CN111883289B - Insulated wire, method for manufacturing same, and coil or winding - Google Patents
Insulated wire, method for manufacturing same, and coil or winding Download PDFInfo
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- CN111883289B CN111883289B CN202010605328.1A CN202010605328A CN111883289B CN 111883289 B CN111883289 B CN 111883289B CN 202010605328 A CN202010605328 A CN 202010605328A CN 111883289 B CN111883289 B CN 111883289B
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/22—Sheathing; Armouring; Screening; Applying other protective layers
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/04—Flexible cables, conductors, or cords, e.g. trailing cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
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Abstract
The application provides an insulated wire, which comprises a wire core and a metal oxide insulating layer coated on the periphery of the wire core; or comprises a wire core, and an intermediate layer and a metal oxide insulating layer which are sequentially coated on the periphery of the wire core; the material of the wire core comprises Cu, Al, Ag or alloy thereof; the intermediate layer comprises single substances of Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo and Cu or an alloy containing one or more metal elements, and the material of the intermediate layer is different from that of the wire core; the metal oxide insulating layer comprises an oxide of one or more metal elements of Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo and Cu. The insulated wire has good high-temperature insulation performance and bending resistance performance by arranging the metal oxide insulating layer at the periphery of the wire core. The insulated wire is used for preparing devices, and can also reduce the difficulty and cost of device assembly. The application also provides a coil or winding and a magnetic component comprising the coil or winding.
Description
Technical Field
The application relates to the technical field of electromagnetic wires, in particular to an insulated wire, a manufacturing method thereof and a coil or winding.
Background
Magnet wires are insulated wires used to make coils or windings in electrical products. The structure of an electromagnetic wire generally includes a conductive core and an electrically insulating layer surrounding the conductive core. At present, the electrical insulating layer mainly includes two types of organic insulating layers and inorganic insulating layers. The existing organic insulating layer is usually made of organic polymer materials such as paper, cotton, silk, glass fiber, resin or insulating paint; the conventional inorganic insulating layer is generally made of Al2O3、SiO2And ZnO and other ceramic materials are mixed with an organic solvent to form slurry and then coated on the surface of the wire core. However, the maximum working temperature of the existing electromagnetic wire adopting the organic insulating layer is generally less than 260 ℃, performance reduction or failure can occur during over-temperature use, and the high-temperature insulation requirement is difficult to meet; the existing inorganic ceramic insulated wire has the defects of large bending radius, no bending resistance and the like, and is not suitable for coating a pure copper wire. Therefore, there is a need for an insulated wire having both good high temperature insulation and good bending resistance.
Disclosure of Invention
The embodiment of the application provides an insulated wire, and the insulated wire has good high-temperature insulating property and bending resistance by arranging a metal oxide insulating layer formed by in-situ oxidation of a metal simple substance or an alloy material on the periphery of a wire core, so that the technical problems that the existing organic insulating layer wire is poor in high-temperature insulating property and an inorganic ceramic insulated wire is not bending-resistant are solved to a certain extent.
The first aspect of the embodiments of the present application provides an insulated wire, which includes a wire core and a metal oxide insulating layer coated on the periphery of the wire core; or the insulated wire comprises a wire core, an intermediate layer coated on the periphery of the wire core and a metal oxide insulating layer coated on the periphery of the intermediate layer;
the material of the wire core comprises Cu, Al or Ag; the intermediate layer comprises single substances of Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo and Cu or an alloy containing one or more metal elements; the material of the intermediate layer is different from that of the wire core; the metal oxide insulating layer comprises an oxide of one or more metal elements of Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo and Cu. In the insulated wire of the embodiment of the application, the metal oxide insulating layer is formed by in-situ oxidation of the intermediate layer material arranged at the periphery of the wire core, is tightly combined with the wire core, is not easy to fall off, has good bending resistance and is suitable for preparing the coil winding; meanwhile, the metal oxide insulating layer has good high-temperature insulating property, and the insulated wire is used for preparing devices and can effectively improve the working temperature of the devices.
In an embodiment of the present invention, the material of the metal oxide insulating layer includes one or more of nickel oxide, niobium oxide, chromium oxide, iron oxide, aluminum oxide, zirconium oxide, titanium oxide, vanadium oxide, tungsten oxide, molybdenum oxide, and copper oxide. The material of the metal oxide insulating layer depends on the material of the intermediate layer, which is the oxidized product of the intermediate layer material. When the intermediate layer material is a simple substance, the material of the metal oxide insulating layer is an oxide of the simple substance metal element; when the intermediate layer is made of an alloy, the metal oxide insulating layer is made of a combination of oxides of the metal elements in the alloy. For example, if the material of the intermediate layer is niobium, the metal oxide insulating layer is niobium oxide; the intermediate layer is made of stainless steel, and the metal oxide insulating layer is a stainless steel oxide layer and comprises the combination of oxides of various metal elements of the stainless steel.
In the embodiment of the application, the metal element composition of the metal oxide insulating layer is different from the metal element composition of the wire core.
In an embodiment of the present application, when the material of the wire core is Cu, Al, or Ag simple substance, and the metal oxide insulating layer includes the same metal element as the wire core, the metal oxide insulating layer includes at least two kinds of metal oxides.
In the embodiment of the present application, when the material of the wire core is Cu, Al, or Ag simple substance, and the metal oxide insulating layer contains the same metal element as the wire core, the mass content of the metal element, which is the same as the wire core, in the metal oxide insulating layer accounts for less than or equal to 80% of the total mass content of the metal element.
