Magnet wire with composite insulating layer, and manufacturing method therefor

Abstract

Disclosed in the present invention is a magnet wire with a composite insulating layer, the magnet wire comprising a conductor, a first polyamide-imide insulating layer, a nano-inorganic insulating layer and a second polyamide-imide insulating layer, which are sequentially arranged from inside to outside. The thickness ratio of the first polyamide-imide insulating layer to the nano-inorganic insulating layer to the second polyamide-imide insulating layer is 3:4:3. The magnet wire with a composite insulating layer of the present invention can improve the withstand voltage level of the magnet wire and reduce the voltage loss of the insulating layer, and has the advantages of good flexibility, high slot fill factor and good heat dissipation performance. Also disclosed in the present invention is a manufacturing method for the magnet wire with a composite insulating layer, in which the latter two rolling processes can achieve correction and supplementation effects on the former two rolling processes, and the deformation rate is controlled within 5‰-32‰, thereby effectively preventing a "rib separation" phenomenon from occurring in the rolling processes, ensuring the ductility of the magnet wire itself, eliminating the need for a subsequent secondary annealing process to soften the magnet wire, and thus improving the overall performance of the magnet wire.

Description

Composite insulation layer electromagnetic wire and manufacturing method thereof TECHNICAL FIELD

[0001] The present application belongs to the technical field of electromagnetic wire, and particularly relates to a composite insulation layer electromagnetic wire and a manufacturing method thereof. BACKGROUND

[0002] The existing technology of electromagnetic wire is to process metal materials (copper, aluminum, copper-coated aluminum), and then to produce high-temperature-resistant electromagnetic wire through drawing and other processes and lacquering equipment; however, the existing technology for producing high-temperature-resistant electromagnetic wire has certain limitations, the temperature resistance level of the organic insulation layer can only reach 220 level at most, and can only reach 240 level at most, the structure characteristics of the organic high polymer material itself determine that the temperature resistance level can only reach 240 level, and under the condition of 240 DEG C, when the electrical and electronic products operate for more than 5000 hours, the organic high polymer material begins to flow, ages, and is carbonized until failure, and under the condition of a certain thickness of the insulation layer, the insulation strength level can only reach 10-15KV; meanwhile, under the conditions of high temperature, high frequency and high voltage, the voltage loss of the organic insulation layer reaches 50-60%, the quality of the insulation layer is poor, and the use requirement is not met. SUMMARY

[0003] The present application belongs to the technical field of electromagnetic wire, and particularly relates to a composite insulation layer electromagnetic wire and a manufacturing method thereof.

[0004] In order to solve the above technical problems, the technical scheme adopted by one aspect of the present application is as follows:

[0005] A composite insulation layer electromagnetic wire comprises a conductor, a first polyamide-imide insulation layer, a nano-inorganic insulation layer and a second polyamide-imide insulation layer arranged from inside to outside in sequence, and the thickness ratio of the first polyamide-imide insulation layer, the nano-inorganic insulation layer and the second polyamide-imide insulation layer is 3:4:3.

[0006] As a preferred scheme of the present application, the temperature resistance level of the electromagnetic wire is 260 level.

[0007] As a preferred scheme of the present application, the first polyamide-imide insulation layer, the nano-inorganic insulation layer and the second polyamide-imide insulation layer are coated in multiple times.

[0008] As a preferred scheme of the present application, the thickness of the first polyamide-imide insulation layer is 0.03 mm.

[0009] As a preferred scheme of the present application, the thickness of the nano-inorganic insulation layer is 0.04 mm.

[0010] As a preferred scheme of the present application, the thickness of the second polyamide-imide insulating layer is 0.03 mm.

[0011] Another aspect of the present application employs the technical scheme as follows: a manufacturing method of a composite insulating layer electromagnetic wire, comprising the following steps:

[0012] Step 1: the semi-finished conductor is guided out of the wire laying device, and is drawn into a round wire through a wire drawing device, and then the wire is cleaned and annealed;

[0013] Step 2: the first polyamide-imide insulating layer is uniformly and densely coated on the surface of the conductor through a mold in multiple passes;

[0014] Step 3: the paint treated wire is baked, cross-linked and cured, and then cooled;

[0015] Step 4: the nano inorganic insulating layer is uniformly and densely coated on the surface of the conductor through a mold in multiple passes;

[0016] Step 5: the paint treated wire is baked, cross-linked and cured, and then cooled;

[0017] Step 6: the second polyamide-imide insulating layer is uniformly and densely coated on the surface of the conductor through a mold in multiple passes;

