CN108666023A - 耐电晕扁平铜电磁线及其制备方法 - Google Patents
耐电晕扁平铜电磁线及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种耐电晕扁平铜电磁线,属于电磁线技术领域,其技术方案要点是其内层为铜扁线导体,铜扁线导体外涂覆有四层漆膜,由内至外依次为粘结层、聚酯亚胺耐电晕绝缘层、聚酰胺酰亚胺耐电晕绝缘层以及自润滑层;所述粘结层、聚酯亚胺耐电晕绝缘层、聚酰胺酰亚胺耐电晕绝缘层以及自润滑层的厚度比分别为1:3:4:1;所述粘结层包括有机硅改性聚酯漆,解决了绝缘层与铜丝的附着力差、易脱落的技术问题,达到了能够提高绝缘层的附着性以减少其脱落及破损的技术效果。
Description
技术领域
本发明涉及电磁线技术领域,特别涉及一种耐电晕扁平铜电磁线及其制备方法。
背景技术
随着电子技术及新型半导体器件的迅速发展,交流调速技术得到不断的完善和提高,逐步完善的变频器以其良好的输出波形、优异的性能价格比在交流电机上得到广泛应用,但是使用普通电磁线的变频电机在工作时发生的局部放电与过热会对漆膜产生严重的破坏,易使匝间击穿,缩短其使用寿命,而提高电磁线的耐电晕性能,是延长变频电机的使用寿命的主要途径,因此交流电机需要使用耐电晕电磁线漆。
现有技术可参考授权公告号为CN101958158B的中国专利,其公开了一种耐电晕漆包线的制备方法及产品,该方法包括以下步骤:拉丝、放线、清洗、退火、冷却、涂漆、烘焙、润滑以及收线;先将裸线表面涂覆4道聚酯耐电晕漆,再涂覆7道聚酯亚胺耐电晕漆,最后涂覆2道聚酰胺酰亚胺漆,每道涂漆后进行烘焙、冷却,再进行下一道涂漆;烘焙时从烘炉下层通过上层,烘炉入口温度155土5℃,烘炉下层温度260土5℃,一次催化前温度370土5℃,催化后补充加热温度470土5℃。
在现有技术中,为了提高绝缘层的耐电晕性,在绝缘层中需要使用聚酯亚胺耐电晕漆以提高绝缘层的耐电晕,但是相较于聚酯漆,其柔韧性以及附着力较差,因此在涂覆和绕线的过程中漆膜易破损甚至脱落,不能发挥漆膜的耐电晕的优点,因此如何能够提高绝缘层的附着性是一个需要解决的问题。
发明内容
本发明的目的之一在于提供一种耐电晕扁平铜电磁线,其在耐电晕层与铜线之间涂覆的粘结层能够增强耐电晕层与铜丝的附着力,在耐电晕层的外层涂覆自润滑层,使漆膜在具有耐电晕性能的同时还能增强其润滑性、柔韧性以及耐磨性,从而提高了耐电晕扁平铜电磁线的整体性能。
本发明的上述技术目的是通过以下技术方案得以实现的:
一种耐电晕扁平铜电磁线,内层为铜扁线导体,其特征在于:铜扁线导体外涂覆有四层漆膜,由内至外依次为粘结层、聚酯亚胺耐电晕绝缘层、聚酰胺酰亚胺耐电晕绝缘层以及自润滑层;所述粘结层、聚酯亚胺耐电晕绝缘层、聚酰胺酰亚胺耐电晕绝缘层以及自润滑层的厚度比分别为1:3:4:1;所述粘结层包括有机硅改性聚酯漆。
通过采用上述方案,在耐电晕绝缘漆涂覆铜扁线前,先涂覆附着性好的有机硅改性聚酯漆,能够提高耐电晕绝缘层与导线的附着性,由于有机硅改性聚酯漆具有优良的电绝缘性、耐热性、低温固化性、浸渍干燥性、漆膜均匀致密性以及防潮性,因此可用作发电机材料上;由于聚酯亚胺的弹性较差,而聚酰胺酰亚胺的柔韧性较好,因此在漆膜成中需要适当的增加聚酰胺酰亚胺的厚度,以提高其漆膜的柔韧性以及耐刮性,在电磁线拉伸的过程中,耐电晕绝缘层能够随之拉伸,从而实现电磁线后不缩漆的高附着性能。
