TWI820493B - 耐電暈漆包圓線及其製備方法 - Google Patents
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Abstract
一種耐電暈漆包圓線適用於電動汽車電機且包含銅導體以及絕緣層,絕緣層包覆銅導體且由內到外依次包含耐電暈聚醯胺醯亞胺塗層、耐電暈特種樹脂塗層、耐電暈聚醯亞胺塗層、耐電暈改性矽樹脂塗層,以及耐電暈聚醯胺醯亞胺塗層。
Description
本發明關於一種耐電暈漆包圓線及其製備方法,尤指一種適用於電動汽車電機之耐電暈漆包圓線及其製備方法。
隨著SiC、GaN高功率元件的應用,對電動汽車電機用絕緣材料及系統提出了更高的技術要求:頻率提升,超高頻化,產生嚴重的局放及電暈腐蝕,增加介質損耗發熱,加速絕緣電熱老化;電壓升高,額定電壓≥800V,產生的高頻脈衝尖峰電壓遠高於現有電壓值,急需絕緣材料及系統提升抵抗高頻尖峰電壓的能力,具備更高的局部放電初始電壓值(Partial Discharge Inception Voltage, PDIV)及局部放電熄滅電值(Partial Discharge Extinction Voltage, PDEV)。
耐電暈漆包圓線作為電動汽車驅動電機主要絕緣材料,其性能對驅動電機的使用壽命等起到決定性作用,隨著驅動電機的額定電壓升高,關鍵是要提升漆包圓線的PDIV/PDEV值。目前現有的耐電暈漆包圓線的PDIV值基本在900V左右,PDEV值500V左右,不能滿足高電壓驅動電機使用技術需求。另外隨著驅動電機超高頻化發展,漆包圓線的耐電暈壽命還需進一步提升。所以急需研製一種具有高PDIV/PDEV值之耐電暈漆包圓線及其製備方法來滿足高電壓電動汽車驅動電機的發展與應用技術需求。
本發明所要解決的技術問題是克服先前技術的不足,提供一種適用於電動汽車電機之耐電暈漆包圓線及其製備方法。
根據一實施例,本發明提供一種耐電暈漆包圓線,其適用於電動汽車電機,該耐電暈漆包圓線包含一銅導體以及一絕緣層。該絕緣層包覆該銅導體且由內到外依次包含一第一耐電暈聚醯胺醯亞胺塗層、一耐電暈特種樹脂塗層、一耐電暈聚醯亞胺塗層、一耐電暈改性矽樹脂塗層,以及一第二耐電暈聚醯胺醯亞胺塗層。
進一步地,該第一耐電暈聚醯胺醯亞胺塗層、該耐電暈特種樹脂塗層、該耐電暈聚醯亞胺塗層、該耐電暈改性矽樹脂塗層,以及該第二耐電暈聚醯胺醯亞胺塗層之厚度比例可分別為10%-20%、10%-25%、5%-15%、25%-35%,以及10%-25%。
進一步地,該第一耐電暈聚醯胺醯亞胺塗層、該耐電暈聚醯亞胺塗層以及該第二耐電暈聚醯胺醯亞胺塗層可由奈米二氧化矽、三氧化二鋁或其組合改性製備之耐電暈聚醯胺醯亞胺/聚醯亞胺漆塗覆而成。
進一步地,該耐電暈特種樹脂塗層可由奈米二氧化矽、三氧化二鋁或其組合改性製備之耐電暈特種樹脂漆液塗覆而成。
進一步地,該耐電暈特種樹脂漆液可選自苯並噁嗪、聚芳醚腈、聚芳醚腈碸、聚醚碸、改性聚醚醚酮、氰酸酯預聚體或其組合。
