High-Voltage Coil Encapsulant Using Liquid Crystalline Polyester
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Solution Overview
Problem
High-voltage coils used in power relays and transformers face challenges with low rigidity and insulating properties at high temperatures, leading to potential electrical breakdowns due to the use of materials like liquid crystalline polyesters, which have not been fully addressed in existing technologies.
Innovation Solution
A high-voltage coil design incorporating a bobbin with a conducting wire encapsulated by a liquid crystalline polyester composition that includes specific repeating units and glass fibers, providing enhanced rigidity and insulating properties at high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If liquid crystalline polyester is used as forming material to reduce weight and resin amount, then weight reduction is achieved, but rigidity at high temperature deteriorates
Solution Approach 1:
The patent uses a composite material system consisting of liquid crystalline polyester combined with specific inorganic fillers (such as aluminum oxide, aluminum hydroxide, or magnesium hydroxide) to achieve both weight reduction and maintained rigidity at high temperatures. The filler content is controlled at 10-70 wt% to optimize the balance between weight and mechanical properties.
2Quantity of substance
If liquid crystalline polyester is used to reduce resin amount, then material usage is reduced, but withstand voltage at high temperature deteriorates
Solution Approach 1:
The patent incorporates inorganic fillers (aluminum oxide, aluminum hydroxide, or magnesium hydroxide) into the liquid crystalline polyester matrix to enhance electrical insulation properties. The filler content of 10-70 wt% provides sufficient electrical resistance to prevent breakdown while maintaining the reduced resin quantity goal.
Solution Approach 2:
The patent modifies the chemical composition parameters of the liquid crystalline polyester by controlling the ratio of specific repeating units (formulae 1-4) and adjusting the content of m-phenylene groups to 0-6.5 mol%, thereby optimizing the base material's electrical properties before adding fillers.
3Volume of moving object
If high voltage is applied to reduce coil size, then compactness is improved, but electrical breakdown risk increases due to low withstand voltage
Solution Approach 1:
The patent uses a composite encapsulant material consisting of liquid crystalline polyester with 10-70 wt% inorganic filler to create an insulation layer that can withstand high voltages. This allows the coil to be compact while maintaining sufficient electrical breakdown resistance through the enhanced dielectric properties of the composite material.
Data Source
AI summary
The present invention provides a high-voltage coil superior in insulating properties and rigidity at high temperatures, which comprises a bobbin, a conducting wire wound around the bobbin, and an encapsulant encapsulating the conducting wire, wherein the encapsulant comprises a liquid crystalline polyester having a repeating unit represented by defined formula (1), —O—Ar1—CO—, a repeating unit represented by defined formula (2), —CO—Ar2—CO—, and a repeating unit represented by defined formula (3), —X—Ar3—Y—, as a forming material.