较佳的,以重量份数计,所述自润滑层包括聚酰亚胺100份、聚四氟乙烯4-6份、玻璃纤维2-4份、纳米二氧化硅1-2份、氧化锌2-4份以及6-8份二甲苯。
通过采用上述方案,自润滑层能够增加漆膜的润滑性,降低漆膜表面的摩擦系数,减少其因摩擦引起的磨损,并且自润滑层能够增加漆膜的耐磨性、耐刮性以及柔韧性,从而改善了耐电晕绝缘层的耐磨性差的缺陷;聚酰亚胺作为高分子基自润滑材料,具有韧性好、低温性能好、化学稳定性好、电绝缘性能优良的特点,其中加入的聚四氟乙烯能够提高其润滑性;玻璃纤维绝缘性好、耐热性强、抗腐蚀性好、机械强度高,能够增加漆膜的硬度;纳米二氧化硅能够提高其强度以及表面硬度,并且纳米材料具有良好的塑性以及韧性,二氧化硅可改善涂料的悬浮稳定性差、触变性差、耐候性差,可以使漆膜与导体的结合强度大幅提高,提高漆膜表面的硬度以及表面自洁能力;氧化锌可用作粘结剂,主要用作电线的补强剂,能够提高漆膜的耐腐蚀性以及弹性;二甲苯作为常用的有机溶剂,用于自润滑电磁线漆中的各个组分的分散,有利于提高各个组分的稳定性,提高漆膜的性能。
较佳的,以重量份数计,所述自润滑层包括聚酰亚胺100份、聚四氟乙烯5份、玻璃纤维3份、纳米二氧化硅1.5份、氧化锌3份以及7份二甲苯。
通过采用上述方案,自润滑层的各个组分通过上述配比,相互协同发挥其性能的优势,以赋予漆膜层优异的性能。
较佳的,漆膜总厚度为0.12-0.14mm。
通过采用上述方案,漆膜总厚度为0.12-0.14mm,保证耐电晕层能够达到最佳的耐电晕性能,同时粘结层增强耐电晕层与铜丝的附着力,通过自润滑层增强其表面的硬度、柔韧性以及耐磨性。
较佳的,玻璃纤维的长度为4±1mm,纤度为0.6±0.2D。
通过采用上述方案,玻璃纤维的长度为4±1mm,纤度为0.6±0.2D,有利于玻璃纤维在溶剂中的分散。
较佳的,纳米二氧化硅的粒径为30±5nm。
通过采用上述方案,纳米二氧化硅的粒径为30±5nm,有利于其在溶剂中的分散,从而能够均匀分散于聚酰亚胺中,以发挥其性能优势。
本发明的目的之二在于提供一种耐电晕扁平铜电磁线的制备方法。
本发明的上述技术目的是通过以下技术方案得以实现的:
耐电晕扁平铜电磁线的制备方法,包括以下步骤:
(1)拉丝:将铜杆拉制成所需规格的裸铜丝;
(2)放线:将检验合格的裸铜丝放置在放线架陶瓷圈垂直下方;
(3)清洗:将裸铜丝引至清洗水箱处,用处理好的清洗水将规格丝表面的油污清洗干净;
(4)退火:将清洗后的裸铜丝从退火炉上层通过下层退火,退火炉上层温度540±5℃,下层温度550±5℃,保温温度60-80min;
(5)冷却:用鼓风机将退火后的铜丝冷却,使其达到所要求的温度;
(6)涂漆、烘焙:先将铜丝表面涂覆2道有机硅改性聚酯漆,采用涂漆模具依次涂覆,逐道烘烤固化形成粘结层;再涂覆3道聚酯亚胺耐电晕漆,逐道烘烤固化形成聚酯亚胺耐电晕绝缘层;再涂覆4道聚酰胺酰亚胺耐电晕漆,采用涂漆模具依次涂覆,逐道烘烤固化形成聚酰胺酰亚胺耐电晕绝缘层;最后再涂覆2道自润滑电磁线漆,逐道烘烤固化形成自润滑层;
(7)收线:将制作好的电磁线绕盘具上。