進一步地,該耐電暈改性矽樹脂塗層由下列製備方法所製成:將一定量正矽酸乙酯或正矽酸丁酯添加到反應瓶內,開動攪拌,加入正矽酸乙酯或正矽酸丁酯質量分數30%-100%含有羥基的聚矽氧烷以及物料總質量分數0.01%-0.2%的催化劑,開始升溫到140℃-150℃,保溫反應,待沒有醇類溶劑蒸餾出,抽真空至-0.09MPa以上,保真空1-2小時,冷卻、待用;將上述物料放料到密封的均質乳化釜內,添加醋酸丁酯調整固體含量到50%-60%;將一定量的奈米粉體添加到均質乳化釜內,開動攪拌速度到8000-12000r/min以均質分散至D50<100nm,以及開動釜內夾套冷卻水冷卻以使釜內物料溫度低於60℃,待冷卻到40℃以下,加入一定量的酚醛環氧樹脂以及促進劑攪拌均勻,且採用10000目濾袋,加壓過濾到潔淨桶內,密封包裝。
根據另一實施例,本發明提供一種耐電暈漆包圓線製備方法,其包含提供一銅導體以及在該銅導體上依次塗覆一第一耐電暈聚醯胺醯亞胺塗層、一耐電暈特種樹脂塗層、一耐電暈聚醯亞胺塗層、一耐電暈改性矽樹脂塗層,以及一第二耐電暈聚醯胺醯亞胺塗層,以形成一絕緣層包覆該銅導體而製得該耐電暈漆包圓線。
本發明與先前技術相比具有如下優點:漆包圓線的PDIV/PDEV值明顯提升,相對於常規技術提升20%以上。耐電暈壽命優異,耐電暈壽命>80小時。漆膜耐高溫性能好,滿足220℃以上耐溫等級需求。漆膜附著性優異,抗彎曲,延展性好,便於高槽滿率驅動電機繞組嵌線。
關於本發明之優點與精神可以藉由以下的實施方式及所附圖式得到進一步的瞭解。
以下結合具體實施例對本發明做進一步說明。應理解的是,這些實施例是用於說明本發明而不限於限制本發明的範圍。
於實施例1中,本發明提供一種適用於電動汽車電機且具有高PDIV/PDEV值之耐電暈漆包圓線,請參閱第1圖,其為根據本發明之一實施例所提供之耐電暈漆包圓線的剖面示意圖,如第1圖所示之耐電暈漆包圓線包含銅導體1及絕緣層2且透過以下步驟製備。
在臥式漆包圓線生產線上採用聚晶材質塗漆模具製備耐電暈漆包圓線,其中銅線退火溫度為500℃/470℃,烘道固化溫度為550℃,生產DV值為53。線規為0.8mm,依次塗覆耐電暈聚醯胺醯亞胺塗層3、耐電暈特種樹脂塗層4、耐電暈聚醯亞胺塗層5、耐電暈改性矽樹脂塗層6,以及耐電暈聚醯胺醯亞胺塗層7以形成絕緣層2包覆銅導體1,其塗層厚度比例分別為18%、19%、11%、30%、22%,漆膜雙邊總厚度為0.13mm。其中耐電暈聚醯胺醯亞胺塗層3、耐電暈聚醯亞胺塗層5以及耐電暈聚醯胺醯亞胺塗層7可由奈米二氧化矽、三氧化二鋁或其組合改性製備之耐電暈聚醯胺醯亞胺/聚醯亞胺漆塗覆而成;耐電暈特種樹脂塗層4可為奈米二氧化矽改性的聚醚碸塗層;耐電暈改性矽樹脂塗層6之製備方法如第2圖所示,其中步驟S20係可較佳地為加入正矽酸乙酯或正矽酸丁酯質量分數30%-100%含有羥基的聚矽氧烷以及物料總質量分數0.01%-0.2%的催化劑(但不受此限):
步驟S20: 將5000g的正矽酸乙酯添加到反應瓶內,開動攪拌,加入3150g含有羥基的超支化聚矽氧烷以及2.5g的氯化亞錫,開始升溫到145℃,待沒有醇類溶劑蒸餾出,抽真空至-0.09MPa,保真空2小時,冷卻、待用;
