Insulated Wire Partial Discharge Resistance Composition
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Solution Overview
Problem
Existing insulated electric wires with high amounts of inorganic insulators suffer from deteriorated physical properties like flexibility and bendability, leading to increased crack occurrence and insufficient partial discharge resistance, especially in thick wires with diameters of at least 1.5 mm, due to the inability to effectively disperse stress and maintain mechanical integrity.
Innovation Solution
A composition for manufacturing insulated electric wires with partial discharge resistance, incorporating an insulating base resin, 5-40 parts by weight of inorganic insulators, and 0.1-30 parts by weight of a rubbery modifier, such as CTB rubber or ATBN rubber, to enhance flexibility and stress dispersion, ensuring sufficient pliability even in thick wires.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the content of fine particles of inorganic insulator is increased to improve partial discharge resistance, then partial discharge resistance is improved, but physical properties such as flexibility, pliability, bendability, and elongation are deteriorated
Solution Approach 1:
The patent changes the particle size parameter of the inorganic insulator from conventional larger sizes to nano-sized (1-100 nm), and optimizes the content ratio between inorganic insulator (5-40 parts by weight) and rubbery modifier (0.1-30 parts by weight). This parameter optimization allows achieving sufficient partial discharge resistance while maintaining flexibility by reducing the negative impact of inorganic particle aggregation.
Solution Approach 2:
The patent creates a composite material system combining insulating base resin, nano-sized inorganic insulator particles, and rubbery modifier. This composite structure leverages the high dielectric strength of inorganic particles for partial discharge resistance while the rubbery modifier matrix provides flexibility and stress dispersion, achieving synergistic performance that resolves the contradiction between rigidity and flexibility.
2Reliability
If a large amount of fine particles of inorganic insulator is used to improve partial discharge resistance, then partial discharge resistance is improved, but crack occurrence is increased upon coating the insulated electric wire
Solution Approach 1:
The patent reduces the particle size parameter to nano-scale (1-100 nm), which fundamentally changes the stress distribution characteristics. Nano-sized particles create more uniform stress fields and reduce stress concentration points that would otherwise initiate cracks during coating and handling processes.
Solution Approach 2:
The rubbery modifier acts as an intermediary material between the inorganic insulator particles and the insulating base resin. This intermediary phase absorbs and disperses mechanical stresses, preventing stress concentration at particle-resin interfaces that would lead to crack formation during coating operations.
3Reliability
If the content of inorganic insulator is increased to improve partial discharge resistance, then partial discharge resistance is improved, but flexibility and pliability are deteriorated
Solution Approach 1:
The patent optimizes the compositional parameters by controlling the weight ratio of inorganic insulator (5-40 parts) to rubbery modifier (0.1-30 parts) to 100 parts of insulating base resin. This precise parameter control ensures sufficient inorganic content for partial discharge resistance while maintaining adequate rubbery modifier content for flexibility.
Solution Approach 2:
The patent creates local quality differentiation where nano-sized inorganic particles are uniformly distributed within the rubbery modifier matrix. This local distribution strategy ensures that inorganic particles provide partial discharge resistance at specific locations without creating overall rigidity, as the rubbery modifier continuously phases maintain flexibility throughout the material.
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 effectively improves flexibility and maintains partial discharge resistance by dispersing stress through the rubbery modifier, preventing crack formation and maintaining electrical insulation under external forces, as demonstrated by consistent film defect and dielectric breakdown voltage performance across various wire configurations.
Implementation Method 1
the insulated electric wire has a sufficient partial discharge resistance and also enhances sufficient physical properties such as flexibility, pliability, bendability, elongation, etc. to maintain an electrically insulating property intactly by dispersing a stress, applied from an external force, by means of a rubber component attached to an end of the insulator
Implementation Method 2
an inorganic insulator such as oxides or nitrides of inorganic materials, glass, mica and the like as an insulator which is not easily deteriorated by partial discharge
Data Source
AI summary
Disclosed are an insulated electric wire with partial discharge resistance and a composition for manufacturing the same. The insulated electric wire with partial discharge resistance according to the present invention includes an insulating base resin constituting a basic material of an insulated electric wire; an inorganic insulator included at a content of 5 to 40 parts by weight on the basis of 100 parts by weight of the insulating base resin; and a rubbery modifier included at a content of 0.1 to 30 parts by weight on the basis of 100 parts by weight of the insulating base resin to improve flexibility of an insulated electric wire. The insulated electric wire with partial discharge resistance of the present invention may be useful to prevent occurrence of cracks caused by winding of an insulated electric wire since the insulated electric wire has a sufficient partial discharge resistance and also enhances sufficient physical properties such as flexibility, pliability, bendability, elongation, etc. to maintain an electrically insulating property intactly by dispersing a stress, applied from an external force, by means of a rubber component attached to an end thereof.