CN114038612A - high-PDIV insulated electromagnetic wire and preparation method and application thereof - Google Patents
high-PDIV insulated electromagnetic wire and preparation method and application thereof Download PDFInfo
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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
- H01B7/0208—Cables with several layers of insulating material
- H01B7/0216—Two layers
-
- 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
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B3/00—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties
- H01B3/18—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances
- H01B3/30—Insulators or insulating bodies characterised by the insulating materials; Selection of materials for their insulating or dielectric properties mainly consisting of organic substances plastics; resins; waxes
- H01B3/303—Macromolecular compounds obtained by reactions forming a linkage containing nitrogen with or without oxygen or carbon in the main chain of the macromolecule, not provided for in groups H01B3/38 or H01B3/302
- H01B3/306—Polyimides or polyesterimides
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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
- H01B7/0291—Disposition of insulation comprising two or more layers of insulation having different electrical properties
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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
- H01B7/08—Flat or ribbon 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
- H01B7/1875—Multi-layer sheaths
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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
- H01B7/29—Protection against damage caused by extremes of temperature or by flame
- H01B7/292—Protection against damage caused by extremes of temperature or by flame using material resistant to heat
-
- H—ELECTRICITY
- H02—GENERATION; CONVERSION OR DISTRIBUTION OF ELECTRIC POWER
- H02K—DYNAMO-ELECTRIC MACHINES
- H02K3/00—Details of windings
- H02K3/30—Windings characterised by the insulating material
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- Engineering & Computer Science (AREA)
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Abstract
The invention discloses a high PDIV insulated electromagnetic wire and a preparation method and application thereof, which are used for a driving motor winding with the voltage grade above 700V and comprise the following components: the method comprises the following steps of (1) sintering an enameled wire and a polyimide-fluorine 46 composite film on the surface of the enameled wire; the enameled wire includes: the copper conductor and the paint film insulating layer coated outside the copper conductor, wherein the paint film insulating layer is a polyimide insulating layer; the polyimide insulating layer adopts polyimide paint, the temperature grade of the polyimide paint is 240 grade, and the glass transition temperature is more than or equal to 260 ℃; the triggering temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film is 250-290 ℃. The high-PDIV insulated electromagnetic wire ensures that the integral insulation thickness is more than 0.30mm, the PDIV is more than or equal to 1200V, and simultaneously keeps the flexibility of a paint film insulating layer and the adhesive force between the paint film insulating layer and a copper conductor, and ensures the machining performance and the electrical level.
Description
Technical Field
The invention relates to the field of driving motors, in particular to a high-PDIV insulated electromagnetic wire. In addition, the invention also relates to the high PDIV insulated electromagnetic wire and a preparation method and application thereof.
Background
The driving motor system is one of three large core components of a new energy automobile, the motor driving control system is a main execution structure in the running of the energy automobile, the driving characteristics of the motor driving control system determine main performance indexes of the running of the automobile, and the motor driving control system is an important component of the electric automobile. The motor of the electric automobile has compact structural design, small size and limited packaging size, and must be specially designed according to specific products. The requirement on the reliability of motor insulation is high, the failure mode is controllable, and the safety of a passenger can be guaranteed. The motor has high efficiency and high power density, and needs to ensure high efficiency in a wider rotating speed and torque range so as to reduce power loss and improve the endurance mileage of one-time charging.
Under the global environment of automobile industry adjustment, new energy automobiles will enter a brand new development trend in 2020. China is a world-wide new energy automobile producing and selling country, and the sales share accounts for more than 50% of the world-wide new energy automobile market at present. In the next decade, the new energy automobile industry will transition from policy-oriented to market-oriented, and while growing at a high speed, the new energy automobile industry focuses more on the high-quality development of the industry. At present, the global automobile industry is at the intersection of historical transformation, and the technical innovation becomes the first power for leading the development of the industry in the face of increasingly intense international competition. At present, the maximum voltage of an electric system of an electric vehicle on the market is basically 400V, and the electric vehicle cannot be applied to the field of high-voltage driving motors. In addition, the winding electromagnetic wire used by the motor completely depends on import at present, so that the important significance of upgrading the level of the driving motor in China to relieve the energy requirement is realized urgently.