步驟S22: 稱取3500g的上述反應物料放料到密封的均質乳化釜內,添加3340g的醋酸丁酯攪拌均勻以調整固體含量到50%-60%;
步驟S24: 將1104g平均粒徑為50nm的奈米三氧化二鋁添加到密封的均質乳化釜內,開動攪拌速度到8000r/min(開動釜內夾套冷卻水冷卻,確保釜內物料溫度低於60℃),均質分散至D50<100nm,冷卻到40℃以下,加入1300g的F51酚醛環氧樹脂及1.44g的三氟化硼乙醚攪拌均勻,採用10000目濾袋,加壓過濾到潔淨桶內,密封包裝。
於實施例2中,本發明提供一種適用於電動汽車電機且具有高PDIV/PDEV值之耐電暈漆包圓線,透過以下步驟製備。
在臥式漆包圓線生產線上採用聚晶材質塗漆模具製備耐電暈漆包圓線,其中銅線退火溫度為500℃/470℃,烘道固化溫度為550℃,生產DV值為53。線規為0.8mm,依次塗覆耐電暈聚醯胺醯亞胺塗層3、耐電暈特種樹脂塗層4、耐電暈聚醯亞胺塗層5、耐電暈改性矽樹脂塗層6,以及耐電暈聚醯胺醯亞胺塗7以形成絕緣層2包覆銅導體1,其塗層厚度比例分別為15%、22%、13%、31%、19%, 漆膜雙邊總厚度為0.13mm。其中耐電暈聚醯胺醯亞胺塗層3、耐電暈聚醯亞胺塗層5以及耐電暈聚醯胺醯亞胺塗層7可由奈米二氧化矽、三氧化二鋁或其組合改性製備之耐電暈聚醯胺醯亞胺/聚醯亞胺漆塗覆而成;耐電暈特種樹脂塗層4可為奈米三氧化二鋁改性的雜萘聯苯聚醚腈碸塗層;耐電暈改性矽樹脂塗層6之製備方法如第3圖所示,其中步驟S30係可較佳地為加入正矽酸乙酯或正矽酸丁酯質量分數30%-100%含有羥基的聚矽氧烷以及物料總質量分數0.01%-0.2%的催化劑(但不受此限):
步驟S30: 將6200g的正矽酸丁酯添加到反應瓶內,開動攪拌,加入4530g含有羥基的多面體倍半矽氧烷寡聚物(polyhedral oligomeric silsesquioxane, POSS)結構聚矽氧烷以及3.2g的氯化亞錫,開始升溫到146℃,待沒有醇類溶劑蒸餾出,抽真空至-0.09MPa,保真空2小時,冷卻、待用;
步驟S32: 稱取5000g的上述反應物料放料到密封的均質乳化釜內,添加4890g的醋酸丁酯攪拌均勻以調整固體含量到50%-60%;
步驟S34: 將1570g平均粒徑45nm的奈米二氧化矽添加到密封的均質乳化釜內,開動攪拌速度到8500r/min(開動釜內夾套冷卻水冷卻,確保釜內物料溫度低於60℃),均質分散至D50<100nm, 冷卻到40℃以下,加入2200g的F44酚醛環氧樹脂及2.16g的三氟化硼乙胺攪拌均勻,採用10000目濾袋,加壓過濾到潔淨桶內,密封包裝。
於實施例3中,本發明提供一種適用於電動汽車電機且具有高PDIV/PDEV值之耐電暈漆包圓線,透過以下步驟製備。
