Pulsed voltage surge resistant magnet wire

• US 5,654,095 A
• Filed: 06/08/1995
• Issued: 08/05/1997
• Est. Priority Date: 06/08/1995
• Status: Expired due to Term

• Current Assignee: General Cable Technologies Corporation (General Cable Corporation)
• Original Assignee: Phelps Dodge Industries Incorporated (Freeport-Mcmoran Copper & Gold Incorporated)
• Inventors: Yin, Weijun, Barta, Donald J.
• Primary Examiner(s): RYAN, PATRICK J
• Application Number:
  US08/482,214
• Time in Patent Office: 789 Days
• Field of Search: 427/120, 428/389, 428/372, 428/379, 428/380, 428/383, 428/384, 428/385, 428/386, 174/110 R, 174/118, 174/120 R, 174/121 A, 174/121 SR, 174/120 SR
• US Class Current: 428/372
• CPC Class Codes: H02K 17/00 Asynchronous induction motors; Asynchronous induction generators
• CPC Class Codes: H02K 3/30 Windings characterised by the insulating material
• CPC Class Codes: H02K 3/34 between conductors or between conductor and core, e.g. slot insulation
• CPC Class Codes: Y10T 428/2927 including structurally defined particulate matter
• CPC Class Codes: Y10T 428/294 including metal or compound thereof [excluding glass, ceramic and asbestos]
• CPC Class Codes: Y10T 428/2942 Plural coatings
• CPC Class Codes: Y10T 428/2947 Synthetic resin or polymer in plural coatings, each of different type
• CPC Class Codes: Y10T 428/2949 Glass, ceramic or metal oxide in coating
• CPC Class Codes: Y10T 428/2951 Metal with weld modifying or stabilizing coating [e.g., flux, slag, producer, etc.]
• CPC Class Codes: Y10T 428/2953 Titanium compound in coating
• CPC Class Codes: Y10T 428/2958 Metal or metal compound in coating

Abstract

A pulsed voltage surge resistant magnet wire comprising a conductor, a continuous and concentric and flexible uniform coat of base insulation material superimposed on the conductor and an essentially continuous and concentric and uniform pulsed voltage surge shield overlaying the coat of base insulation material.

Claims

1. A magnet wire comprising a conductor, and a pulse voltage surge shield superimposed thereon, said shield including a binder and an effective amount of a particulate material to increase said pulsed voltage surge resistance of said shield by at least ten fold in comparison testing at 20 kHz, less than 1 kV per mil, 50% duty cycle, from about 30°

to about 130°

C., and a rate of rise of about 83 kV per microsecond, said material having a particulate size ranging from about 0.005 to about 1 micron, said conductor and said shield being in compliance with ANSI/NEMA MW1000 1993.

2. The magnet wire of claim 1 wherein said magnet wire includes a conductor with a continuous and concentric and flexible and uniform coat of insulation material superimposed on said conductor.

3. The magnet wire of claim 1 wherein said particulate material has a particulate size from about 0.01 to about 0.8 microns.

4. The magnet wire of claim 1 wherein said particulate material is chosen from the group of materials consisting of metallic oxides, naturally occurring clays, and mixtures thereof.

5. The magnet wire of claim 1 wherein said particulate material is chosen from the group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof.

6. The magnet wire of claim 2 wherein said insulation material is chosen from the group of polymeric materials consisting of polyamides, polyimides, polyamideimides, polyesters, polyesterimide, polyamide esters, polyamideimides, polyimide esters, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics and combinations thereof.

7. The magnet wire of claim 1 wherein said binder is chosen from the group of polymeric materials consisting of polyamides, polyimides, polyamideimides, polyesters, polyesterimides, polyamide esters, polyesteramideimides, polyimide esters, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics and combinations thereof.

8. The magnet wire of claim 1 wherein said particulate material is dispersed throughout said shield.

9. The magnet wire of claim 1 wherein said particulate filler material is present in said shield from about 1% to about 65% by weight of said shield.

10. The magnet wire of claim 1 wherein said particulate material is a metallic oxide having a particulate size from about 0.01 to about 0.8 micron present in an amount of less than 20% weight of said shield.

