Electrical conductors coated with corona resistant multilayer insulation system

• US 5,917,155 A
• Filed: 02/02/1998
• Issued: 06/29/1999
• Est. Priority Date: 01/27/1997
• Status: Expired due to Term

• Current Assignee: Rea Magnet Wire Company Incorporated
• Original Assignee: Rea Magnet Wire Company Incorporated
• Inventors: Hake, John E., Metzler, David A.
• Primary Examiner(s): Ramirez, Nestor
• Assistant Examiner(s): Waks, Joseph
• Application Number:
  US09/017,636
• Time in Patent Office: 512 Days
• Field of Search: 174/120 R, 174/120 S, 174/120 SC, 174/105 SC, 174/107, 174/127
• US Class Current: 174/120.00R
• CPC Class Codes: H01B 3/306 Polyimides or polyesterimides
• CPC Class Codes: H01B 3/421 Polyesters

Abstract

Electrical conductor coated with a corona-resistant, multilayer insulation system comprising first, second, and third insulation layers. The first insulation layer is disposed peripherally around the electrical conductor, the second layer is disposed peripherally around the first layer, and the third layer is disposed peripherally around the second layer. The second layer is sandwiched between the first and second layers and comprises 10 to 50 parts by weight of alumina particles dispersed in 100 parts by weight of a polymeric binder.

Claims

1. An electrical conductor coated with a multilayer insulation system, said insulation system comprising:

(a) a first insulation layer disposed peripherally around the electrical conductor;

(b) a second insulation layer disposed peripherally around the first insulation layer, wherein said second insulation layer comprises from about 10 to about 50 parts by weight of alumina particles dispersed in about 80 parts by weight of a polymeric binder, and

(c) a third insulation layer disposed peripherally around the second insulation layer.

2. The coated electrical conductor of claim 1, wherein the alumina particles have a size which is sufficiently small such that the alumina particles are substantially transparent and said second insulation layer further comprises a coloring amount of a coloring agent.

3. The coated electrical conductor of claim 2, wherein the coloring agent comprises titanium dioxide.

4. The coated electrical conductor of claim 3, wherein the titanium dioxide has a size in the range from about 0.005 microns to about 0.25 microns.

5. The coated electrical conductor of claim 2, wherein the coloring agent is a dye.

6. The coated electrical conductor of claim 1, wherein the alumina particles have a size in the range from about 0.005 microns to about 0.25 microns.

7. The coated electrical conductor of claim 1, wherein the second insulation layer includes from about 15 to about 30 parts by weight of said alumina particles based on 80 parts by weight of the polymeric binder.

8. The coated electrical conductor of claim 1, wherein the third insulation layer comprises substantially no inorganic particles.

9. The coated electrical conductor of claim 1, wherein the first insulation layer comprises substantially no inorganic particles.

10. The coated electrical conductor of claim 1, wherein the first insulation layer comprises at least one resin selected from terephthalic acid alkyd, polyester, polyesterimide, polyesteramide, polyesteramideimide, polyesterurethane, polyurethane, epoxy resin, polyamide, polyimide, polyamideimide, polysulphone, silicone resin, polymers incorporating polyhydantoin, phenolic resin, vinyl copolymer, polyolefin, polycarbonate, polyether, polyetherimide, polyetheramide, polyetheramideimide, polyisocyanate and combinations of these materials.

11. The coated electrical conductor of claim 1, wherein the first insulation layer comprises a polyesterimide resin.

12. The coated electrical conductor of claim 1, wherein the second insulation layer comprises a polyesterimide resin.

13. The coated electrical conductor of claim 1, wherein the second insulation layer comprises a polyetheramideimide resin.

14. The coated electrical conductor of claim 1, wherein the first insulation layer comprises a polymeric resin which is the same as a polymeric resin contained in the second insulation layer.

15. The coated electrical conductor of claim 1, wherein the third insulation layer comprises a polymeric resin selected from terephthalic acid alkyd, polyester, polyesterimide, polyesteramide, polyesteramideimide, polyesterurethane, polyurethane, epoxy resin, polyamide, polyimide, polyamideimide, polysulphone, silicone resin, polymers incorporating polyhydantoin, phenolic resin, vinyl copolymer, polyolefin, polycarbonate, polyether, polyetherimide, polyetheramide, polyetheramideimide, polyisocyanate and combinations of these materials.

16. The coated electrical conductor of claim 1, wherein the third insulation layer comprises a polyetheramideimide resin.

17. The coated electrical conductor of claim 1, wherein the third insulation layer comprises a polymeric resin which is different from any resin included in the first and second insulation layers.