在臥式漆包圓線生產線上採用聚晶材質塗漆模具製備耐電暈漆包圓線,其中銅線退火溫度為500℃/470℃,烘道固化溫度為550℃,生產DV值為53。線規為0.8mm,依次塗覆耐電暈聚醯胺醯亞胺塗層3、耐電暈特種樹脂塗層4、耐電暈聚醯亞胺塗層5、耐電暈改性矽樹脂塗層6,以及耐電暈聚醯胺醯亞胺塗層7以形成絕緣層2包覆銅導體1,其塗層厚度比例分別為16%、23%、12%、30%、19%, 漆膜雙邊總厚度為0.13mm。其中耐電暈聚醯胺醯亞胺塗層3、耐電暈聚醯亞胺塗層5以及耐電暈聚醯胺醯亞胺塗層7可由奈米二氧化矽、三氧化二鋁或其組合改性製備之耐電暈聚醯胺醯亞胺/聚醯亞胺漆塗覆而成;耐電暈特種樹脂塗層4為奈米三氧化二鋁改性的聚醚碸塗層;耐電暈改性矽樹脂塗層6的製備方法如第4圖所示,其中步驟S40係可較佳地為加入正矽酸乙酯或正矽酸丁酯質量分數30%-100%含有羥基的聚矽氧烷以及物料總質量分數0.01%-0.2%的催化劑(但不受此限):
步驟S40: 將4500g的正矽酸乙酯添加到反應瓶內,開動攪拌,加入3600g含有羥基的超支化聚矽氧烷以及2.3g的氯化亞錫,開始升溫到150℃,待沒有醇類溶劑蒸餾出,抽真空至-0.09MPa,保真空2小時,冷卻、待用;
步驟S42: 稱取3000g的上述反應物料放料到密封的均質乳化釜內,添加2172g的醋酸丁酯攪拌均勻以調整固體含量到50%-60%;
步驟S44: 將890g平均粒徑52nm的奈米二氧化矽添加到密封的均質乳化釜內,開動攪拌速度到9500r/min(開動釜內夾套冷卻水冷卻,確保釜內物料溫度低於60℃),均質分散至D50<100nm, 冷卻到40℃以下,加入1280g的F51酚醛環氧樹脂及1.2g的環氧樹脂固化促進劑(DMP-30)攪拌均勻,採用10000目濾袋,加壓過濾到潔淨桶內,密封包裝。
於對比例1中,在臥式漆包圓線生產線上採用聚晶材質塗漆模具製備耐電暈漆包圓線,其中銅線退火溫度為500℃/470℃,烘道固化溫度為550℃,生產DV值為53。線規為0.8mm,依次塗覆耐電暈聚酯亞胺塗層以及聚醯胺醯亞胺塗層,塗層厚度比例分別為85%、15%(市場上常規複合塗層耐電暈漆包圓線),漆膜雙邊總厚度為0.13mm。
於對比例2中,在臥式漆包圓線生產線上採用聚晶材質塗漆模具製備耐電暈漆包圓線,其中銅線退火溫度為500℃/470℃,烘道固化溫度為550℃,生產DV值為53。線規為0.8mm,塗覆耐電暈聚醯胺醯亞胺單塗層(耐電暈單塗層聚醯胺醯亞胺漆塗製),漆膜雙邊總厚度為0.13mm。
對實施例1-3及對比例1-2之耐電暈漆包圓線各項性能進行測試,結果參見表一。
表一 實施例1-3和對比例1-2浸漬樹脂的性能對比
性能指標 | 實施例1 | 實施例2 | 實施例3 | 對比例1 | 對比例2 |
急拉斷試驗 | 未失去附著力 | 未失去附著力 | 未失去附著力 | 未失去附著力 | 未失去附著力 |
彎曲試驗 (在1d圓棒上緊緊纏繞10圈,漆層不應開裂) | 未開裂 | 未開裂 | 未開裂 | 未開裂 | 未開裂 |
PDIV( V) | 1030 | 1080 | 1056 | 736 | 805 |
PDEV( V) | 959 | 916 | 983 | 516 | 532 |