In the embodiment of the present application, the thickness of the metal oxide insulating layer is 1 μm to 300 μm. In some embodiments of the present application, the metal oxide insulating layer has a thickness of 3 μm to 300 μm. The arrangement of the metal oxide insulating layer with proper thickness can obtain better insulating performance and maintain the insulating stability.
In the embodiment of the application, when the material of the wire core is Cu, Al or Ag simple substance, and the intermediate layer includes the same metal element as the wire core, the content of the metal element in the intermediate layer, which is the same as the wire core, is less than or equal to 80%.
In an embodiment of the present application, the melting point of the intermediate layer is greater than or equal to 600 ℃.
In an embodiment of the present application, the thickness of the intermediate layer is greater than 0 and less than or equal to 2 μm. Specifically, the thickness may be 0.01 μm to 2 μm.
In an embodiment of the present application, the thickness of the metal oxide insulating layer is greater than or equal to the thickness of the intermediate layer.
In an embodiment of the present application, the metal oxide insulating layer is formed by oxidizing the interlayer material.
In the embodiment of the application, the diameter of the insulated wire is 0.05mm-150 mm. The insulated conductor may be a single core conductor or a multiple core conductor.
In the embodiment of the present application, the breakdown voltage of the winding made of the insulated conductive wire at 500 ℃ or higher is 20V to 2000V.
In the embodiment of the application, the insulated wire is terminated by a metal sheet.
A second aspect of the embodiments of the present application provides a method for manufacturing an insulated wire, including:
forming a metal simple substance or an alloy layer at the periphery of the wire core in a physical or chemical mode to obtain a semi-finished product; the material of the wire core comprises Cu, Al, Ag or alloy thereof; the metal simple substance or the alloy layer comprises Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo and Cu simple substances or an alloy containing one or more metal elements;
and carrying out in-situ oxidation treatment on the semi-finished product in an oxidizing atmosphere to oxidize part or all of the metal simple substance or the alloy layer, forming a metal oxide insulating layer on the oxidized part, and forming an intermediate layer on the unoxidized part to obtain the insulated wire.
In the embodiment of the application, the oxidizing atmosphere comprises air, oxygen, water vapor, mixed gas of water vapor and ethanol, or mixed gas of water vapor and carbon dioxide, and the temperature of the oxidizing treatment is 300-900 ℃.
In the embodiments of the present application, the physical or chemical means includes one or more of a tube coating method, a magnetron sputtering method, an electroplating method, a vapor deposition method, a hot dipping method, and a coating method.
In the embodiment of the application, a metal simple substance or an alloy layer is formed on the periphery of a wire core by adopting a tube coating method to obtain a semi-finished product, and the specific operations comprise:
extruding the metal simple substance or alloy layer material into a metal simple substance or alloy sleeve;
sleeving a wire core bar into the metal simple substance or the alloy sleeve to extrude into a composite bar;
and annealing and drawing the composite bar to obtain the semi-finished product.
In the embodiment of the application, after the composite bar is annealed, the HB hardness of a metal simple substance or an alloy sleeve positioned on the outer side of the composite bar is 50-200.
A third aspect of embodiments of the present application provides a coil or winding comprising an insulated conductor as described in the first aspect of embodiments of the present application. The breakdown voltage of the coil or winding is 20V-2000V. The insulated wire provided by the embodiment of the application is wound around a magnetic material in a coil or winding form, generates a magnetic field when current is introduced, and can be applied to various devices which change power density by using the magnetic field, such as inductors, motors, electromagnets, speakers, motors, transformers, loop antennas and the like.
A fourth aspect of the embodiments of the present application provides a magnetic component, including the coil or winding according to the third aspect of the present application. The magnetic components comprise an inductor, a motor, an electromagnet, a loudspeaker, a motor, a transformer or a loop antenna and the like.
The embodiment of the present application further provides a terminal, which includes the magnetic component described in the fourth aspect of the present application.
The insulated wire provided by the embodiment of the application is suitable for coating wire cores made of various materials by arranging the metal oxide insulating layer formed by in-situ oxidation of a metal simple substance or an alloy material on the periphery of the wire cores. The insulated wire can keep the conductive capability of the wire core, has good high-temperature insulation performance and working temperature of more than 500 ℃, and the breakdown voltage of the winding can reach 20V-2000V; meanwhile, the insulated wire has good bending resistance, can be used for preparing coils and windings, and effectively prevents the damage of the insulating layer of the wire in the practical application process (winding); in addition, the insulated wire can be annealed at high temperature together with the magnetic material before the metal oxide insulating layer is formed, and oxidation and assembly are completed simultaneously, so that the assembly difficulty and cost can be greatly reduced, the production efficiency is improved, and the insulated wire is suitable for large-scale mass production.
Drawings
Fig. 1 is a schematic cross-sectional view of an insulated conductor according to an embodiment of the present application;
FIG. 2 is a schematic cross-sectional view of an insulated conductor according to another embodiment of the present application;
FIG. 3 is a flow chart of a method for manufacturing an insulated conductor according to an embodiment of the present application;
fig. 4 is a schematic flow chart of a process for preparing an insulated conductor semi-finished product by using a tube cladding method provided by an embodiment of the application.
Detailed Description
The embodiments of the present application will be described below with reference to the drawings.
In order to solve the technical problems that the high-temperature insulation performance of the existing organic insulation layer wire is poor, and the inorganic ceramic insulation wire is not resistant to bending, the embodiment of the application provides an insulation wire with good high-temperature insulation performance and bending resistance.
Referring to fig. 1, an embodiment of the present application provides an insulated wire 10, and a cross section of the insulated wire 10 includes, from inside to outside, a wire core 11, an intermediate layer 12 covering the wire core 11, and a metal oxide insulation layer 13 covering the intermediate layer 12. The metal oxide insulating layer 13 is formed in situ on the surface of the intermediate layer 12, specifically by in situ oxidation of the intermediate layer material.
