Insulated Wire Mixed Resin Coating High Temperature PDIV
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Solution Overview
Problem
Insulated wires used in electrical equipment face thermal deterioration and cracking due to high temperatures, especially in compact designs where the space factor is improved, leading to reduced partial discharge inception voltage and mechanical properties.
Innovation Solution
An insulated wire with a mixed resin extrusion covering layer composed of polyallyletherketone and non-fluorine-based resins, such as polycarbonate or polyphenylsulfone, with a specific mass ratio and thermosetting resin layer, which maintains a low relative permittivity ratio at high temperatures, enhancing mechanical properties and thermal stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a resin with low relative permittivity is used for the electrical wire coating to improve PDIV characteristics, then PDIV is improved, but thermal shrinkage resistance at high temperatures deteriorates
Solution Approach 1:
The patent uses a composite resin composition comprising a fluorinated polyolefin resin (providing low relative permittivity for high PDIV) and a crosslinking agent (providing thermal shrinkage resistance). The crosslinking agent forms a three-dimensional network structure that suppresses thermal shrinkage at high temperatures while the fluorinated polyolefin maintains low relative permittivity. This composite approach resolves the contradiction by combining materials with complementary properties.
Solution Approach 2:
The patent modifies the chemical structure of the resin by introducing crosslinking bonds through a crosslinking agent. This changes the physical parameters of the coating, specifically reducing the thermal shrinkage rate from typical values to 5% or less at high temperatures, while maintaining the low relative permittivity characteristic needed for high PDIV. The crosslinking degree is controlled to achieve optimal balance between thermal stability and electrical properties.
2Volume of moving object
If the space factor is improved by using compact wire design, then equipment size is reduced, but thermal deterioration and cracking increase at high temperatures
Solution Approach 1:
The patent employs a composite resin system combining fluorinated polyolefin with crosslinking agents to create a coating that maintains flexibility and resistance to thermal deterioration in compact wire designs. The crosslinked network structure prevents cracking that would otherwise occur in tightly packed wires subjected to thermal cycling, while the fluorinated polyolefin base maintains low relative permittivity for electrical reliability.
Solution Approach 2:
The crosslinked resin structure acts as a preventive measure against thermal deterioration before it occurs. The three-dimensional network formed by the crosslinking agent creates a robust structure that anticipates and resists the thermal stresses and mechanical stresses that compact wires experience during operation, preventing cracking and degradation before they can initiate.
3Ease of manufacture
If a single resin type is used for the covering layer, then manufacturing is simplified, but both low relative permittivity and thermal shrinkage resistance cannot be achieved simultaneously
Solution Approach 1:
The patent combines fluorinated polyolefin resin and crosslinking agent in a single coating composition that can be applied in one extrusion step. This composite formulation maintains manufacturing simplicity while achieving both low relative permittivity (from the fluorinated polyolefin) and thermal shrinkage resistance (from the crosslinked network). The crosslinking agent is incorporated into the resin composition and activates during curing to form the protective network.
Solution Approach 2:
The patent merges the functions of electrical insulation (low relative permittivity) and thermal protection (shrinkage resistance) into a single integrated coating layer. By combining the fluorinated polyolefin resin with the crosslinking agent in one coating composition, the patent eliminates the need for separate coating steps while achieving both critical performance requirements simultaneously.
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 improves partial discharge inception voltage and mechanical properties at high temperatures, suppressing thermal deterioration and inverter surge, while maintaining a compact design, thus enhancing the performance and reliability of electrical equipment.
Implementation Method 1
the covering resin layer is thermally deteriorated to cause thermal shrinkage
Implementation Method 2
relative permittivity of an electrical wire coating significantly influences PDIV of the insulated wire
Data Source
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Figure 3
AI summary
{Problem} To provide: an insulated wire, in which a partial discharge inception voltage of the insulated wire is improved, in which, even at such a high temperature over 200°C, mechanical properties are excellent, and in which thermal deterioration is suppressed; a coil; and an electric or electronic equipment; and a method of producing the insulated wire. {Solution to Problem} An insulated wire, comprising at least one layer of an electrical wire coating, including an extrusion covering resin layer, on an outer periphery of a conductor, wherein the extrusion covering resin layer is composed of a mixed resin of a resin (A) and a resin (B) each having different relative permittivity, wherein the resin (A) is a polyallyletherketone resin selected from polyetheretherketone, polyetherketoneketone, polyetherketone, polyetheretherketoneketone, polyetherketoneetherketoneketone, and polyketone, wherein the resin (B) is a non-fluorine-based resin having lower relative permittivity at 200°C, than the resin (A), wherein a mixing mass ratio of the mixed resin {a mass of the resin (A):a mass of the resin (B)} is 90:10 to 51:49, and wherein a value of a ratio of the relative permittivity at 200°C to the relative permittivity at 25°C and 50% relative humidity, in the relative permittivity of a whole of the electrical wire coating, is less than 1.20; a coil; an electrical or electronic equipment; and a method of producing the insulated wire.