耐電暈壽命(h:min) | 85:39 | 86:21 | 87:26 | 56:52 | 68:36 |
其中,PDIV值測試,背景雜音<5pc;耐電暈壽命測試條件為:在高頻脈衝測試上進行測試,波形方波,溫度155℃,頻率20kHz,脈衝時間100ns,電壓3000V。
由於上述實施例1-3的實施,本發明與先前技術相比具有如下優點:漆包圓線的PDIV/PDEV值明顯提升,相對於常規技術提升20%以上。耐電暈壽命優異,耐電暈壽命>80小時。漆膜耐高溫性能好,滿足220℃以上耐溫等級需求。漆膜附著性優異,抗彎曲,延展性好,便於高槽滿率驅動電機繞組嵌線。
以上所述僅為本發明之較佳實施例,凡依本發明申請專利範圍所做之均等變化與修飾,皆應屬本發明之涵蓋範圍。
1:銅導體
2:絕緣層
3:耐電暈聚醯胺醯亞胺塗層
4:耐電暈特種樹脂塗層
5:耐電暈聚醯亞胺塗層
6:耐電暈改性矽樹脂塗層
7:耐電暈聚醯胺醯亞胺塗層
S20、S22、S24、S30、S32、S34、S40、S42、S44:步驟
第1圖為根據本發明之一實施例所提出之耐電暈漆包圓線的剖面示意圖。
第2圖為根據本發明之一實施例所提出之耐電暈漆包圓線之耐電暈改性矽樹脂塗層製備方法的流程圖。
第3圖為根據本發明之另一實施例所提出之耐電暈漆包圓線之耐電暈改性矽樹脂塗層製備方法的流程圖。
第4圖為根據本發明之另一實施例所提出之耐電暈漆包圓線之耐電暈改性矽樹脂塗層製備方法的流程圖。
1:銅導體
2:絕緣層
3:耐電暈聚醯胺醯亞胺塗層
4:耐電暈特種樹脂塗層
5:耐電暈聚醯亞胺塗層
6:耐電暈改性矽樹脂塗層
7:耐電暈聚醯胺醯亞胺塗層
Claims (12)
- 一種耐電暈漆包圓線,其適用於電動汽車電機,該耐電暈漆包圓線包含:銅導體;以及絕緣層,其包覆該銅導體且由內到外依次包含第一耐電暈聚醯胺醯亞胺塗層、耐電暈特種樹脂塗層、耐電暈聚醯亞胺塗層、耐電暈改性矽樹脂塗層,以及第二耐電暈聚醯胺醯亞胺塗層,其中該耐電暈聚醯亞胺塗層由奈米二氧化矽、三氧化二鋁或其組合改性製備之耐電暈聚醯亞胺漆塗覆而成。
- 如請求項1之耐電暈漆包圓線,其中該第一耐電暈聚醯胺醯亞胺塗層、該耐電暈特種樹脂塗層、該耐電暈聚醯亞胺塗層、該耐電暈改性矽樹脂塗層,以及該第二耐電暈聚醯胺醯亞胺塗層之厚度比例分別為10%-20%、10%-25%、5%-15%、25%-35%,以及10%-25%。
- 如請求項1或2之耐電暈漆包圓線,其中該第一耐電暈聚醯胺醯亞胺塗層、該耐電暈聚醯亞胺塗層以及該第二耐電暈聚醯胺醯亞胺塗層由奈米二氧化矽、三氧化二鋁或其組合改性製備之耐電暈聚醯胺醯亞胺/聚醯亞胺漆塗覆而成。
- 如請求項1或2之耐電暈漆包圓線,其中該耐電暈特種樹脂塗層由奈米二氧化矽、三氧化二鋁或其組合改性製備之耐電暈特種樹脂漆液塗覆而成。
- 如請求項4之耐電暈漆包圓線,其中該耐 電暈特種樹脂漆液選自苯並噁嗪、聚芳醚腈、聚芳醚腈碸、聚醚碸、改性聚醚醚酮、氰酸酯預聚體或其組合。