In the embodiment of the present application, the material of the wire core 11 may be Cu, Al, Ag or an alloy thereof. In some embodiments of the present application, the wire core 11 is a Cu wire core, i.e. a pure copper wire core; in other embodiments, the wire core 11 is an Al wire core, i.e. a pure aluminum wire core; in other embodiments, the wire core 11 may also be an Ag wire core, i.e. a pure silver wire core. In other embodiments, the wire core 11 may also be a copper alloy, an aluminum alloy, or a silver alloy. Among them, the Cu wire core is widely used because of its excellent electrical properties.
In the embodiment of the present application, the insulated wire 10 may be a single core wire as shown in fig. 1, or may be a multi-core wire. When the insulated wire 10 is a single core wire, the diameter of the wire may be 0.05mm to 5mm, and further may be 1mm to 3 mm; when the insulated conductor 10 is a multicore conductor, the diameter of the conductor may be 1.5mm to 150 mm. The diameters of the single core or the multiple cores and the insulated conductor can be specifically set according to different standards as required.
In the embodiment of the present application, the intermediate layer 12 as a part of the wire also needs to satisfy normal operation at high temperature (e.g. above 500 ℃) and have a high melting point, and the intermediate layer 12 needs to undergo extrusion and drawing processes in the wire manufacturing process and also needs to have a high melting point. Specifically, the material of the intermediate layer 12 may be a simple metal or an alloy having a melting point of 600 ℃ or higher. In some embodiments of the present application, the material of the intermediate layer 12 may be a simple metal or an alloy with a melting point greater than or equal to 800 ℃. In other embodiments of the present disclosure, the material of the intermediate layer 12 is a simple metal or an alloy with a melting point greater than or equal to 1000 ℃. In the embodiment of the present application, the simple metal or alloy of the intermediate layer 12 can be oxidized to form a metal oxide having a good high-temperature insulating property. Specifically, the intermediate layer 12 may include simple substances of Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo, Cu, or an alloy containing one or more of the above metal elements. In this embodiment, the material of the intermediate layer 12 may be a simple metal of the above-mentioned metal elements, such as a simple metal of Ni, a simple metal of Nb, a simple metal of Cr, a simple metal of Fe, a simple metal of Al, a simple metal of Zr, a simple metal of Ti, a simple metal of V, a simple metal of W, a simple metal of Mo, or a simple metal of Cu, or an alloy including one or more of the above-mentioned metal elements, and the alloy may specifically be formed by a plurality of metal elements among the above-mentioned metal elements, or by one or more of the above-mentioned metal elements and other metal elements, or by one or more of the above-mentioned metal elements and non-metal elements. The nonmetal element may be, for example, carbon, silicon, nitrogen, or the like. In some embodiments of the present application, the intermediate layer 12 is a Ni alloy layer, a Nb alloy layer, a Cr alloy layer, a Fe alloy layer, an Al alloy layer, a Zr alloy layer, a Ti alloy layer, a V alloy layer, a W alloy layer, a Mo alloy layer, a Cu alloy layer, or a stainless steel layer. In order to meet different high-temperature working requirements, different metal simple substances or alloys can be selected to form the intermediate layer 12 by comprehensively considering the melting point of the metal simple substance or alloy and the high-temperature insulation effect of the metal oxide formed after oxidation.
In some embodiments of the present disclosure, the intermediate layer 12 is made of an alloy, and the total content of the metal elements, i.e., Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo, and Cu, in the alloy is greater than or equal to 50%. In the embodiment of the present application, since the high-temperature insulating property of the oxides of Cu and Fe is relatively low, the total content of Cu and Fe in the intermediate layer 12 can be controlled within 20%.
In the embodiment of the present application, the material of the intermediate layer 12 is different from the material of the core 11. The material difference specifically means that the element composition of the intermediate layer 12 is different from that of the wire core 11. Specifically, when the material of the wire core 11 is a simple substance of Cu, Al or Ag, the material of the intermediate layer 12 may be a simple substance of metal different from that of the wire core 11, or may be an alloy. When the wire core 11 is made of Cu alloy, Al alloy or Ag alloy, the intermediate layer 12 may be made of a simple metal or an alloy having a composition different from that of the wire core 11.
In the embodiment of the application, considering that the high-temperature insulating property of the copper oxide is relatively lower, the aluminum oxide film layer is easy to generate a loose porous structure, and the silver is difficult to oxidize, so the difficulty in the silver oxide layer process is higher, and therefore, when the intermediate layer 12 comprises the same metal elements as the wire core 11, the content of the same metal elements as the wire core 11 in the intermediate layer 12 is less than or equal to 80%. Further, the content of the same metal element as the wire core 11 in the intermediate layer 12 is less than or equal to 60%. Further, the content of the same metal element as the wire core 11 in the intermediate layer 12 is less than or equal to 50%. For example, when the wire core 11 is a Cu wire, if the intermediate layer 12 is a copper-containing alloy, the content of copper element in the copper-containing alloy is controlled to be 80% or less.
