Laminated Insulated Wire Coating for Crack-Resistant Coil Winding
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Solution Overview
Problem
Conventional insulated wires with rectangular conductors face issues of brittle corners during coil processing, leading to cracked coatings and insufficient insulation, which affects dielectric strength and mechanical properties, especially when space factor requirements necessitate thicker insulating layers.
Innovation Solution
The insulated wire features a laminated insulating coated film with a thick enamel layer and a thinner extruded layer, where the thickness and relative permittivity ratios are optimized to enhance dielectric strength, mechanical characteristics, and heat resistance, using specific thermosetting and thermoplastic resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the insulating coated film is increased to improve insulation performance, then the dielectric strength is improved, but the mechanical characteristics deteriorate due to cracking of the coated film during coil processing
Solution Approach 1:
The insulating coated film is divided into multiple layers: an inner enamel insulating layer and an outer extruded insulating layer. This segmentation allows each layer to have different thicknesses and material properties, enabling the inner layer to provide mechanical flexibility during coil processing while the outer layer provides enhanced insulation performance.
Solution Approach 2:
Different regions of the insulating coated film have different thicknesses and material compositions. The enamel layer closer to the conductor has optimized thickness for mechanical flexibility, while the extruded layer provides additional insulation. This local variation in quality allows simultaneous achievement of mechanical strength and dielectric strength.
2Reliability
If the thickness of the enamel insulating layer is increased to improve heat resistance and insulation property, then the insulation property against external damage is enhanced, but the dielectric strength deteriorates due to excessive thickness of single layer
Solution Approach 1:
The thick insulating coated film is segmented into multiple layers with the enamel layer forming the inner portion and the extruded layer forming the outer portion. This segmentation allows the total thickness to exceed 100 μm while maintaining dielectric strength, as each individual layer remains within the optimal thickness range.
Solution Approach 2:
The insulating coated film uses a composite structure combining enamel resin and extruded resin materials. This composite material approach allows the system to achieve both high heat resistance from the enamel layer and high dielectric strength through the combined structure, overcoming the limitations of single-material single-layer designs.
Data Source
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Figure 3
AI summary
An insulated wire, containing: a conductor having a rectangular cross-section; and an insulating coated film having at least two insulating layers laminated together on the conductor, wherein the laminated insulating coated film is composed of: an enamel insulating layer formed from a thermosetting resin on the outer periphery of the conductor, and an extruded insulating layer formed from a thermoplastic resin on the outer side of the enamel insulating layer, wherein the thickness of the enamel insulating layer is 50 µm or more, and wherein the total thickness (T) and the relative permittivity (ε) at 100°C of the laminated insulating coated film; and the maximum thickness (Tmax), and the maximum value (emax) and the minimum value (εmin) of the relative permittivity at 100°C of one layer among the laminated insulating layers; satisfy all of the following relations: T≧100μm Tmax≦100μm 1.5≦ε≦3.5 1.0≦εmax/εmin≦1.2 a coil; and an electrical or electronic equipment.