- 如請求項1或2之耐電暈漆包圓線,其中該耐電暈改性矽樹脂塗層由下列製備方法所製成:將一定量正矽酸乙酯或正矽酸丁酯添加到反應瓶內,開動攪拌,加入正矽酸乙酯或正矽酸丁酯質量分數30%-100%含有羥基的聚矽氧烷以及物料總質量分數0.01%-0.2%的催化劑,開始升溫到140℃-150℃,保溫反應,待沒有醇類溶劑蒸餾出,抽真空至-0.09MPa以上,保真空1-2小時,冷卻、待用;將上述物料放料到密封的均質乳化釜內,添加醋酸丁酯調整固體含量到50%-60%;以及將一定量的奈米粉體添加到均質乳化釜內,開動攪拌速度到8000-12000r/min以均質分散至D50<100nm,以及開動釜內夾套冷卻水冷卻以使釜內物料溫度低於60℃,待冷卻到40℃以下,加入一定量的酚醛環氧樹脂以及促進劑攪拌均勻,且採用10000目濾袋,加壓過濾到潔淨桶內,密封包裝。
- 一種耐電暈漆包圓線製備方法,其包含:提供銅導體;以及在該銅導體上依次塗覆第一耐電暈聚醯胺醯亞胺塗層、耐電暈特種樹脂塗層、耐電暈聚醯亞胺塗層、耐電暈改性矽樹脂塗層,以及第二耐電暈聚醯胺醯亞胺塗層,以 形成絕緣層包覆該銅導體而製得該耐電暈漆包圓線,其中該耐電暈聚醯亞胺塗層由奈米二氧化矽、三氧化二鋁或其組合改性製備之耐電暈聚醯亞胺漆塗覆而成。
- 如請求項7之耐電暈漆包圓線製備方法,其中該第一耐電暈聚醯胺醯亞胺塗層、該耐電暈特種樹脂塗層、該耐電暈聚醯亞胺塗層、該耐電暈改性矽樹脂塗層,以及該第二耐電暈聚醯胺醯亞胺塗層之厚度比例分別為10%-20%、10%-25%、5%-15%、25%-35%,以及10%-25%。
- 如請求項7或8之耐電暈漆包圓線製備方法,其中該第一耐電暈聚醯胺醯亞胺塗層、該耐電暈聚醯亞胺塗層以及該第二耐電暈聚醯胺醯亞胺塗層由奈米二氧化矽、三氧化二鋁或其組合改性製備之耐電暈聚醯胺醯亞胺/聚醯亞胺漆塗覆而成。
- 如請求項7或8之耐電暈漆包圓線製備方法,其中該耐電暈特種樹脂塗層由奈米二氧化矽、三氧化二鋁或其組合改性製備之耐電暈特種樹脂漆液塗覆而成。
- 如請求項10之耐電暈漆包圓線製備方法,其中該耐電暈特種樹脂漆液選自苯並噁嗪、聚芳醚腈、聚芳醚腈碸、聚醚碸、改性聚醚醚酮、氰酸酯預聚體或其組合。
- 如請求項7或8之耐電暈漆包圓線製備方法,其中該耐電暈改性矽樹脂塗層由下列製備方法所製成: 將一定量正矽酸乙酯或正矽酸丁酯添加到反應瓶內,開動攪拌,加入一定量含有羥基的聚矽氧烷以及催化劑,開始升溫到140℃-150℃,保溫反應,待沒有醇類溶劑蒸餾出,抽真空至-0.09MPa以上,保真空1-2小時,冷卻、待用;將上述物料放料到密封的均質乳化釜內,添加醋酸丁酯調整固體含量到50%-60%;以及將一定量的奈米粉體添加到均質乳化釜內,開動攪拌速度到8000-12000r/min以均質分散至D50<100nm,以及開動釜內夾套冷卻水冷卻以使釜內物料溫度低於60℃,待冷卻到40℃以下,加入一定量的酚醛環氧樹脂以及促進劑攪拌均勻,且採用10000目濾袋,加壓過濾到潔淨桶內,密封包裝。
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