Disclosure of Invention
The invention provides a high-PDIV insulated electromagnetic wire and a preparation method and application thereof, and aims to solve the technical problems that the existing winding electromagnetic wire cannot be applied to a high-voltage driving motor, and the winding electromagnetic wire is imported and expensive.
The technical scheme adopted by the invention is as follows:
a high PDIV insulated magnet wire for driving motor windings with voltage class above 700V, comprising: the method comprises the following steps of (1) sintering an enameled wire and a polyimide-fluorine 46 composite film on the surface of the enameled wire; the enameled wire includes: the copper conductor and the paint film insulating layer coated outside the copper conductor, wherein the paint film insulating layer is a polyimide insulating layer; the polyimide insulating layer adopts polyimide paint, the temperature grade of the polyimide paint is 240 grade, and the glass transition temperature is more than or equal to 260 ℃; the triggering temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film is 250-290 ℃.
Furthermore, the triggering temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film is 250-260 ℃.
Further, the thickness of the polyimide insulating layer is 0.08mm to 0.16 mm.
According to another aspect of the present invention, there is also provided a method for preparing the insulated electromagnetic wire with high PDIV, comprising the following steps: and (3) wrapping the polyimide-fluorine 46 composite film on the outer wall surface of the enameled wire along the axial direction of the enameled wire, and then putting the enameled wire into high-frequency sintering equipment, wherein the temperature is controlled to be 250-330 ℃, and the production speed is 3-11 m/min, so that the high-PDIV insulated electromagnetic wire is obtained.
Further, the preparation method of the enameled wire comprises the following steps: drawing the electromagnetic wire rod into a copper conductor by adopting a slow wire-feeding one-step forming polycrystalline die; and (3) placing the copper conductor in an integrally formed painting mold, and painting to form a paint film insulating layer to obtain the enameled wire.
Further, the dimensional tolerance of the copper conductor is less than or equal to +/-0.01 mm.
Further, the deviation value of the thickness of the insulating layer of the paint film is less than or equal to 1.3.
Further, the thickness of the polyimide-fluorine 46 composite film is 0.12mm to 0.25 mm.
Further, the covering rate of the polyimide-fluorine 46 composite film wrapped on the enameled wire is 33.3% -66.67%; the width of the polyimide-fluorine 46 composite film is 8 mm-20 mm.
According to another aspect of the invention, a coil winding is further provided, and the high PDIV insulated electromagnetic wire is formed into a hairpin electromagnetic wire rod by adopting a one-step forming process, so as to obtain the coil winding.
The invention has the following beneficial effects:
the invention provides a high PDIV insulated electromagnetic wire, comprising: the enameled wire comprises a copper conductor and a paint film insulating layer, wherein the paint film insulating layer is a polyimide insulating layer; the temperature grade of the polyimide-fluorine 46 composite film is 240 grade, and the glass transition temperature is more than or equal to 260 ℃; the triggering temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film is 250-290 ℃. According to the high-PDIV insulated electromagnetic wire, the inner layer is coated with polyimide insulating paint to form an enameled wire, a polyimide-fluorine 46 composite film is sintered outside the paint film insulating layer, the fluorine 46 glue layer is melted and is bonded with the paint film insulating layer to form an insulated integral structure, the temperature grade of the polyimide insulating layer is 240 ℃, and the temperature grade of the polyimide-fluorine 46 composite film is 240 ℃, so that the defect of insufficient mechanical strength of the paint film insulating layer is overcome. The high PDIV insulated electromagnetic wire ensures that the integral insulation thickness is more than 0.30mm, the PDIV of the high PDIV insulated electromagnetic wire is more than or equal to 1200V, the flexibility of a paint film insulating layer and the adhesive force between the paint film insulating layer and a copper conductor are maintained, and the machining performance and the electrical level of the high PDIV insulated electromagnetic wire are ensured. The high PDIV insulation is subjected to a breakdown voltage test in saline water with the concentration of 50g/L, the breakdown voltage check requirement is more than or equal to 7000V, and 100 percent of continuous 100 samples are qualified. The invention develops a high PDIV insulated electromagnetic wire with excellent full-automatic machining performance, mechanical impact resistance, good insulation continuity and ultrahigh voltage level.