通过采用上述方案,在铜丝的外层依次涂覆粘结层、耐电晕层以及自润滑层,增强耐电晕层与铜丝的附着性,降低其在使用的过程中发生脱落的情况,在耐电晕层的外层涂覆的自润滑层能够增强漆膜的润滑性以及耐磨性,减少其在绕线的过程中发生破损,从而能够最大程度地发挥耐电晕层的耐电晕的作用。
较佳的,所述铜杆为电工韧铜杆。
通过采用上述方案,电工韧铜杆相较于无氧铜杆有更好的退火功能,电工韧铜晶粒较为均匀、细小,为明显的再结晶组织,能在较低的能耗下实现软化的目的。
综上所述,本发明具有以下有益效果:
在铜丝的外层依次涂覆粘结层、聚酯亚胺耐电晕层、聚酰胺酰亚胺耐电晕层以及自润滑层,增强耐电晕层与铜丝的附着性,降低其在使用的过程中发生脱落的情况,在耐电晕层的外层涂覆的自润滑层能够增强漆膜的润滑性以及耐磨性,减少其在绕线的过程中发生破损,从而能够最大程度地发挥耐电晕层的耐电晕的作用。
具体实施方式
以下对本发明作进一步详细说明。
一、实施例1-3
实施例1:一种耐电晕扁平铜电磁线采用如下方法制备而得:
(1)拉丝:将电工韧铜杆拉制成所需规格的裸铜丝;
(2)放线:将检验合格的裸铜丝放置在放线架陶瓷圈垂直下方;
(3)清洗:将裸铜丝引至清洗水箱处,用处理好的清洗水将规格丝表面的油污清洗干净;
(4)退火:将清洗后的裸铜丝从退火炉上层通过下层退火,退火炉上层温度540℃,下层温度550℃,保温温度70min;
(5)冷却:用鼓风机将退火后的铜丝冷却,使其达到所要求的温度;
(6)涂漆、烘焙:先将铜丝表面涂覆2道有机硅改性聚酯漆,采用涂漆模具依次涂覆,逐道烘烤固化形成粘结层;再涂覆3道聚酯亚胺耐电晕漆,逐道烘烤固化形成聚酯亚胺耐电晕绝缘层;再涂覆4道聚酰胺酰亚胺耐电晕漆,采用涂漆模具依次涂覆,逐道烘烤固化形成聚酰胺酰亚胺耐电晕绝缘层;最后再涂覆2道自润滑电磁线漆,逐道烘烤固化形成自润滑层;其中漆膜总厚度为0.13mm,粘结层、聚酯亚胺耐电晕绝缘层、聚酰胺酰亚胺耐电晕绝缘层以及自润滑层的厚度分别为0.014mm、0.044mm、0.058mm、0.014mm;自润滑层包括聚酰亚胺100kg、聚四氟乙烯5kg、玻璃纤维3kg、纳米二氧化硅1.5kg、氧化锌3kg以及7kg二甲苯;玻璃纤维的长度为4±1mm,纤度为0.6±0.2D;纳米二氧化硅的粒径为30±5nm。
(7)收线:将制作好的电磁线绕盘具上。
实施例2:一种耐电晕扁平铜电磁线采用如下方法制备而得:
(1)拉丝:将电工韧铜杆拉制成所需规格的裸铜丝;
(2)放线:将检验合格的裸铜丝放置在放线架陶瓷圈垂直下方;
(3)清洗:将裸铜丝引至清洗水箱处,用处理好的清洗水将规格丝表面的油污清洗干净;
(4)退火:将清洗后的裸铜丝从退火炉上层通过下层退火,退火炉上层温度535℃,下层温度545℃,保温温度80min;
(5)冷却:用鼓风机将退火后的铜丝冷却,使其达到所要求的温度;
(6)涂漆、烘焙:先将铜丝表面涂覆2道有机硅改性聚酯漆,采用涂漆模具依次涂覆,逐道烘烤固化形成粘结层;再涂覆3道聚酯亚胺耐电晕漆,逐道烘烤固化形成聚酯亚胺耐电晕绝缘层;再涂覆4道聚酰胺酰亚胺耐电晕漆,采用涂漆模具依次涂覆,逐道烘烤固化形成聚酰胺酰亚胺耐电晕绝缘层;最后再涂覆2道自润滑电磁线漆,逐道烘烤固化形成自润滑层;其中漆膜总厚度为0.12mm,粘结层、聚酯亚胺耐电晕绝缘层、聚酰胺酰亚胺耐电晕绝缘层以及自润滑层的厚度分别为0.013mm、0.041mm、0.053mm、0.013mm;自润滑层包括聚酰亚胺100kg、聚四氟乙烯4kg、玻璃纤维2kg、纳米二氧化硅1kg、氧化锌2kg以及6kg二甲苯;玻璃纤维的长度为4±1mm,纤度为0.6±0.2D;纳米二氧化硅的粒径为30±5nm。