In the present embodiment, the metal oxide insulating layer 13 includes an oxide of one or more metal elements of Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo, and Cu. The metal element in the metal oxide insulating layer 13 is determined by the metal element contained in the intermediate layer 12. All the metal elements contained in the metal oxide insulating layer 13 are present in the intermediate layer 12. The intermediate layer 12 contains all the metal elements in the metal oxide insulating layer. The metal oxide insulating layer 13 contains the same metal element as the intermediate layer 12. Of course, when the intermediate layer 12 contains a plurality of metal elements, since the plurality of metal elements of the intermediate layer 12 may be entirely oxidized or may be partially oxidized, the metal oxide insulating layer 13 may contain all the metal elements in the intermediate layer 12 or may contain only a part of the metal elements in the intermediate layer 12. In the present embodiment, the material of the metal oxide insulating layer 13 includes one or more of nickel oxide, niobium oxide, chromium oxide, iron oxide, aluminum oxide, zirconium oxide, titanium oxide, vanadium oxide, tungsten oxide, molybdenum oxide, and copper oxide. In the embodiment of the present application, in the metal oxide insulating layer 13, the total content of the metal elements of Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo, and Cu accounts for 50% or more of the total metal element content. And further may be greater than or equal to 60%. In the embodiment, the metal oxide insulating layer 13 may further include a multi-component composite oxide of two or more metal elements described above. Because the high temperature insulation performance of copper oxide and iron oxide is relatively weak, in some embodiments of the present application, the total copper and iron content in the metal oxide insulation layer may be controlled to be less than 20% of the total mass of the metal elements. Further, the total amount of copper and iron in the metal oxide insulating layer may be controlled to be less than 10% of the total mass of the metal elements.
In the present embodiment, the metal element composition of the metal oxide insulating layer 13 is different from the metal element composition of the wire core 11. In the embodiment, when the material of the wire core 11 is Cu, Al or Ag, if the metal oxide insulating layer 13 contains the same metal element as the wire core 11, the metal oxide insulating layer 13 includes at least two metal oxides. In the embodiment of the present application, when the material of the wire core 11 is Cu alloy, Al alloy or Ag alloy, the material of the intermediate layer 12 may be a simple metal substance, or an alloy having a composition different from that of the wire core 11.
In the embodiment of the application, when the material of the wire core is Cu, Al or Ag simple substance, and the metal oxide insulating layer contains the same metal element as the wire core, the mass content of the metal element in the metal oxide insulating layer, which is the same as the wire core, accounts for less than or equal to 80% of the total mass content of the metal element. Further, the content of the same metal element as the wire core 11 is less than or equal to 60%. Further, the content of the same metal element as the wire core 11 is less than or equal to 50%.
It is understood that when the intermediate layer 12 contains a nonmetallic element, a small amount of a nonmetallic oxide may also be contained in the metal oxide insulating layer 13.
In the present embodiment, the thickness of the metal oxide insulating layer 13 is 1 μm to 300 μm. The metal oxide insulating layer with the appropriate thickness can ensure the insulating property of the insulated wire at high temperature. In some embodiments of the present application, the thickness of the metal oxide insulating layer 13 is 3 μm to 300 μm; in other embodiments of the present application, the thickness of the metal oxide insulating layer 13 is 10 μm to 250 μm; in other embodiments of the present application, the thickness of the metal oxide insulating layer 13 is 30 μm to 200 μm; in other embodiments of the present application, the thickness of the metal oxide insulating layer 13 is 100 μm to 300 μm. The metal oxide insulating layer 13 of this application embodiment is because adopt normal position oxidation to form, can prepare great thickness, and strong with sinle silk 11's cohesion moreover, resistant buckling, and this application embodiment metal oxide insulating layer 13 itself has higher intensity in addition, consequently is difficult for damaging in wire winding process metal oxide insulating layer 13 and drops. In the embodiment of the application, the metal oxide insulating layer 13 can be set to have different thicknesses according to application requirements, and the different thicknesses can correspond to different breakdown voltage requirements.
The insulated wire provided by the embodiment of the application can effectively prevent accidents such as electric leakage, short circuit and electric shock caused by the contact of the conductor body of the wire core and the outside world through the metal oxide insulating layer uniformly and hermetically wrapping a certain thickness on the periphery of the wire core, and the safety and the reliability of the wire are improved.
In the embodiment of the present application, the thickness of the intermediate layer 12 may be greater than 0 and less than or equal to 300 μm. In some embodiments of the present application, the thickness of the intermediate layer 12 may also be in the range of 0.01 μm to 300 μm. In other embodiments of the present application, the thickness of the intermediate layer 12 may also be in the range of 0.1 μm to 50 μm. In other embodiments of the present application, the thickness of the intermediate layer 12 may also be in the range of 0.1 μm to 10 μm. In the embodiment of the present application, the thickness of the intermediate layer 12 may be as small as practicable, and specifically, the thickness of the intermediate layer 12 may be 0.1 μm to 2 μm. In this embodiment, a certain thickness of the intermediate layer 12 is retained, which is easier to achieve in the current process than the solution of fig. 2 of the present application without an intermediate layer at all.
In the embodiment, the thickness of the metal oxide insulating layer 13 is equal to or greater than the thickness of the intermediate layer 12. Since the metal oxide insulating layer 13 is formed by in-situ oxidation of the interlayer material, in order to obtain a metal oxide insulating layer with a larger thickness, the interlayer is oxidized to a thickness of more than 50%, and the metal oxide insulating layer 13 with a final thickness greater than or equal to that of the interlayer 12 is obtained.
In the embodiment of the application, because the metal oxide insulating layer 13 is formed in situ on the surface of the intermediate layer 12, the metal oxide insulating layer 13 can be tightly combined with the intermediate layer 12, the binding force is strong, and the insulated wire 10 is not easy to fall off and damage in the winding process; the intermediate layer 12 can be prepared by tube coating extrusion, magnetron sputtering, electroplating or evaporation, and has strong bonding force with the wire core 11. Moreover, the metal oxide of the metal oxide insulating layer 13 has good high-temperature insulating performance, can have good insulating effect even under the high-temperature condition of more than 500 ℃, can keep good adhesive force, and can meet the application of higher working temperature requirement.