In addition to the objects, features and advantages described above, other objects, features and advantages of the present invention are also provided. The present invention will be described in further detail below with reference to the accompanying drawings.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this application, illustrate embodiments of the invention and, together with the description, serve to explain the invention and not to limit the invention. In the drawings:
FIG. 1 is a schematic view of a high PDIV insulated magnet wire according to a preferred embodiment of the present invention.
The reference numbers illustrate:
1. a copper conductor; 2. a paint film insulating layer; 3. polyimide-fluorine 46 composite films.
Detailed Description
It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict. The present invention will be described in detail below with reference to the embodiments with reference to the attached drawings.
FIG. 1 is a schematic view of a high PDIV insulated magnet wire according to a preferred embodiment of the present invention.
As shown in fig. 1, the insulated electromagnetic wire with high PDIV of the present embodiment, which is used for a driving motor winding with a voltage level above 700V, includes: the enameled wire and the polyimide-fluorine 46 composite film 3 sintered on the surface of the enameled wire; the enameled wire includes: the copper-clad plate comprises a copper conductor 1 and a paint film insulating layer 2 coated outside the copper conductor 1, wherein the paint film insulating layer 2 is a polyimide insulating layer; the polyimide insulating layer adopts polyimide paint, the temperature grade of the polyimide paint is 240 grade, and the glass transition temperature is more than or equal to 260 ℃; the triggering temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film 3 is 250-290 ℃.
The invention provides a high PDIV insulated electromagnetic wire, comprising: the enameled wire comprises a copper conductor 1 and a paint film insulating layer 2, and the paint film insulating layer 2 adopts a polyimide insulating layer; the temperature grade of the polyimide-fluorine 46 composite film 3 is 240 grade, and the glass transition temperature is more than or equal to 260 ℃; the triggering temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film 3 is 250-290 ℃. According to the high-PDIV insulated electromagnetic wire, the inner layer is coated with polyimide insulating paint to form an enameled wire, a polyimide-fluorine 46 composite film 3 is sintered outside the paint film insulating layer 2, the fluorine 46 glue layer is melted and is bonded with the paint film insulating layer 2 to form an insulating integral structure, the temperature grade of the polyimide insulating layer is 240 ℃, the temperature grade of the polyimide-fluorine 46 composite film 3 is 240 ℃, and the defect of insufficient mechanical strength of the paint film insulating layer 2 is overcome. The high-PDIV insulated electromagnetic wire ensures that the integral insulation thickness is more than 0.30mm, the PDIV of the high-PDIV insulated electromagnetic wire is more than or equal to 1200V, the flexibility of the paint film insulating layer 2 and the adhesive force between the paint film insulating layer 2 and the copper conductor 1 are maintained, and the machining performance and the electrical level of the high-PDIV insulated electromagnetic wire are ensured. The high PDIV insulation is subjected to a breakdown voltage test in saline water with the concentration of 50g/L, the breakdown voltage check requirement is more than or equal to 7000V, and 100 percent of continuous 100 samples are qualified. The invention develops a high PDIV insulated electromagnetic wire with excellent full-automatic machining performance, mechanical impact resistance, good insulation continuity and ultrahigh voltage level.
The Partial Discharge initiation Voltage is referred to as PDIV.