[0018] Step 7: the paint treated wire is baked, cross-linked and cured, and then cooled;

[0019] Step 8: the paint treated wire is subjected to first longitudinal calendering treatment, and the deformation rate is 5‰-32‰;

[0020] Step 9: the paint treated wire is subjected to first transverse calendering treatment, and the deformation rate is 5‰-32‰;

[0021] Step 10: the paint treated wire is subjected to second longitudinal calendering treatment, and the deformation rate is 5‰-32‰;

[0022] Step 11: the paint treated wire is subjected to second transverse calendering treatment, and the deformation rate is 5‰-32‰;

[0023] The thickness ratio of the first polyamide-imide insulating layer, the nano inorganic insulating layer and the second polyamide-imide insulating layer is 3:4:3.

[0024] As a preferred scheme of the present application, between Step 6 and Step 7, a material with self-adhesive properties is uniformly and densely extruded on the second polyamide-imide insulating layer through an extruder.

[0025] As a preferred scheme of the present application, the temperature resistance grade of the electromagnetic wire is 260 grade.

[0026] The composite insulation layer electromagnetic wire and the manufacturing method thereof provided by the present application have the following beneficial effects compared with the prior art:

[0027] The electromagnetic wire provided by the present application comprises, from inside to outside, a conductor, a first polyamide-imide insulation layer, a nano-inorganic insulation layer and a second polyamide-imide insulation layer, the thickness ratio of the first polyamide-imide insulation layer, the nano-inorganic insulation layer and the second polyamide-imide insulation layer is 3:4:3, and under the conditions of high temperature, high frequency and high voltage, the voltage loss of the insulation layer of the electromagnetic wire as a whole can be reduced to 10-20%, that is, the voltage level is kept above 80% of that under normal temperature conditions; due to the arrangement of the nano-inorganic insulation layer, the space charge can be effectively dispersed when the electromagnetic wire is electrified, thereby preventing the electric breakdown phenomenon caused by excessive local electric field intensity, and improving the voltage resistance level of the product; thus, the voltage resistance level of the electromagnetic wire can be improved, the voltage loss of the insulation layer can be reduced, and the electromagnetic wire has the advantages of good flexibility, high slot fill ratio and good heat dissipation; in addition, in the process of manufacturing the composite insulation layer electromagnetic wire, four calendering processes are included, the last two calendering processes can correct and supplement the first two calendering processes, avoid the phenomenon of incomplete processing, and control the deformation rate at 5‰-32‰, effectively avoiding the "muscle gap" phenomenon in the calendering process, ensuring the ductility of the electromagnetic wire itself, thus the softening of the electromagnetic wire does not need to rely on the subsequent secondary annealing process, and the overall performance of the electromagnetic wire is improved. BRIEF DESCRIPTION OF DRAWINGS

[0028] In order to more clearly illustrate the technical scheme of the embodiments of the present application, the drawings of the embodiments will be briefly introduced below.

[0029] Fig. 1 is a structural schematic view of a composite insulation layer electromagnetic wire provided by an embodiment of the present application.

[0030] Markings in the figure:

[0031] Conductor 1; first polyamide-imide insulation layer 2; nano-inorganic insulation layer 3; second polyamide-imide insulation layer 4; self-adhesive layer 5. DETAILED DESCRIPTION

[0032] The specific embodiments of the present application will be further described in detail below in combination with the drawings and embodiments. The following embodiments are used to illustrate the present application, but are not used to limit the scope of the present application.

[0033] In the description of the present application, it should be understood that the terms "upper", "lower", "left", "right", "front", "back", "top", "bottom" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation of the present application. It should be understood that the terms "first", "second" and the like are used to describe various information in the present application, but these information should not be limited to these terms, and these terms are only used to distinguish the same type of information from each other. For example, the "first" information can also be referred to as "second" information without departing from the scope of the present application, and similarly, the "second" information can also be referred to as "first" information.

[0034] As shown in FIG. 1, the preferred embodiment one of the present application provides a composite insulation layer electromagnetic wire, which comprises a conductor 1, a first polyamide-imide insulation layer 2, a nano-inorganic insulation layer 3 and a second polyamide-imide insulation layer 4 arranged from inside to outside, and the thickness ratio of the first polyamide-imide insulation layer 2, the nano-inorganic insulation layer 3 and the second polyamide-imide insulation layer 4 is 3:4:3.