Referring to fig. 2, the cross section of the insulated conductor 10 in another embodiment of the present application includes, from inside to outside, a core 11 and a metal oxide insulation layer 13 covering the core 11. I.e. the intermediate layer 12 in fig. 1 has been fully oxidized to form a metal oxide. In this embodiment, the intermediate layer 12 is not present, and the insulated conductor can have a core with a larger diameter under the same diameter, so as to better ensure the conductivity of the core.
In the embodiment of the application, the metal oxide insulating layer 13 and the wire core 11 are tightly combined together, so that the bonding force is strong, and the insulated wire 10 is not easy to fall off and damage in the winding process; moreover, the metal oxide of the metal oxide insulating layer 13 has good high-temperature insulating performance, can have good insulating effect even under the high-temperature condition of more than 500 ℃, can keep good adhesive force, and can meet the application of higher working temperature requirement.
In the embodiment of the application, the breakdown voltage of the winding formed by winding the insulated conducting wire 10 is 20V-2000V, the high-temperature insulating property is excellent, and the high-temperature working requirement above 500 ℃ can be met.
In the embodiment of the application, the insulated wire can be terminated by a metal sheet. The metal sheet can be a copper sheet, an aluminum sheet, a silver sheet and the like, and the end sealing of the metal sheet can prevent the wire core from being oxidized in the drawing process in the preparation process of the wire.
Referring to fig. 3, an embodiment of the present application further provides a method for manufacturing an insulated wire, including:
s101, forming a metal simple substance or an alloy layer at the periphery of the wire core in a physical or chemical mode to obtain a semi-finished product; the material of the wire core comprises Cu, Al, Ag or alloy thereof; the metal simple substance or the alloy layer comprises Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo and Cu simple substances or an alloy containing one or more metal elements;
and S102, carrying out in-situ oxidation treatment on the semi-finished product obtained in the step S101 in an oxidizing atmosphere to oxidize a simple metal substance or an alloy layer partially or completely, wherein the oxidized part forms a metal oxide insulating layer, and the unoxidized part forms an intermediate layer, so that the insulated wire is obtained. The material of the metal simple substance or the alloy layer is different from that of the wire core.
In the present embodiment, in step S101, the physical or chemical method includes, but is not limited to, one or more of a tube coating method, a magnetron sputtering method, a plating method, a vapor deposition method, a hot dipping method, and a coating method.
Referring to fig. 4, taking preparation of a single core wire as an example, in the embodiment of the present application, in step S101, a metal simple substance or an alloy layer is formed on the periphery of a wire core by using a tube cladding method, and specific operations of obtaining a semi-finished product include:
step (1): extruding the metal simple substance or alloy layer material into a metal simple substance or alloy sleeve;
step (2): sleeving a wire core bar into the metal simple substance or the alloy sleeve to extrude into a composite bar;
and (3): and annealing and drawing the composite bar to obtain the semi-finished product.
In the embodiment of the application, in the step (1), the inner diameter of the metal simple substance or the alloy sleeve may be 1mm to 100mm, and the wall thickness may be 0.5mm to 10 mm. Before compounding the sleeve, the inner wall of the sleeve can be subjected to surface alkali washing and ultrasonic cleaning at the temperature of 30-80 ℃, and then is dried in the air after cleaning.
In the embodiment of the application, in the step (2), a wire core rod with the diameter of 1mm-100mm can be selected to be sleeved into the metal simple substance or the alloy sleeve obtained in the step (1) after surface descaling, and the wire core rod and the sleeve can be in interference fit or clearance fit. When the wire core rod is arranged in the sleeve through thermal interference fit to be made into an extrusion blank, the outer diameter of the wire core rod can be-0.5 mm smaller than the inner diameter of the sleeve.
In the embodiment of the application, the melting point of the metal simple substance or the alloy sleeve is more than or equal to 600 ℃, and after the composite bar is annealed, the HB hardness of the metal simple substance or the alloy sleeve positioned on the outer side of the composite bar is 50-200. In the present embodiment, the metal simple substance or the alloy sleeve may be a Ni alloy pipe, a Zr alloy pipe, a 2520 stainless steel pipe, a 316L stainless steel pipe, or the like.
In the embodiment of the application, the step (2) may further include welding a back cover to the prepared end of the composite rod by using a metal sheet.
In the embodiment of the present application, in step (3), the specific operation of annealing and drawing the composite rod to obtain the semi-finished product may be: annealing the composite bar at 600-800 deg.c, hot extruding at 100-600 deg.c and at 0.5-10.0 m/min. And then carrying out multi-pass drawing processing on the composite bar subjected to hot extrusion processing at the deformation rate of 5-15% per pass and the speed of 1-200 m/min, carrying out discontinuous annealing, carrying out rough drawing, medium drawing and fine drawing to obtain a composite wire rod with the diameter of 0.05-5 mm, and carrying out annealing treatment after each pass of drawing, wherein the annealing treatment temperature is 600-900 ℃.
In the present embodiment, in step S102, the oxidizing atmosphere includes air, oxygen, water vapor, a mixed gas of water vapor and ethanol, or a mixed gas of water vapor and carbon dioxide. The temperature of the oxidation treatment is 300-900 ℃, and the time of the oxidation treatment can be 0.1-20 h. After oxidation treatment, a compact oxide film can be formed on the surface of the wire core. By controlling the conditions such as oxidation time and the like, the oxidation of the metal simple substance or the alloy in different degrees can be realized, and the metal oxide insulating layers with different thicknesses can be obtained. It is understood that when the simple metal or the alloy is partially oxidized, the insulated wire of the structure shown in fig. 1 in the present application can be obtained; when the metal simple substance or the alloy is completely oxidized, the insulated wire having the structure shown in fig. 2 in the present application can be obtained. In the embodiment of the application, the thickness of the metal oxide insulating layer can be controlled to be 3 μm to 300 μm, and the metal oxide insulating layer accounts for 50% to 100% of the volume of the metal simple substance or the alloy sleeve.