In this embodiment, the trigger temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film 3 is 250 ℃ to 260 ℃. The high PDIV insulated magnet wire is mainly applied to the field of high-voltage driving motors above 700V, and power P is current I × voltage U according to ohm's law, so that to achieve a specific power, high current and low voltage or low current and high voltage can be used. However, the magnet wire has a certain resistance, and when a large amount of current passes through the wire, a large amount of heat is generated to heat the wire, and the high PDIV insulated magnet wire has a temperature level of 240 ℃, and a lighter cross-sectional design. Moreover, on the premise of fixed motor volume and current density, the effective cross section area of the electromagnetic wire is a relatively fixed value, so the voltage withstanding level of turn-to-turn insulation and slot insulation of the motor determines the overall power of the motor. The voltage-resistant level of turn-to-turn insulation and slot insulation of the motor can be improved through two modes, wherein the first mode is corona-resistant insulation, the second mode is high PDIV insulation, the high PDIV insulation is adopted, namely a polyimide-fluorine 46 composite film 3 is sintered on the finished product insulation of the enameled wire, and the hot processing performance of a paint film insulation layer 2 needs to be screened and verified for insulating paints with different temperature grades on the market. Preferably, the polyimide lacquer has a temperature rating of 240 and a glass transition temperature of 275 ℃ to 310 ℃. More preferably, the polyimide lacquer has a temperature rating of 240 and a glass transition temperature of 310 ℃.
In the process of preparing the electromagnetic wire insulating layer, on one hand, because the organic insulating paint is not completely reacted, an insulating layer formed by the organic insulating paint is heated and volatilized in the subsequent heat treatment process, and the volatilized gas can corrode the insulating layer, so that the performance of the electromagnetic wire is influenced; on the other hand, the organic insulating paint can also generate decomposition reaction in the heat treatment process, which is not beneficial to the stability of the insulating layer, so that the insulating paint on the market at present is screened, and the polyimide paint with high glass transition temperature is selected as the insulation of the inner-layer enameled wire, thereby reducing the risk of failure of the insulating paint. By comparing the glass transition temperatures of the insulating paint materials, the insulating paint with the highest glass transition temperature is selected, the temperature grade is 240 degrees, and the glass transition temperature is 310 ℃.
Moreover, in order to meet the requirement of good adhesion capability of the polyimide-fluorine 46 composite film 3 and the paint film insulating layer 2 and avoid damage to the paint film insulating layer 2 in the heating process, a sintered film with good performance on the market needs to be screened and verified, and finally the polyimide-fluorine 46 composite film 3 with better adhesive layer uniformity and lower sintering trigger temperature is determined, and the uniformity of the film fluorine 46 adhesive layer is mainly compared with the sintering contact temperature of the adhesive layer. The more uniform the adhesive layer is, the more stable and consistent the adhesive force between the film and the paint film layer is, the lower the adhesive layer triggering temperature is, the less the damage to the paint film insulating layer 2 is during high-frequency heat treatment, and the lower the probability of failure of the paint film insulating layer 2 due to thermal decomposition during post-process thermal processing of the paint film insulating layer 2. Preferably, the triggering temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film 3 reaches 250-260 ℃. The uniformity of the fluorine 46 glue layer in the polyimide-fluorine 46 composite film 3 is 0.0123 mm-0.0127 mm.
Preferably, the thickness of the polyimide insulating layer is 0.08mm to 0.16 mm. The thickness of the paint film insulating layer 2 is more than 0.30mm, the PDIV of the high PDIV insulated electromagnetic wire can be more than or equal to 1200V, meanwhile, the flexibility of the paint film insulating layer 2 and the adhesive force between the paint film insulating layer 2 and the copper conductor 1 are kept, and the machining performance and the electrical level of the high PDIV insulated electromagnetic wire are ensured.
