Insulated Wire with Microporous Varnish for High PDIV
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Solution Overview
Problem
Next-generation electric vehicle motors require insulated electric wires with improved partial discharge inception voltage (PDIV) due to higher voltages, but existing methods to lower the dielectric constant of varnish compromise adhesion, heat resistance, and mechanical properties.
Innovation Solution
Incorporating a varnish with evenly dispersed micropores of 3.14×10−6 mm2 or less cross-sectional area into the insulating layer, maintaining low dielectric constant while enhancing PDIV, achieved by using a solvent and polyamic acid mixture with specific viscosity and surface tension, and ensuring thermal and mechanical stability through controlled thermal decomposition and pore formation methods.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the dielectric constant of the varnish is lowered by using fluorine-containing monomers or reducing polarity, then the PDIV is improved, but the adhesion, heat resistance, and mechanical properties deteriorate
Solution Approach 1:
The patent introduces micropores (0.1-10 μm) into the varnish layer to create a porous insulating material structure. These micropores reduce the dielectric constant and improve PDIV while the continuous polymer matrix maintains adhesion and mechanical strength. The porous structure allows the material to achieve low dielectric constant without compromising other critical properties.
Solution Approach 2:
The patent creates a composite varnish structure combining polymer base material with dispersed micropores. This composite approach allows the solid polymer matrix to provide mechanical strength and adhesion, while the micropore phase reduces dielectric constant and enhances PDIV performance, achieving multiple property optimization simultaneously.
2Reliability
If the dielectric constant is reduced to improve PDIV, then the insulating performance is enhanced, but the thermal and mechanical stability is compromised
Solution Approach 1:
The microporous structure reduces dielectric constant and improves insulating performance while the small pore size (0.1-10 μm) and continuous matrix structure maintain thermal and mechanical stability. The porous design allows insulation enhancement without sacrificing structural integrity.
Solution Approach 2:
The patent applies local quality by creating micropores distributed within the varnish layer rather than uniformly changing the entire material composition. This localized porous structure improves insulating performance in specific regions while the overall material maintains its thermal and mechanical stability through the continuous polymer matrix.
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 increases PDIV without sacrificing thermal and mechanical properties, enabling the use of insulated electric wires in next-generation electric vehicle motors operating at higher voltages.
Implementation Method 1
a plurality of micropores with a cross-sectional area of 3.14×10−6 mm2 or less are evenly dispersed inside a varnish used as an insulating material, thereby a dielectric constant is lowered and a partial discharge inception voltage (PDIV) is improved
Data Source
AI summary
The present disclosure relates to an insulated electric wire, and more particularly, to an insulated electric wire that has characteristics of a low dielectric constant and a high partial discharge inception voltage (PDIV) by forming a plurality of micropores inside insulating material of an insulating layer. According to the present disclosure, the insulated electric wire may have the plurality of micropores evenly dispersed inside the insulating material of the insulating layer to have the low dielectric constant without lowering the thermal and mechanical properties and increase the PDIV, so the insulated electric wire can be used as the insulated electric wire for the next-generation electric vehicle motors that use a higher voltage than the existing voltage.