11. A pulsed voltage surge resistant magnet wire comprising a conductor, a continuous and concentric and flexible and uniform coat of base insulation material superimposed on said conductor, and an essentially continuous and concentric and uniform pulse voltage surge shield overlaying said coat of base insulation material said shield including a binder and an effective amount of particulate material to increase said pulsed voltage surge resistance of said shield by at least ten-fold in comparison testing at 20 kHz, less than 1 kV per mil, 50% duty cycle, from about 30°

to about 130°

C., and a rate of rise of about 83 kV per microsecond, said conductor and base insulation material and said shield all being in compliance with ANSI/NEMA MW1000 1993.

12. The magnet wire of claim 11 wherein said shield includes particulate material having a particulate size from about 0.01 to about 0.8 microns.

13. The magnet wire of claim 12 wherein said particulate material is chosen from the group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof.

14. The magnet wire of claim 12 wherein said particulate material is chosen from the group of materials consisting of metallic oxides, naturally occurring clays and mixtures thereof.

15. The magnet wire of claim 14 wherein said clays are chosen from the group consisting of aluminosilicate clays and combinations thereof.

16. The magnet wire of claim 12 wherein said particulate material is dispersed throughout said shield by high shear mixing.

17. The magnet wire of claim 12 wherein said particulate material is present in said shield from about 1% to about 65% by weight of said shield.

18. The magnet wire of claim 12 wherein said particulate material is a metallic oxide having a particulate size from about 0.01 to about 0.8 micron present in an amount of less than 20% weight of said shield.

19. The magnet wire of claim 11 wherein said insulation material is chosen from the group of polymeric materials consisting of polyamides, polyimides, polyamideimides, polyesters, polyesterimide, polyamide esters, polyamideimides, polyimide esters, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics and combinations thereof.

20. The magnet wire of claim 11 wherein said shield includes a binder and said binder is chosen from the group of polymeric materials consisting of polyamide, polyimides, polyamideimides;

polyesters, polyesterimides, polyamide esters, polyesteramideimides, polyimide esters, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics and combinations thereof.

21. A magnet wire having a pulse voltage surge shield superimposed thereon for use in PWM, variable frequency and/or inverter driven motors, said shield including a binder and an effective mount of a particulate material to increase said pulsed voltage surge resistance of said shield by at least ten-fold in comparison testing at 20 kHz, less than 1 kV per mil, 50% duty cycle, from about 30°

to about 130°

C., and a rate of rise of about 83 kv per microsecond, said material having a particulate size ranging from about 0.005 to about 1 micron, said magnet wire with said shield being in compliance with ANSI/NEMA MW1000 1993.

22. The magnet wire of claim 21 wherein said magnet wire includes a conductor with a continuous and concentric and flexible and uniform coat of insulation material superimposed on said conductor.

23. The magnet wire of claim 21 wherein said particulate material has a particulate size from about 0.01 to about 0.8 microns.

24. The magnet wire of claim 21 wherein said particulate material is chosen from the group of materials consisting of metallic oxides, naturally occurring clays, and mixtures thereof.

25. The magnet wire of claim 21 wherein said particulate material is chosen from the group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof.

26. The magnet wire of claim 22 wherein said insulation material is chosen from the group of polymeric materials consisting of polyamides, polyimides, polyamideimides, polyesters, polyesterimide, polyamide esters, polyamideimides, polyimide esters, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics and combinations thereof.

27. The magnet wire of claim 21 wherein said binder is chosen from the group of polymeric materials consisting of polyamides, polyimides, polyamideimides, polyesters, polyesterimides, polyamide esters, polyesteramideimides, polyimide esters, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics and combinations thereof.

28. The magnet wire of claim 21 wherein said particulate material is dispersed throughout said shield.

29. The magnet wire of claim 21 wherein said particulate filler material is present in said shield from about 1% to about 65% by weight of said shield.

30. The magnet wire of claim 21 wherein said particulate material is a metallic oxide having a particulate size from about 0.01 to about 0.8 micron present in an amount of less than 20% weight of said shield.