According to another aspect of the present invention, there is also provided a method for preparing the insulated electromagnetic wire with high PDIV, comprising the following steps: and (3) wrapping the polyimide-fluorine 46 composite film 3 on the outer wall surface of the enameled wire along the axial direction of the enameled wire, and then putting the enameled wire into high-frequency sintering equipment, wherein the temperature is controlled to be 250-330 ℃, and the production speed is 3-11 m/min, so that the high-PDIV insulated electromagnetic wire is obtained. According to the preparation method of the high-PDIV insulated electromagnetic wire, the prepared high-PDIV insulated electromagnetic wire combines the advantageous properties of two insulation, namely inner-layer enameled wire and outer-layer film wrapping and sintering, the inner-layer paint film insulation layer 2 meets the motor operation temperature level and guarantees the basic electrical performance of the electromagnetic wire, and the outer-layer film layer has good insulation flexibility and mechanical impact resistance after being sintered, so that the electromagnetic wire shows excellent electrical performance and insulation flexibility after the U-shaped hairpin of the motor bar is formed.
According to the preparation method of the high PDIV insulated electromagnetic wire, the inner layer is coated with polyimide paint for multiple times to form an enameled wire, then a layer of polyimide-fluorine 46 composite film 3 is wound on the paint film insulating layer 2, and after the polyimide-fluorine 46 composite film 3 is subjected to high-frequency sintering and heating, the fluorine 46 glue layer is melted and is bonded with the paint film insulating layer 2 to form an insulating whole. The high-PDIV insulated electromagnetic wire is different from the traditional electromagnetic wire in that a layer of polyimide-fluorine 46 composite film 3 is sintered on an enameled wire, the temperature trigger point of a fluorine 46 adhesive layer is generally about 260 ℃, and simultaneously, the high-frequency sintering characteristic is combined, the conductor is heated from inside to outside, the inner layer paint film insulating layer 2 can generate a reversible reaction in the thermal processing process so as to be decomposed and lose efficacy, the polyimide paint is adopted to ensure that the paint film insulating layer 2 is completely cured in the subsequent thermal processing process, and meanwhile, the flexibility of the paint film insulating layer 2 in the mechanical bending process is also met. In the process stage of the enameled wire, the dielectric loss value of a paint film insulating layer 2 prepared from the polyimide paint is stabilized in a range of more than or equal to 260 ℃, the paint film insulating layer 2 has the characteristic of high temperature resistance in a short time and can endure for 2min at 450 ℃, and meanwhile, the paint film insulating layer 2 does not crack after being knocked after being bent by 1 time.
The high-PDIV insulated electromagnetic wire has better temperature resistance level and more excellent machining capacity. The inner paint film insulating layer 2 and the outer wrapping polyimide-fluorine 46 composite film 3 of the high PDIV insulated electromagnetic wire product are added, and the outer polyimide-fluorine 46 composite film 3 can also serve as the slot insulation of a driving motor, so that the turn-to-turn insulation and slot insulation of the motor are higher in integral voltage resistance level.
In this embodiment, the preparation method of the enameled wire includes: the electromagnetic wire rod is drawn into a copper conductor 1 by adopting a slow-speed wire-feeding one-step forming polycrystalline die; and (3) placing the copper conductor 1 in an integrally formed painting mold, and painting to form a paint film insulating layer 2 to obtain the enameled wire. The design size of the driving motor is smaller and smaller, the requirement on power density is higher and higher, the space inside the motor is smaller and smaller, the high-PDIV insulated electromagnetic wire is required to have more stable and consistent electrical performance under the condition of limited insulation thickness, in order to meet the performance requirement, the insulation continuity of the paint film insulation layer 2 is required to be good, and the main characteristic of ensuring the insulation continuity is to ensure the uniformity of the paint film insulation layer 2. Starting from the copper conductor 1, the electromagnetic wire rod adopts a slow-moving wire one-step forming polycrystalline die, and the dimensional tolerance of the copper conductor 1 is ensured to meet the requirement of being less than +/-0.01 mm; the slow-speed wire processing mode is realized by slow-speed wire processing equipment. The copper conductor 1 is placed in an integrally formed painting mold for painting, and a high matching degree of the copper conductor 1 and the painting mold is guaranteed by adopting a high-precision integrally formed painting mold manufacturing technology, so that high uniformity of insulation of the enameled wire is guaranteed, the deviation of the whole insulation thickness is controllable, and the thickness deviation value is that the ratio of the maximum unilateral insulation thickness to the minimum unilateral insulation thickness of the enameled wire is less than or equal to 1.3. Most of traditional painting molds are manufactured in a mode of combining a mold sleeve and a mold core, and in the combining process, the matching degree of the mold sleeve and the mold core can influence the painting effect of the molds. Therefore, the integrally formed painting mold is adopted, the mold sleeve and the mold core are integrated, the matching problem does not exist, and the painting precision can be greatly improved. The painting precision of each pass of the traditional combined die is +/-0.005 mm, and after the integrated die is adopted, the painting precision of each pass can be controlled to be +/-0.003 mm. After painting is performed in multiple passes, the eccentricity of the insulating layer is lower in the whole conductor section.