(7)收线:将制作好的电磁线绕盘具上。
实施例3:一种耐电晕扁平铜电磁线采用如下方法制备而得:
(1)拉丝:将电工韧铜杆拉制成所需规格的裸铜丝;
(2)放线:将检验合格的裸铜丝放置在放线架陶瓷圈垂直下方;
(3)清洗:将裸铜丝引至清洗水箱处,用处理好的清洗水将规格丝表面的油污清洗干净;
(4)退火:将清洗后的裸铜丝从退火炉上层通过下层退火,退火炉上层温度545℃,下层温度555℃,保温温度60min;
(5)冷却:用鼓风机将退火后的铜丝冷却,使其达到所要求的温度;
(6)涂漆、烘焙:先将铜丝表面涂覆2道有机硅改性聚酯漆,采用涂漆模具依次涂覆,逐道烘烤固化形成粘结层;再涂覆3道聚酯亚胺耐电晕漆,逐道烘烤固化形成聚酯亚胺耐电晕绝缘层;再涂覆4道聚酰胺酰亚胺耐电晕漆,采用涂漆模具依次涂覆,逐道烘烤固化形成聚酰胺酰亚胺耐电晕绝缘层;最后再涂覆2道自润滑电磁线漆,逐道烘烤固化形成自润滑层;其中漆膜总厚度为0.14mm,粘结层、聚酯亚胺耐电晕绝缘层、聚酰胺酰亚胺耐电晕绝缘层以及自润滑层的厚度分别为0.015mm、0.047mm、0.063mm、0.015mm;自润滑层包括聚酰亚胺100kg、聚四氟乙烯6kg、玻璃纤4kg、纳米二氧化硅2kg、氧化锌4kg以及8kg二甲苯;玻璃纤维的长度为4±1mm,纤度为0.6±0.2D;纳米二氧化硅的粒径为30±5nm。
(7)收线:将制作好的电磁线绕盘具上。
二、对比例1-3
对比例1:采用授权公告号为CN101958158B的中国专利,其公开了一种耐电晕漆包线的制备方法及产品,该方法包括以下步骤:拉丝、放线、清洗、退火、冷却、涂漆、烘焙、润滑以及收线;先将裸线表面涂覆4道聚酯耐电晕漆,再涂覆7道聚酯亚胺耐电晕漆,最后涂覆2道聚酰胺酰亚胺漆,每道涂漆后进行烘焙、冷却,再进行下一道涂漆;烘焙时从烘炉下层通过上层,烘炉入口温度155土5℃,烘炉下层温度260土5℃,一次催化前温度370土5℃,催化后补充加热温度470土5℃。
对比例2:采用授权公告号为CN101325102B的中国专利,其公开了一种变频漆包线的生产工艺,工艺步骤如下:(1)放线;(2)拉丝;(3)清洗;(4)退火;(5)冷却;(6)涂漆、烘焙、冷却;先将规格丝表面涂覆10道变频聚酯漆,再涂覆3道聚酰胺酰亚胺漆,每道涂漆后进行烘焙、冷却、再进行下道涂漆,烘焙时从烘炉下层通过上层,烘炉入口温度220C℃,烘炉下层温度330℃,一次催化前温度430℃,催化后补充加热温度470℃;(7)润滑;(8)收线。
对比例3:采用申请公布号为CN105976924A的专利申请文件,其公开了一种自润滑耐电晕复合漆包线,漆包线由三部分构成,第一层为耐电晕绝缘漆,为变频电机的核心层,中间为聚酰胺酰亚胺漆,外层为具有自润滑耐磨功能的绝缘漆。
三、以尺寸为宽边1.530-1.610mm、窄边0.800-0.860mm的铜扁线为例,将实施例1-3以及对比例1-3制备的电磁线的性能进行测试,测试结果如表1所示。
表1实施例1-3以及对比例1-3制备的电磁线的性能测试表
