Fluororesin Flat Insulated Wire for Thin High-Voltage Motor Insulation
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Solution Overview
Problem
Current enameled flat wires for high-voltage vehicle motors face issues with rapid insulating layer damage due to high-frequency pulse harmonics, low heat dissipation efficiency, reduced strength after thermal aging, and shortened service life under water and oil environments, while requiring thinner insulating layers with maintained insulation performance.
Innovation Solution
A flat insulated electric wire with a fluororesin insulating layer composed of a fluorine-containing polymer containing a carbonyl group, another fluorine-containing polymer without a carbonyl group, and a metal oxide, blended in specific ratios, enhances insulation properties, aging resistance, and adhesion to the conductor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polyimide or polyetherimide is used as insulating material, then manufacturing is easier, but insulation properties, aging resistance, and corrosion resistance are insufficient
Solution Approach 1:
The patent uses a composite insulating layer comprising a fluororesin base layer (providing corrosion and aging resistance) combined with a fluorocarbon resin coating layer (providing enhanced insulation properties). This composite structure achieves superior reliability while maintaining manufacturability through a standardized multi-layer construction approach.
Solution Approach 2:
The patent specifies precise compositional parameters for the fluorocarbon resin coating layer, including fluorine content (20-40 atom%) and specific functional group ratios, to optimize insulation performance. These parameter optimizations enable the material to achieve breakdown voltages exceeding 10 kV while remaining compatible with existing manufacturing processes.
2Volume of moving object
If insulating layer is made thinner to increase space factor, then space utilization improves, but insulation performance may deteriorate
Solution Approach 1:
The patent achieves high insulation performance in thin layers by optimizing the fluorocarbon resin coating thickness to 1-10 μm and controlling the fluorine content at 20-40 atom%. This parameter optimization allows the breakdown voltage to exceed 10 kV even at minimal thickness, enabling high space factor while maintaining superior insulation.
Solution Approach 2:
The patent applies a specialized fluorocarbon resin coating with optimized fluorine distribution and functional group composition specifically at the insulator surface and interface regions. This local quality enhancement ensures maximum insulation performance at critical locations while keeping the overall layer thickness minimal.
3Strength
If conventional enameled flat wire is used, then bending is easier, but the insulating layer is easily broken during high-voltage corona discharge and has low adhesion
Solution Approach 1:
The patent employs a composite structure where the fluororesin base layer provides mechanical flexibility and adhesion to the conductor, while the fluorocarbon resin coating layer provides exceptional resistance to corona discharge and high-voltage breakdown. This composite approach enables the wire to withstand bending during manufacturing while resisting insulating layer breakdown during high-voltage operation.
Solution Approach 2:
The patent uses a thin fluorocarbon resin coating layer (1-10 μm) that provides exceptional durability against corona discharge and electrical breakdown. Although thin, this layer acts as a sacrificial protective barrier that prevents damage to the underlying conductor and base insulating layer, effectively extending the service life of the wire in high-voltage environments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a flat insulated electric wire with improved insulation, corrosion resistance, and bending resistance, along with enhanced adhesion between the insulating layer and conductor, suitable for high-voltage applications in electric vehicles.
Implementation Method 1
a fluororesin insulating layer containing a fluorine-containing polymer (A) having a carbonyl-containing group, a fluorine-containing polymer (B) having no carbonyl-containing group, and a metal oxide
Implementation Method 2
an enameled flat wire having a higher overload capacity is required. During motor operation, high-frequency pulse harmonics due to frequency control devices, inverters, current switching power supplies, other current conversion devices, and the like frequently affect the insulating layer
Implementation Method 3
the heat dissipation efficiency is low
Data Source
AI summary
The present disclosure includes a flat conductor and a fluororesin insulating layer that covers the flat conductor. The fluororesin insulating layer contains a fluorine-containing polymer (A) having a carbonyl-containing group, a fluorine-containing polymer (B) having no carbonyl-containing group, and a metal oxide. The fluorine-containing polymer (A) is a hot-melt tetrafluoroethylene copolymer having a carbonyl-containing group. The carbonyl-containing group is at least one selected from a group having a carbonyl group between carbon atoms of a hydrocarbon group, a carbonate group, a carboxyl group, an alkoxycarbonyl group, or an anhydride residue. The blending amount of the fluorine-containing polymer (A) is from 10 to 25 parts by mass with respect to 100 parts by mass of the fluorine-containing polymer (B), and the mass ratio of the fluorine-containing polymer (A) to the metal oxide is from 3.5 : 1 to 5.5 : 1.