Preferably, the dimensional tolerance of the copper conductor 1 is equal to or less than ± 0.01 mm.
Preferably, the thickness deviation value of the paint film insulating layer 2 is 1.3 or less.
In this example, the thickness of the polyimide-fluorine 46 composite film 3 is 0.12mm to 0.25 mm. The thickness of the polyimide-fluorine 46 composite film 3 is the thickness wound on an enameled wire.
In the embodiment, the covering rate of the polyimide-fluorine 46 composite film 3 wrapped on the enameled wire is 33.3% -66.67%; the width of the polyimide-fluorine 46 composite film 3 is 8 mm-20 mm. The lapping rate of the polyimide-fluorine 46 composite film 3 is strictly controlled according to 33.3-66.67 percent, and the continuity of the sintering lapping is ensured.
According to another aspect of the invention, a coil winding is further provided, and the high PDIV insulated electromagnetic wire is formed into a hairpin electromagnetic wire rod by adopting a one-step forming process, so as to obtain the coil winding. The coil winding adopts a hairpin one-step forming process, and the copper filling coefficient is improved by 30 percent compared with that of the traditional winding process, so that the coil winding has higher power output and torque in the same volume. The one-step forming process adopts full-automatic equipment to produce the hairpin bar which is similar to hairpin shape, consistent in size and height and is directly inserted into the slot, and the electromagnetic bar adopts the electromagnetic wire with high PDIV value and reduced insulation thickness, and the turn-to-turn insulation thickness is small. In the traditional winding process, the size consistency of the winding rod has large fluctuation, and the adopted turn-to-turn insulation thickness is large. In the same slot space, the net copper sectional area of the coil conductor in the form of a hairpin bar is greatly improved.
Examples
Example 1
High PDIV insulated magnet wire:
the method comprises the following steps: the enameled wire and a layer of polyimide-fluorine 46 composite film 3 sintered on the surface of the enameled wire; the enameled wire includes: the copper-clad plate comprises a copper conductor 1 and a paint film insulating layer 2 coated outside the copper conductor 1, wherein the paint film insulating layer 2 is a polyimide insulating layer with the thickness of 0.12 mm; the polyimide insulating layer adopts polyimide paint, the temperature grade of the polyimide paint is 240 grade, and the glass transition temperature is 310 ℃; the trigger temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film 3 is 255 ℃.
The preparation method of the high PDIV insulated electromagnetic wire comprises the following steps:
the electromagnetic wire rod is drawn into a copper conductor 1 by adopting a slow-speed wire-feeding one-step forming polycrystalline die; placing the copper conductor 1 in an integrally formed painting mold, and painting for 4 times to form a paint film insulating layer 2 to obtain an enameled wire;
wrapping the polyimide-fluorine 46 composite film 3 on the outer wall surface of the enameled wire along the axial direction of the enameled wire, wherein the covering rate of the polyimide-fluorine 46 composite film 3 on the enameled wire is 66%; the thickness of the polyimide-fluorine 46 composite film 3 is 0.22mm, the width is 18mm, and then the polyimide-fluorine 46 composite film is put into high-frequency sintering equipment, the temperature is controlled to be 290 ℃, the vehicle speed is controlled to be 5m/min, and the high-PDIV insulated electromagnetic wire is obtained.