The breakdown voltage resistance of the metal oxide insulating layer on the surface of the insulated wire provided by the embodiment of the application is 20V-2000V, and the insulated wire still has good covering power and insulating property after being processed at high temperature (500 ℃ -1000 ℃). The method for manufacturing the insulated wire can effectively prevent the wire core from being oxidized in the manufacturing process, so that the conductive capacity of the wire core can be well maintained, the method can be suitable for preparing the insulating film on the surface of the pure copper wire core, the working temperature (above 500 ℃) of a copper wire can be remarkably increased while the conductive capacity of the copper wire is maintained, the insulating property and the mechanical strength of the metal oxide insulating layer are good when the metal oxide insulating layer is used above 500 ℃, and the breakdown voltage of a winding is 20V-2000V. The thickness of the metal oxide insulating layer can be controlled as required.
When the insulated wire is used for preparing magnetic elements such as inductors, motors, electromagnets and the like, the insulated wire can be wound into a coil or a winding after being obtained, and then the coil or the winding and a soft magnetic material are made into the magnetic elements; the semi-finished product of the insulated conductor and the soft magnetic material can be made into a magnetic element and then are oxidized together to form an insulating film, so that the thickness and the withstand voltage of the insulating film can be greatly improved, and the problem that the thicker the oxide layer is, the insulating film is easy to damage in the winding process of the conductor is solved; and the semi-finished product of the insulated conducting wire and the magnetic material can be annealed and sintered together at high temperature (for example 700 ℃), so that the assembly difficulty and cost are greatly reduced, the production efficiency is improved, and the method is suitable for large-scale mass production.
Embodiments of the present application also provide a coil or winding, which includes the insulated wire described above in embodiments of the present application. The breakdown voltage of the coil or winding is 20V-2000V. The coil is a basic unit for forming a winding, and the winding is the arrangement and connection of the coil according to a certain rule. The coil may be a multi-turn coil or a single-turn coil.
The insulated wire provided by the embodiment of the application is wound around a magnetic material in a coil or winding form, generates a magnetic field when current is introduced, and can be applied to various devices which change power density by using the magnetic field, such as inductors, motors, electromagnets, speakers, motors, transformers, loop antennas and the like.
The embodiment of the application also provides a magnetic component, which comprises the coil or the winding provided by the embodiment of the application. The magnetic component can be an inductive element, a motor, an electromagnet, a loudspeaker, a transformer, a motor, a loop antenna or the like. The inductance element may be a coil or winding including a magnetic material and a winding wound around the magnetic material. Wherein, the magnetic material can be soft magnetic materials such as iron silicon aluminum, iron nickel, iron silicon chromium, ferrite and the like.
In the embodiment of the present application, taking an inductance element as an example, the inductance element can be prepared by the following two methods:
the first method is as follows: and winding the insulated conductor finished product into an insulated coil, at least partially placing the insulated coil in a soft magnetic material, and pressing and annealing the soft magnetic material and the insulated conductor to obtain the inductance element.
The second method comprises the following steps: winding the semi-finished product of the insulated conducting wire into a coil, at least partially placing the coil in a soft magnetic material, and carrying out high-temperature (500-700 ℃) oxidation annealing treatment on the soft magnetic material and the semi-finished product of the insulated conducting wire together in an oxidizing atmosphere after compression molding. After oxidation treatment, a metal oxide insulating layer is formed on the surface of the semi-finished product of the insulated conducting wire to become an insulated conducting wire coil, and the insulated conducting wire coil and the soft magnetic body form an inductance element. The mode can not only greatly improve the thickness and the withstand voltage of the insulating layer, but also solve the problem that the insulating film is easy to damage in the winding process; and the semi-finished product of the insulated conducting wire and the magnetic material can be annealed and sintered together at high temperature (for example 700 ℃), so that the assembly difficulty and cost can be greatly reduced, the production efficiency is improved, and the method is suitable for large-scale mass production.
The motor provided by the embodiment of the application can comprise a rotor and a stator fixedly arranged around the rotor, wherein the stator comprises a winding formed by winding the insulated conducting wire. The coil or winding prepared by the insulated conducting wire provided by the embodiment of the application can obviously improve the highest working temperature of the motor.
The embodiment of the application also provides a terminal, and the terminal comprises the magnetic component provided by the embodiment of the application.
The insulated wire provided by the embodiment of the application is suitable for coating the wire cores made of various materials by arranging the metal oxide insulating layer formed by in-situ oxidation of the intermediate layer material on the periphery of the wire cores. The insulated wire can keep the conductive capability of a wire core, has good high-temperature insulation performance, has the working temperature of more than 500 ℃, and has the winding breakdown voltage of 20-2000V; meanwhile, the insulated wire has good bending performance, and the damage of the insulating layer of the wire in the practical application process (winding) is effectively prevented; in addition, the semi-finished product of the insulated conducting wire and the magnetic material can be annealed and sintered under a high-temperature environment, so that the assembly difficulty and cost are greatly reduced, the production efficiency is improved, and the method is suitable for large-scale mass production.
The technical solution of the embodiments of the present application is further described below by specific examples.