[0035] It should be further pointed out that in the present embodiment, the temperature resistance grade of the electromagnetic wire is 260, and at the same time, the electromagnetic wire of the present application has a product life of more than 5000 hours under the condition of 260℃ temperature, can withstand heat shock for more than 30 minutes under the condition of 280℃ temperature, and the insulating paint film will not appear softening phenomenon within 2 minutes under the condition of 400℃, has strong thermoplastic flowability, can provide a high-performance composite insulation layer electromagnetic wire, and is suitable for more special application scenarios, for example, in the field of special transformers, when the size of the transformer framework is certain, the product size cannot be increased, and the transformer needs to withstand high frequency, high temperature and high pressure, therefore, the composite insulation layer electromagnetic wire of the present application can meet the use requirements; in addition, in the field of special motors, when the motor design size is certain, the power needs to be increased and the voltage needs to be increased from 400V to 800V, the composite insulation layer electromagnetic wire of the present application can solve the customer's requirements.

[0036] Exemplarily, a self-adhesive layer 5 is arranged on the outer periphery of the second polyamide-imide insulation layer 4; in actual use, a self-adhesive layer 5 can be arranged on the outermost layer as needed, and the self-adhesive layer 5 has a self-adhesion function, that is, it does not need to be wound on the framework, and can be made into a framework-free coil.

[0037] Exemplarily, the first polyamide-imide insulation layer 2, the nano-inorganic insulation layer 3 and the second polyamide-imide insulation layer 4 are coated in multiple ways.

[0038] Exemplarily, the thickness of the first polyamide-imide insulating layer 2 is 0.03 mm.

[0039] Exemplarily, the thickness of the nano-inorganic insulating layer 3 is 0.04 mm.

[0040] Exemplarily, the thickness of the second polyamide-imide insulating layer 4 is 0.03 mm.

[0041] In order to verify the performance of the composite insulating layer electromagnetic wire of the present application, the present scheme carries out verification test on the 220-grade polyamide-imide enameled wire and the composite insulating layer electromagnetic wire in the present scheme, and the results are as follows:

[0042] As can be seen from the above table, under the premise of the same conductor 1 diameter and paint film thickness, the insulation breakdown voltage of the 220-grade polyamide-imide enameled wire is 12000V, and the breakdown voltage under high temperature condition is 6000V, while the composite insulating layer electromagnetic wire of the present application can reach an insulation breakdown voltage of 14000V, and the breakdown voltage under high temperature condition can reach 12000V; and for the heat shock resistance, the 220-grade polyamide-imide enameled wire can only withstand heat shock for more than 30 minutes at 240℃, while the composite insulating layer electromagnetic wire of the present application can withstand heat shock for more than 30 minutes at 280℃; in addition, the insulation paint film of the 220-grade polyamide-imide enameled wire will soften within two minutes at 400℃, and the thermoplastic flowability is poor, while the insulation paint film of the composite insulating layer of the present application will soften within two minutes at 420℃, and the thermoplastic flowability is strong.

[0043] The preferred embodiment two of the present application provides a manufacturing method of a composite insulating layer electromagnetic wire, comprising the following steps:

[0044] Step 1: the semi-finished conductor is led out from the unwinding device, and is drawn into a circular wire through the wire drawing equipment, and then the wire is cleaned and annealed; wherein the semi-finished conductor 1 is copper or copper-clad aluminum, of course, different materials can also be selected according to actual needs, the ultrasonic cleaning equipment can be used in the cleaning process, the cleaning steps can remove the copper powder, oil stains or other dirt on the surface of the electromagnetic wire, ensure the adhesion of the insulating paint in the subsequent painting process, and the annealing process can make the electromagnetic wire soften at high temperature, and further remove the copper powder, oil stains or other dirt on the surface of the electromagnetic wire, ensure the surface cleanliness of the electromagnetic wire, and facilitate the subsequent painting operation; in addition, the annealing temperature of the electromagnetic wire is 400-500℃.

[0045] Step 2: the first polyamide-imide insulating layer 2 is uniformly and densely coated on the surface of the conductor 1 through a plurality of passes of a mold;

[0046] Step 3: baking the coated wire, cross-linking and curing, and then cooling;

[0047] Step 4: uniformly and densely coating the nano-inorganic insulation layer 3 on the surface of the conductor 1 by multiple passes of a mold;

[0048] Step 5: baking the coated wire, cross-linking and curing, and then cooling;

[0049] Step 6: uniformly and densely coating the second polyamide-imide insulation layer 4 on the surface of the conductor 1 by multiple passes of a mold;

[0050] Step 7: baking the coated wire, cross-linking and curing, and then cooling;

[0051] Step 8: first longitudinal calendering of the coated wire, with a deformation rate of 5‰-32‰;

[0052] Step 9: first transverse calendering of the coated wire, with a deformation rate of 5‰-32‰;

[0053] Step 10: second longitudinal calendering of the coated wire, with a deformation rate of 5‰-32‰;

[0054] Step 11: second transverse calendering of the coated wire, with a deformation rate of 5‰-32‰;

[0055] The thickness ratio of the first polyamide-imide insulation layer, the nano-inorganic insulation layer, and the second polyamide-imide insulation layer is 3:4:3.