Example 2
High PDIV insulated electromagnetic wire
The method comprises the following steps: the enameled wire and a layer of polyimide-fluorine 46 composite film 3 sintered on the surface of the enameled wire; the enameled wire includes: the copper-clad plate comprises a copper conductor 1 and a paint film insulating layer 2 coated outside the copper conductor 1, wherein the paint film insulating layer 2 is a polyimide insulating layer with the thickness of 0.15 mm; the polyimide insulating layer adopts polyimide paint, the temperature grade of the polyimide paint is 240 grade, and the glass transition temperature is 310 ℃; the trigger temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film 3 is 255 ℃.
The preparation method of the high PDIV insulated electromagnetic wire comprises the following steps:
the electromagnetic wire rod is drawn into a copper conductor 1 by adopting a slow-speed wire-feeding one-step forming polycrystalline die; placing the copper conductor 1 in an integrally formed painting mold, and painting for 5 times to form a paint film insulating layer 2 to obtain an enameled wire;
wrapping the polyimide-fluorine 46 composite film 3 on the outer wall surface of the enameled wire along the axial direction of the enameled wire, wherein the covering rate of the polyimide-fluorine 46 composite film 3 on the enameled wire is 66.7%; the thickness of the polyimide-fluorine 46 composite film 3 is 0.24mm, the width is 10mm, and then the polyimide-fluorine 46 composite film is put into high-frequency sintering equipment, the temperature is controlled to be 310 ℃, the vehicle speed is controlled to be 6m/min, and the high-PDIV insulated electromagnetic wire is obtained.
Example 3
A high PDIV insulated electromagnetic wire comprising: the enameled wire and a polyimide-fluorine 46 composite film 3 sintered on the surface of the enameled wire; the enameled wire includes: the copper-clad plate comprises a copper conductor 1 and a paint film insulating layer 2 coated outside the copper conductor 1, wherein the paint film insulating layer 2 is a polyimide insulating layer with the thickness of 0.1 mm; the polyimide insulating layer adopts polyimide paint, the temperature grade of the polyimide paint is 240 grade, and the glass transition temperature is 310 ℃; the trigger temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film 3 is 255 ℃.
The preparation method of the high PDIV insulated electromagnetic wire comprises the following steps:
the electromagnetic wire rod is drawn into a copper conductor 1 by adopting a slow-speed wire-feeding one-step forming polycrystalline die; placing the copper conductor 1 in an integrally formed painting mold, and painting for 3 times to form a paint film insulating layer 2 to obtain an enameled wire;
wrapping the polyimide-fluorine 46 composite film 3 on the outer wall surface of the enameled wire along the axial direction of the enameled wire, wherein the covering rate of the polyimide-fluorine 46 composite film 3 on the enameled wire is 66.5%; the thickness of the polyimide-fluorine 46 composite film 3 is 0.23mm, the width is 15mm, and then the polyimide-fluorine 46 composite film is put into high-frequency sintering equipment, the temperature is controlled to be 270 ℃, the vehicle speed is controlled to be 4m/min, and the high-PDIV insulated electromagnetic wire is obtained.
Comparative example 1
A corona resistant insulated magnet wire, differing from example 1 by: the polyimide-fluorine 46 composite film added with inorganic corona-resistant substances, wherein the inorganic corona-resistant substances comprise silicon dioxide or aluminum oxide.
The high-PDIV insulated electromagnetic wire obtained in the embodiment 1-3 is subjected to a breakdown voltage test in saline water with the concentration of 50g/L, the breakdown voltage check requirement is more than or equal to 7000V, and 100% of continuous 100 samples are qualified.
The above example 1 and comparative example 1 were subjected to a performance test.