The first embodiment is as follows:
a method of making an insulated conductor comprising:
1. 2520 stainless steel seamless tube is selected as a sleeve material, the inner diameter of the stainless steel sleeve is 20.1mm, and the wall thickness is 1 mm; alkali washing the inner wall of the stainless steel sleeve, performing ultrasonic washing in pure water at 30-40 ℃, and then air-drying;
2. selecting a copper bar with the diameter of 20.0mm for surface treatment, removing oxide skin, and then sleeving the copper bar into the inner hole of the stainless steel sleeve pipe cleaned in the step 1 to form 2520 stainless steel/Cu composite blank; welding one end of the stainless steel sleeve with a copper sheet to seal the bottom;
3. annealing the composite blank at 800 ℃, and then performing hot extrusion at the high pressure of 400 ℃, wherein the hot extrusion rate is 2.6mm/min, and finally preparing 2520 stainless steel/Cu composite bars;
4. carrying out multi-pass drawing processing on the composite bar at the deformation rate of 3-9% and the speed of 5-20m/min per pass, carrying out discontinuous annealing, carrying out rough drawing, medium drawing and fine drawing to obtain a 2520 stainless steel/Cu composite wire with the diameter of 0.21mm, and carrying out annealing treatment after each pass of drawing, wherein the annealing treatment temperature is 800 ℃;
5. placing the composite wire in a vacuum atmosphere furnace, and continuously introducing 80% CO at the temperature of 700 DEG C2+ 20% of water vapor for 2h of oxidation treatment; after oxidation treatment, the stainless steel part of the composite wire is oxidized to form a compact insulating oxide layer, and the thickness of the oxide layer is 5-10 μm.
According to the detection of the enameled wire performance detection national standards GB4074.5 and GB6109.1, the breakdown voltage of the insulated wire is 80V at normal temperature and 50V at 500 ℃.
Example two:
a method of making an insulated conductor comprising:
1. selecting an Nb pipe as a sleeve material, wherein the inner diameter of the Nb pipe is 25.0mm, and the wall thickness is 5 mm; alkali washing the inner wall of the Nb pipe, performing ultrasonic washing in pure water at 30-40 ℃, and air-drying;
2. selecting a copper bar with the diameter of 25.0mm for surface treatment, removing oxide skin, and putting the copper bar into the inner hole of the treated Nb pipe in a heating state to form an Nb/Cu composite blank; welding one end of the Nb pipe with a copper sheet to seal the bottom;
3. annealing the composite blank at 750 ℃, and then performing hot extrusion at 300 ℃ under high pressure, wherein the hot extrusion rate is 4.2mm/min, and finally preparing the Nb/Cu composite bar;
4. carrying out multi-pass drawing processing on the composite bar at the deformation rate of 6-15% and the speed of 10-20m/min per pass, carrying out discontinuous annealing, carrying out rough drawing, medium drawing and fine drawing to obtain an Nb/Cu composite wire with the diameter of 0.15mm, and carrying out annealing treatment after each pass of drawing, wherein the annealing treatment temperature is 750 ℃;
5. placing the composite wire in a vacuum atmosphere furnace, and continuously introducing 70% Ar at the temperature of 700 DEG C2+20％CO2+ 10% of water vapor for 2h of oxidation treatment; and (3) oxidizing the Nb layer part of the composite wire by oxidation treatment to form a compact insulating oxide layer, wherein the thickness of the oxide layer is 10-15 mu m.
Through detection, the breakdown voltage of the insulated wire of the embodiment is 100V at normal temperature and 70V at 500 ℃.
EXAMPLE III
A method of making an insulated conductor comprising:
1. selecting a pure copper wire with the diameter of 0.9mm after drawing and annealing, carrying out acid washing on the surface of the pure copper wire, carrying out ultrasonic cleaning in pure water, and then drying;
2. heating the aluminum-magnesium alloy material to 560-580 ℃ in a vacuum reactor to fully melt the aluminum-magnesium alloy material; immersing a pure copper wire into molten aluminum at a speed of 5-10m/min from an inlet phi 0.9mm at the upper end of the reactor, and then passing through an outlet phi 0.910mm at the lower end of the reactor; after infiltration, a layer of aluminum alloy layer with the thickness of 10 microns is formed on the surface of the copper wire, and the diameter of the composite wire is 0.910 mm;
3. carrying out hard anodic oxidation treatment on the composite wire to form an aluminum oxide layer, wherein the parameters of the anodic oxidation treatment are as follows: the sulfuric acid type anodic oxidation liquid with the concentration of 180-200g/L is adopted, the oxidation temperature is 15-18 ℃, the oxidation voltage is 12V, and the oxidation current is 0.8-1.0A/dm 2. After anodic oxidation treatment, the aluminum alloy layer is oxidized to form a compact insulating oxide layer, and the thickness of the oxide layer is 8-10 mu m.
Through detection, the breakdown voltage of the insulated wire of the embodiment is 100V at normal temperature and 240V at 500 ℃.
Claims (19)
1. An insulated wire is characterized by comprising a wire core and a metal oxide insulating layer coated on the periphery of the wire core; or the insulated wire comprises a wire core, an intermediate layer coated on the periphery of the wire core and a metal oxide insulating layer coated on the periphery of the intermediate layer;
the material of the wire core comprises Cu, Al, Ag or alloy thereof; the intermediate layer comprises single substances of Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo and Cu or an alloy containing one or more metal elements, and the material of the intermediate layer is different from that of the wire core; the metal oxide insulating layer comprises oxides of one or more metal elements of Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo and Cu; the metal oxide insulating layer is formed by oxidizing the intermediate layer material;
when the material of the wire core is a simple substance of Cu, Al or Ag, and the metal oxide insulating layer contains the same metal elements as the wire core, the metal oxide insulating layer comprises at least two metal oxides;
when the wire core is made of a simple substance of Cu, Al or Ag and the intermediate layer comprises the same metal elements as the wire core, the content of the metal elements in the intermediate layer is less than or equal to 80 percent.