[0056] Optionally, between Step 6 and Step 7, a material with self-adhesive properties is uniformly and densely extruded onto the second polyamide-imide insulation layer 4 by an extruder.

[0057] The composite insulation layer electromagnetic wire and the manufacturing method thereof adopt the structure that the conductor 1, the first polyamide imide insulation layer 2, the nano inorganic insulation layer 3 and the second polyamide imide insulation layer 4 are sequentially arranged from inside to outside, the thickness ratio of the first polyamide imide insulation layer 2, the nano inorganic insulation layer 3 and the second polyamide imide insulation layer 4 is 3:4:3, and the voltage loss of the insulation layer of the electromagnetic wire as a whole can be reduced to 10-20% under the conditions of high temperature, high frequency and high voltage, that is, the voltage level is kept above 80% of that under normal temperature conditions; the nano inorganic insulation layer 3 can effectively disperse space charges when electrified, thereby preventing the electric breakdown phenomenon caused by excessive local electric field intensity, and improving the voltage resistance level of the product; the present application can improve the voltage resistance level of the electromagnetic wire, reduce the voltage loss of the insulation layer, and has the advantages of good flexibility, high slot fill ratio and good heat dissipation; in addition, the manufacturing process of the composite insulation layer electromagnetic wire includes four calendering processes, the last two calendering processes can correct and supplement the first two calendering processes, avoid the phenomenon of incomplete processing, and control the deformation rate to 5‰-32‰, effectively avoiding the "muscle gap" phenomenon in the calendering process, ensuring the ductility of the electromagnetic wire itself, thus eliminating the need for subsequent secondary annealing process to soften the electromagnetic wire and improving the overall performance of the electromagnetic wire.

[0058] In the embodiment, the temperature resistance level of the electromagnetic wire is 260.

[0059] In the description of the present application, it should be noted that unless otherwise specified and limited, the terms "connected", "connected" should be understood broadly, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium, or it can be the communication inside two elements. For ordinary skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0060] The above is only the preferred embodiment of the present application, and it should be pointed out that for ordinary skilled in the art, without departing from the technical principles of the present application, a number of improvements and replacements can be made, which should also be regarded as the protection scope of the present application.

Claims

1. A method for manufacturing a composite insulating layer electromagnetic wire, characterized in that, Includes the following steps: Step 1: The semi-finished conductor is taken out from the wire feeding equipment and drawn into a round wire by the wire drawing equipment. Then the wire is cleaned and annealed. Step 2: Apply the first polyamide-imide insulating layer evenly and densely to the surface of the conductor through multiple passes using a mold; Step 3: Baking the coated wires to induce a cross-linking and curing reaction, followed by cooling. Step 4: Apply the nano-inorganic insulating layer evenly and densely to the surface of the conductor through multiple passes using a mold; Step 5: Baking the coated wires to induce a cross-linking and curing reaction, followed by cooling. Step 6: Apply the second polyamide-imide insulating layer evenly and densely to the surface of the conductor through multiple passes using a mold; Step 7: Baking the coated wires to induce a cross-linking and curing reaction, followed by cooling. Step 8: Perform the first longitudinal rolling treatment on the coated wire, with a deformation rate of 5‰~32‰; Step 9: Perform the first transverse rolling treatment on the coated wire, with a deformation rate of 5‰~32‰; Step 10: Perform a second longitudinal rolling process on the coated wire, with a deformation rate of 5‰ to 32‰; Step 11: Perform a second transverse rolling process on the coated wire, with a deformation rate of 5‰ to 32‰; The thickness ratio of the first polyamide-imide insulating layer, the nano-inorganic insulating layer, and the second polyamide-imide insulating layer is 3:4:

3.

2. The method for manufacturing a composite insulating layer electromagnetic wire according to claim 1, characterized in that, Between steps 6 and 7, a material with self-adhesive properties is extruded uniformly and densely onto the second polyamide-imide insulating layer using an extruder.

3. The method for manufacturing a composite insulating layer electromagnetic wire according to claim 1, characterized in that, The electromagnetic wire has a temperature rating of 260°C.

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