Insulated Winding Wire PEEK Composite Dielectric Strength
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Solution Overview
Problem
Conventional magnet wire insulation materials face challenges in achieving high dielectric strength and partial discharge inception voltage, are prone to degradation from hydrocarbon oils and moisture, and have limitations in thickness for tight packing in electrical devices.
Innovation Solution
A multilayer insulation system for magnet wire comprising a base polymeric layer and an extruded thermoplastic top coat, using materials like PEEK or PAEK, which provides a thin, robust, and flexible insulation with enhanced dielectric properties, resistance to oils and moisture, and ability to withstand high temperatures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional polymeric enamel insulation is applied in successive layers to achieve higher dielectric strength and partial discharge performance, then the insulation thickness increases, but the adhesive force between enamel and conductor decreases and flexibility is reduced
Solution Approach 1:
The patent combines polymeric enamel insulation with polyphenylene sulfide (PPS) resin to create a composite insulation system. The PPS resin is extruded over the enamel layer to form a coating that provides enhanced dielectric strength and partial discharge performance while maintaining flexibility and avoiding the need for excessive enamel layering.
Solution Approach 2:
The patent changes the material parameters by introducing PPS resin with specific properties (dielectric constant, breakdown voltage characteristics) to complement the enamel layer. This material substitution allows achieving higher dielectric strength without increasing the number of enamel layers, thereby maintaining adhesive force and flexibility.
2Reliability
If enamel insulation thickness is increased to achieve higher dielectric strength, then partial discharge performance improves, but the wire becomes less flexible and harder to pack tightly
Solution Approach 1:
The composite structure of enamel plus PPS resin coating provides the necessary dielectric strength and partial discharge resistance without requiring thick enamel layers. The PPS resin layer contributes to the overall insulation performance while the combined structure maintains flexibility for tight packing in electrical devices.
Solution Approach 2:
The patent applies different materials with different properties to different layers: the enamel layer provides base insulation and adhesion to the conductor, while the outer PPS resin layer provides enhanced dielectric strength and partial discharge resistance. This localized material assignment optimizes both flexibility and electrical performance.
3Adaptability or versatility
If traditional magnet wire insulation is used in vehicle applications with transmission fluid, then the wire can be submerged in oil, but the insulation material breaks down from hydrocarbon oil exposure
Solution Approach 1:
The PPS resin material is inherently resistant to hydrocarbon oils and transmission fluids. By extruding this oil-resistant material over the enamel layer, the composite insulation system gains protection against chemical degradation from oil exposure while maintaining its dielectric properties and overall integrity in vehicle applications.
Data Source
AI summary
Insulated winding wires and associated methods for forming winding wires are described. A winding wire may include a conductor and insulation formed around the conductor. The insulation may provide a partial discharge inception voltage greater than approximately 1,000 volts and a dielectric strength greater than approximately 10,000 volts. Additionally, the insulation may be capable of withstanding a continuous operating temperature of approximately 220° C. without degradation. The insulation may include at least one base layer formed around an outer periphery of the conductor, and an extruded thermoplastic layer formed around the base layer. The extruded layer may include at least one of polyetheretherketone (PEEK) or polyaryletherketone (PAEK).