2. The insulated wire of claim 1, wherein the material of the metal oxide insulating layer comprises one or more of nickel oxide, niobium oxide, chromium oxide, iron oxide, aluminum oxide, zirconium oxide, titanium oxide, vanadium oxide, tungsten oxide, molybdenum oxide, and copper oxide.
3. The insulated wire of claim 1, wherein the metallic element composition of the metal oxide insulation layer is different from the metallic element composition of the wire core.
4. The insulated wire of claim 3, wherein when the core is made of Cu, Al or Ag, and the metal oxide insulating layer contains the same metal element as the core, the mass content of the same metal element as the core in the metal oxide insulating layer is less than or equal to 80% of the total mass content of the metal element.
5. The insulated wire of any one of claims 1-4, wherein the metal oxide insulating layer has a thickness of 1 μm to 300 μm.
6. The insulated wire of claim 1, wherein the intermediate layer has a melting point of 600 ℃ or greater.
7. The insulated wire of claim 1, wherein the thickness of the intermediate layer is greater than 0 and less than or equal to 2 μ ι η.
8. The insulated wire of claim 1, wherein the metal oxide insulating layer has a thickness greater than or equal to a thickness of the intermediate layer.
9. The insulated wire of claim 1, wherein the diameter of the insulated wire is 0.05mm to 150 mm.
10. The insulated wire of claim 1, wherein a breakdown voltage of a winding formed from the insulated wire is 20V to 2000V.
11. A method of manufacturing an insulated wire, comprising:
forming a metal simple substance or an alloy layer at the periphery of the wire core in a physical or chemical mode to obtain a semi-finished product; the material of the wire core comprises Cu, Al, Ag or alloy thereof; the metal simple substance or the alloy layer comprises Ni, Nb, Cr, Fe, Al, Zr, Ti, V, W, Mo and Cu simple substances or an alloy containing one or more metal elements;
carrying out in-situ oxidation treatment on the semi-finished product in an oxidizing atmosphere to oxidize part or all of the metal simple substance or the alloy layer, wherein the oxidized part forms a metal oxide insulating layer, and the unoxidized part forms an intermediate layer to obtain an insulated wire;
when the material of the wire core is a simple substance of Cu, Al or Ag, and the metal oxide insulating layer contains the same metal elements as the wire core, the metal oxide insulating layer comprises at least two metal oxides;
when the wire core is made of a simple substance of Cu, Al or Ag and the intermediate layer comprises the same metal elements as the wire core, the content of the metal elements in the intermediate layer is less than or equal to 80 percent.
12. The manufacturing method according to claim 11, wherein the oxidizing atmosphere comprises air, oxygen, water vapor, a mixed gas of water vapor and ethanol, or a mixed gas of water vapor and carbon dioxide, and the temperature of the oxidizing treatment is 300 ℃ to 900 ℃.
13. The method of claim 11, wherein the physical or chemical means comprises one or more of tube coating, magnetron sputtering, electroplating, evaporation, hot dipping, and coating.
14. The manufacturing method according to claim 13, wherein a metal simple substance or an alloy layer is formed on the periphery of the core by a tube cladding method to obtain a semi-finished product, and the specific operations include:
extruding the metal simple substance or alloy layer material into a metal simple substance or alloy sleeve;
sleeving a wire core bar into the metal simple substance or the alloy sleeve to extrude into a composite bar;
and annealing and drawing the composite bar to obtain the semi-finished product.
15. The manufacturing method of claim 14, wherein after the composite bar is annealed, the HB hardness of the metal simple substance or alloy sleeve positioned on the outer side of the composite bar is 50-200.
16. A coil or winding comprising an insulated conductor according to any one of claims 1 to 10.
17. A magnetic component comprising a coil or winding as claimed in claim 16.
18. The magnetic component of claim 17, wherein the magnetic component comprises an inductor, a motor, an electromagnet, a speaker, a transformer, or a loop antenna.
19. A terminal comprising a magnetic component as claimed in claim 17 or 18.
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| CN112466512B (en) * | 2020-11-16 | 2023-02-03 | 深圳市铂科新材料股份有限公司 | Inorganic coated insulated copper wire and preparation method thereof |
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| JPH02301909A (en) * | 1989-05-16 | 1990-12-14 | Sumitomo Electric Ind Ltd | Inorganic insulated cable and its manufacture |
| JPH05314821A (en) * | 1992-05-07 | 1993-11-26 | Sumitomo Electric Ind Ltd | Inorganic insulation coated conductor |
| JPH08264028A (en) * | 1995-03-22 | 1996-10-11 | Sumitomo Electric Ind Ltd | Insulation-coated electric conductor and manufacture thereof |
| CN101728011A (en) * | 2010-01-17 | 2010-06-09 | 大连海事大学 | Copper wire with insulating layer and manufacture method thereof |
| CN102254638B (en) * | 2011-04-19 | 2012-10-03 | 徐志峰 | Production system for carrying out anodizing low-voltage insulation treatment on copper clad aluminum wires |
| CN103700469A (en) * | 2012-09-27 | 2014-04-02 | 三星电机株式会社 | Coil for chip inductor, and chip inductor by using coil |
| CN103952742B (en) * | 2014-04-22 | 2016-06-08 | 上海理工大学 | Copper conductor with insulating barrier and preparation method thereof |
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