由以上数据可以看出,本发明制备的耐电晕扁平铜电磁线的耐电晕性能优良,符合标准值,此外漆膜的附着力较佳,能够减少其在使用过程中的脱落情况,并且热冲击测试中无开裂现象,说明其在使用过程中不易破损。
本具体实施例仅仅是对本发明的解释,其并不是对本发明的限制,本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改,但只要在本发明的权利要求范围内都受到专利法的保护。
Claims (8)
1.一种耐电晕扁平铜电磁线,内层为铜扁线导体,其特征在于:铜扁线导体外涂覆有四层漆膜,由内至外依次为粘结层、聚酯亚胺耐电晕绝缘层、聚酰胺酰亚胺耐电晕绝缘层以及自润滑层;
所述粘结层、聚酯亚胺耐电晕绝缘层、聚酰胺酰亚胺耐电晕绝缘层以及自润滑层的厚度比分别为1:3:4:1;
所述粘结层包括有机硅改性聚酯漆。
2.根据权利要求1所述的耐电晕扁平铜电磁线,其特征在于:以重量份数计,所述自润滑层包括聚酰亚胺100份、聚四氟乙烯4-6份、玻璃纤维2-4份、纳米二氧化硅1-2份、氧化锌2-4份以及6-8份二甲苯。
3.根据权利要求2所述的耐电晕扁平铜电磁线,其特征在于:以重量份数计,所述自润滑层包括聚酰亚胺100份、聚四氟乙烯5份、玻璃纤维3份、纳米二氧化硅1.5份、氧化锌3份以及7份二甲苯。
4.根据权利要求1所述的耐电晕扁平铜电磁线,其特征在于:漆膜总厚度为0.12-0.14mm。
5.根据权利要求1所述的耐电晕扁平铜电磁线,其特征在于:玻璃纤维的长度为4±1mm,纤度为0.6±0.2D。
6.根据权利要求1所述的耐电晕扁平铜电磁线,其特征在于:纳米二氧化硅的粒径为30±5nm。
7.耐电晕扁平铜电磁线的制备方法,其特征在于:包括以下步骤:
(1)拉丝:将铜杆拉制成所需规格的裸铜丝;
(2)放线:将检验合格的裸铜丝放置在放线架陶瓷圈垂直下方;
(3)清洗:将裸铜丝引至清洗水箱处,用处理好的清洗水将规格丝表面的油污清洗干净;
(4)退火:将清洗后的裸铜丝从退火炉上层通过下层退火,退火炉上层温度540±5℃,下层温度550±5℃,保温温度60-80min;
(5)冷却:用鼓风机将退火后的铜丝冷却,使其达到所要求的温度;
(6)涂漆、烘焙:先将铜丝表面涂覆2道有机硅改性聚酯漆,采用涂漆模具依次涂覆,逐道烘烤固化形成粘结层;再涂覆3道聚酯亚胺耐电晕漆,逐道烘烤固化形成聚酯亚胺耐电晕绝缘层;再涂覆4道聚酰胺酰亚胺耐电晕漆,采用涂漆模具依次涂覆,逐道烘烤固化形成聚酰胺酰亚胺耐电晕绝缘层;最后再涂覆2道自润滑电磁线漆,逐道烘烤固化形成自润滑层;
(7)收线:将制作好的电磁线绕盘具上。
8.根据权利要求7所述的耐电晕扁平铜电磁线的制备方法,其特征在于:所述铜杆为电工韧铜杆。
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CN114628078A (zh) * | 2021-12-31 | 2022-06-14 | 露笑科技股份有限公司 | 一种抗剥离性能优良的电磁线的制备方法 |
CN117965106A (zh) * | 2024-04-02 | 2024-05-03 | 天蔚蓝电驱动科技(江苏)有限公司 | 耐电晕绝缘膜及其制备方法、电磁线及其制备方法 |
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