Three-Layer Covered Wire Coating for Low Dielectric Insulation
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Solution Overview
Problem
Existing coated electric wires face issues with high relative dielectric constant, low partial discharge inception voltage, and wrinkle formation when bent, along with insufficient adhesion strength between the substrate and coating layer.
Innovation Solution
A coated electric wire design featuring a three-layer structure: a first layer with a polymer compound having amide or imide groups, a second layer with a polymer compound and fluorine-containing polymer compound, and a third layer formed by extrusion of a fluorine-containing polymer compound, ensuring close contact and adhesion without increasing dielectric constant or reducing partial discharge voltage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional coating material is used to form a coating layer on the electric wire substrate, then the coating layer can be formed, but the relative dielectric constant becomes high and the partial discharge inception voltage becomes low
Solution Approach 1:
The patent applies composite materials by combining polymer compounds with amide or imide groups and fluorine-containing polymer compounds in specific layers. The fluorine-containing polymer compound has a low dielectric constant, which reduces the overall relative dielectric constant of the coating layer while maintaining high partial discharge inception voltage through the synergistic effect of the composite structure.
Solution Approach 2:
The patent implements local quality by creating a multi-layer structure where different layers have different material compositions optimized for specific functions. The first layer uses polymer compounds with amide/imide groups for adhesion, while the second and third layers incorporate fluorine-containing polymer compounds to reduce dielectric constant in specific regions of the coating.
2Reliability
If a coating layer is formed on the electric wire substrate, then insulation is provided, but wrinkles occur on the coating layer when the wire is bent
Solution Approach 1:
The patent applies flexible shells and thin films by using polymer compounds with amide or imide groups that possess inherent flexibility and elongation properties. These materials can accommodate bending stresses without forming wrinkles, while the multi-layer structure maintains insulation performance through the combined properties of each layer.
Solution Approach 2:
The composite material structure combines flexible polymer compounds with fluorine-containing polymer compounds to achieve both flexibility (preventing wrinkles during bending) and insulation performance. The different material properties in each layer work together to prevent wrinkle formation while maintaining electrical insulation.
3Reliability
If a coating layer is formed on the electric wire substrate, then insulation is provided, but the adhesion strength between the substrate and coating layer is insufficient
Solution Approach 1:
The patent uses polymer compounds with amide or imide groups as intermediary materials in the first layer. These compounds have functional groups that can form strong chemical bonds with both the electric wire substrate and the subsequent fluorine-containing polymer layers, acting as a mediator that enhances adhesion strength while maintaining insulation performance.
Solution Approach 2:
The composite material system combines polymer compounds with specific functional groups (amide/imide) and fluorine-containing polymer compounds to achieve both strong adhesion and insulation. The functional groups in the polymer compounds provide bonding sites for strong adhesion to the substrate, while the fluorine-containing components maintain the insulating properties.
Data Source
AI summary
Provided is a coated electric wire including a flat electric wire substrate and a coating layer formed on the outer periphery of the flat electric wire substrate, wherein the coating layer includes: a first layer formed of a liquid coating material composition (1) containing a polymer compound (1) having any one or both of an amide group and an imide group; a second layer formed of a liquid coating material composition (2) containing a polymer compound (2) having any one or both of an amide group and an imide group, and a fluorine-containing polymer compound (2), or of a powder coating material composition (2) containing a polymer compound (2) having any one or both of an amide group and an imide group, and a fluorine-containing polymer compound (2); and a third layer formed by extrusion of a fluorine-containing polymer compound (3).