Insulated Wire Polyphenylene Sulfide Polyamide Composite Resin
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Solution Overview
Problem
Conventional insulated wires with fluorine-containing polyimide resin coatings suffer from poor adhesion to wire conductors under mechanical stress, leading to potential dielectric breakdown, while thickening the extrusion coated resin layer to increase partial discharge inception voltage complicates the manufacturing process and increases costs.
Innovation Solution
An insulated wire with an extrusion-coated resin composition of polyphenylene sulfide-based resin and polyamide-based resin, with a specific mass ratio, heat-treated at 250° C. or higher, to enhance adhesion and partial discharge inception voltage without sacrificing mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fluorine-containing polyimide resin is used for insulation coating, then partial discharge inception voltage is improved, but adhesion to wire conductor deteriorates
Solution Approach 1:
The patent uses a composite resin composition combining polyphenylene sulfide resin (providing high partial discharge inception voltage) with polyamide resin (providing good adhesion to wire conductors). This composite approach allows the insulation coating to simultaneously achieve both high reliability against partial discharge and strong mechanical adhesion, resolving the contradiction between these two properties.
Solution Approach 2:
The patent modifies the chemical composition parameters of the insulation coating by selecting specific resin types and ratios. By changing from fluorine-containing polyimide resin to a polyphenylene sulfide-polyamide composite system, the patent achieves both high partial discharge inception voltage and good adhesion through parameter optimization rather than using a single material with compromised properties.
2Reliability
If extrusion coated resin layer is thickened to increase partial discharge inception voltage, then reliability is improved, but manufacturing complexity and cost increase
Solution Approach 1:
Instead of increasing the thickness of the resin layer, the patent changes the material composition parameters to achieve higher partial discharge inception voltage. The polyphenylene sulfide-polyamide composite resin provides enhanced electrical performance at standard thicknesses, avoiding the need for thicker coatings and the associated manufacturing complexities.
Solution Approach 2:
The patent employs a single-layer extrusion-coated resin composition that can be applied directly without requiring multiple layers or complex post-processing. This simplifies the manufacturing process while achieving the desired electrical performance, effectively replacing complex multi-layer structures with a simpler, more cost-effective single-layer solution.
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 achieves a higher partial discharge inception voltage than conventional wires while maintaining adhesion comparable to conventional coatings, simplifying the manufacturing process and reducing costs by using a single-layer insulation coating.
Implementation Method 1
heat-treated at 250° C. or higher, to enhance adhesion and partial discharge inception voltage
Implementation Method 2
an extrusion coated insulation layer formed by extrusion coating a resin composition on a wire conductor
Data Source
AI summary
There is provided an insulated wire including a wire conductor and an insulation coating formed on the wire conductor by extrusion coating a resin composition. The resin composition is a mixture of a polyphenylene sulfide-based resin (A) and a polyamide-based resin (B), in which a ratio of parts by mass of the resin (B) to that of the resin (A), i.e. (B)/(A), is not less than 5/95 and not more than 30/70.