Abrasion resistant coated wire

Details Abrasion resistant coated wire Abrasion resistant coated wire

1999-11-08

2001-11-20

Kelly, Cynthia H. (Department: 1774)

Stock material or miscellaneous articles

Coated or structually defined flake, particle, cell, strand,...

Rod, strand, filament or fiber

C428S372000, C428S383000, C428S389000, C174S1100SR, C174S1020SP, C174S1100FC, C174S1100PM, C174S11000P

Reexamination Certificate

active

06319604

ABSTRACT:

TECHNICAL FIELD
This invention relates to an electrical conductor having an insulation coating. More particularly, the present invention relates to an electrical conductor having an abrasion and varnish craze resistant lubricated coat system.
BACKGROUND ART
Coated electrical conductors may comprise one or more electrical insulation layers formed around a conductive core. Magnet wire is one form of coated electrical conductor in which the conductive core is a copper wire, and the insulation layer or layers comprise dielectric materials, such as polymeric resins. Magnet wire is used in the electromagnet windings of transformers, electric motors, and the like. Because of its use in such windings, friction, and abrading forces are often encountered. As a result, this insulation layer can be susceptible to damage.
High voltage-surge failure rate, for example, has been of concern to motor manufacturers. Surge failure is associated with insulation damage resulting from modern, fast automatic winding and abusive coil insertion processes for motor stators. Coating a polyester insulated wire with an abrasion resistant polyamideimide and wax is one way to minimize friction thereby reducing wire surface damage during the winding process. Wires manufactured in this manner, however, can experience surge failure rates of at least about 10,0000-20,0000 parts per million. Another form of failure is varnish craze. Varnish craze is a small fissure (about 1-2 microns deep) on the surface of the coating. Typically, varnish craze includes several fissures in a localized area that impair the insulative properties of the wire. Therefore, a need exists for a wire coating that will offer high resistance to the various damaging effects to wire coatings, including abrasion, and varnish craze.
SUMMARY OF THE INVENTION
According to certain features, characteristics, embodiments and alternatives of the present invention which will become apparent as the description thereof proceeds below, the present invention provides an electrical conductor having an abrasion and varnish craze resistant lubricated coat system. The coating is made of a ceramic particulate material dispersed in a polyamideimide binder. Ceramic particulate materials suitable for incorporation in the coatings include silicon nitride (Si
3
N
4
) , aluminum nitride (AlN) , and titanium nitride (TiN). The particulate size for these ceramic materials generally ranges from 1 to 10 microns. The amount of ceramic particulate material that is used is generally from 1 to 15 percent by weight.
In another embodiment, the coating includes a ceramic particulate material and a fluoroplastic dispersed in a polyamideimide. The ceramic particulate materials being used are the same as those listed above. The fluoroplastics that may be used include polytetrafluoroethylene, polychlorotrifluoroethylene, polyvinylidene fluoride, and fluorinated ethylene propylene.
In still another embodiment, the coating includes a ceramic particulate material with polyethylene dispersed in polyamideimide. The ceramic particulate materials that can be used are, again, the same as those listed above.
In a further embodiment, a base insulation coat may be applied to a conductor. The base insulation coat may be made from any of a variety of heat resistant, electrical insulation materials such as polyetherimide, polyimide, polyesterimide, epoxy resin, polyester used as basecoat and bondable coat, polyarylsufone, and polyether ether ketone. All of the above embodiments may be used as an enamel topcoat over the insulation coat.


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