Bending test: 1a, bending by 180 degrees along the direction of wide sides by using a round bar with the diameter being one time of the thickness of the conductor; 1b bending, bending by 180 degrees along the direction of narrow side by round bar with the diameter being one time of the width of the conductor, and observing the cracking condition.
Table 1 results of performance testing
As shown in table 1, as a result of performance tests of example 1 and comparative example 1, the corona resistant insulated magnet wire of comparative example 1 is degraded in mechanical properties of the composite film by adding the inorganic substance, and in order to ensure the mechanical properties of the composite film, the temperature needs to be lowered during the heat treatment, and after the temperature is lowered, the fluorine 46 glue layer is not sufficiently melted, and the adhesion effect with the varnish insulation layer 2 is lowered, and thus, the bending crack (mechanical properties) and the peeling force (adhesion effect) are poor, and thus, the high PDIV insulated magnet wire of the present invention is excellent in performance.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (10)
1. A high PDIV insulated electromagnetic wire is used for driving motor windings with the voltage level above 700V,
the method comprises the following steps: the preparation method comprises the steps of coating an enameled wire and sintering a polyimide-fluorine 46 composite film (3) on the surface of the enameled wire;
the enameled wire includes: the copper-clad plate comprises a copper conductor (1) and a paint film insulating layer (2) coated outside the copper conductor (1), wherein the paint film insulating layer (2) is a polyimide insulating layer;
the polyimide insulating layer is made of polyimide paint, the temperature grade of the polyimide paint is 240 grade, and the glass transition temperature is more than or equal to 260 DEG C
The triggering temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film (3) is 250-290 ℃.
2. The high PDIV insulated electromagnetic wire of claim 1,
the triggering temperature of the fluorine 46 glue layer of the polyimide-fluorine 46 composite film (3) is 250-260 ℃.
3. The high PDIV insulated electromagnetic wire of claim 1,
the thickness of the polyimide insulating layer is 0.08-0.16 mm.
4. A method of manufacturing a high PDIV insulated magnet wire according to any of claims 1 to 3, comprising the steps of:
and (3) wrapping the polyimide-fluorine 46 composite film (3) on the outer wall surface of the enameled wire along the axial direction of the enameled wire, and then putting the enameled wire into high-frequency sintering equipment, wherein the temperature is controlled to be 250-330 ℃, and the production speed is 3-11 m/min, so that the high-PDIV insulated electromagnetic wire is obtained.
5. The method of manufacturing an insulated magnet wire with high PDIV according to claim 4,
the preparation method of the enameled wire comprises the following steps:
the electromagnetic wire rod is drawn into a copper conductor (1) by adopting a slow wire-feeding one-step forming polycrystalline die;
and (3) placing the copper conductor (1) in an integrally formed painting mold, and painting to form a paint film insulating layer (2) to obtain the enameled wire.
6. The method of manufacturing an insulated magnet wire with high PDIV according to claim 5,
the dimensional tolerance of the copper conductor (1) is less than or equal to +/-0.01 mm.
7. The method of manufacturing an insulated magnet wire with high PDIV according to claim 5,
the thickness deviation value of the paint film insulating layer (2) is less than or equal to 1.3.
8. The method of manufacturing an insulated magnet wire with high PDIV according to claim 4,
the thickness of the polyimide-fluorine 46 composite film (3) is 0.12 mm-0.25 mm.
9. The method of manufacturing an insulated magnet wire with high PDIV according to claim 5,
the covering rate of the polyimide-fluorine 46 composite film (3) wrapped on the enameled wire is 33.3% -66.67%;
the width of the polyimide-fluorine 46 composite film (3) is 8-20 mm.
10. A coil winding characterized by using the insulated electromagnetic wire with high PDIV as claimed in any one of claims 1 to 4,
and forming the high PDIV insulated electromagnetic wire into a hairpin type electromagnetic wire rod by adopting a one-step forming process to obtain a coil winding.
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