and covering another portion of the one or more non-conductive layers. **Claim 30** An electrically insulated conductor according to any one of claims 1 to 26, wherein the one or more non-conductive layers are wound along a range less than the entire periphery of the conductive core, and the one or more non-conductive layers include first and second longitudinal ends on both sides, and they are spaced apart and discontinuous, and the spaced-apart first and second longitudinal ends define a gap that extends longitudinally at least partially along the length of the conductive core therebetween. **Claim 31** The one or more non-conductive layers are wound along the entire circumference of the conductive core, the one or more non-conductive layers include first and second longitudinal ends on both sides that abut each other, and the abutting first and second longitudinal ends define a longitudinal seam therebetween that extends longitudinally at least partially along the length of the conductive core. The electrically insulated conductor according to any one of claims 1 to 26.

32. The one or more non-conductive layers are wound along the entire circumference of the conductive core, the one or more non-conductive layers include first and second longitudinal ends on both sides that overlap each other, and the overlapping first and second longitudinal ends define an overlapping seam therebetween that extends at least partially along the length of the conductive core. The electrically insulated conductor according to any one of claims 1 to 26.

33. The conductive core includes a plurality of sides that define the perimeter. The one or more non-conductive layers are wound so as to extend longitudinally at least partially along at least two of the plurality of sides of the conductive core. The electrically insulated conductor according to any one of claims 1 to 26.

34. The one or more non-conductive layers are wound so as to extend longitudinally at least partially along each of the plurality of sides of the conductive core. The electrically insulated conductor according to claim 33.

35. The conductive core includes a plurality of sides that define the perimeter. The one or more non-conductive layers are wound so as to extend longitudinally along less than all of the plurality of sides of the conductive core. The electrically insulated conductor according to any one of claims 1 to 26.

36. The conductive core includes a plurality of sides that define the perimeter. The one or more non-conductive layers are disposed only along one of the plurality of sides of the conductive core. The electrically insulated conductor according to any one of claims 1 to 26.

37. The conductive core includes a plurality of sides that define the perimeter. The one or more non-conductive layers are helically wrapped with a polymer film. The electrically insulated conductor includes a second one or more non-conductive layers disposed only along one side of the conductive core or along the plurality of sides. The electrically insulated conductor according to any one of claims 1 to 26.

38. The conductive core includes a plurality of sides that define the perimeter, The one or more non-conductive layers are disposed along only one side of the conductive core or along the plurality of sides, The electrically insulated conductor includes one or more second non-conductive layers spirally wound with a polymer film, The electrically insulated conductor according to any one of claims 1 to 26.

39. The one or more non-conductive layers are configured to electrically insulate the conductive core for use in a distributed electrical winding, whereby the one or more non-conductive layers are configured to provide a dielectric barrier to the distributed electrical winding defined by the electrically insulated conductor. The electrically insulated conductor according to any one of claims 1 to 38.

40. A winding driven by a converter device, the winding including the electrically insulated conductor according to any one of claims 1 to 39, wherein the one or more non-conductive layers are disposed along or in the vicinity of one or more predetermined high electric field regions along the conductive core within the winding.

41. A stator winding for an electric motor, the stator winding including the electrically insulated conductor according to any one of claims 1 to 39, wherein the one or more non-conductive layers are disposed along or in the vicinity of one or more predetermined high electric field regions along the conductive core within the stator winding.

42. A method of manufacturing an electrically insulated conductor for a winding driven by a converter device, the method including adhering ends of one or more non-conductive layers parallel to and / or longitudinally along at least a portion of the length of a conductive core, the one or more non-conductive layers being at least partially along the perimeter of the conductive core and configured to target one or more predetermined high electric field regions along the conductive core within a winding driven by a converter device.

43. The method includes winding the one or more non-conductive layers at least partially along the perimeter of the conductive core, The one or more non-conductive layers are heterogeneous and / or asymmetric at least partially along the perimeter of the conductive core, or The one or more non-conductive layers are symmetric at least partially along the periphery of the conductive core. The method according to claim 42, wherein at least a part of the one or more non-conductive layers is arranged in or near the one or more predetermined high electric field regions along the conductive core in the winding driven by the converter device. **Claim 44** The method according to claim 42 or 43, including arranging the electrically insulated conductor in the winding such that at least a part of the one or more non-conductive layers is located in or near the one or more predetermined high electric field regions along the conductive core in the winding driven by the converter device. **Claim 45** The method according to any one of claims 42 to 44, including selectively applying the one or more non-conductive layers at least partially along the length of the conductive core. **Claim 46** The method according to any one of claims 42 to 45, including selectively applying fragments of the one or more non-conductive layers at index positions spaced along the length of the conductive core. **Claim 47** The method according to any one of claims 42 to 46, including manufacturing the electrically insulated conductor according to any one of claims 1 to 39. **Claim 48** A system configured to execute the method according to any one of claims 42 to 46.

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