Pulsed voltage surge resistant magnet wire

• US 6,180,888 B1
• Filed: 02/03/1997
• Issued: 01/30/2001
• Est. Priority Date: 06/08/1995
• Status: Expired due to Fees

• 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): Kincaid, Kristine
• Assistant Examiner(s): Nguyen, Chau N.
• Application Number:
  US08/792,790
• Time in Patent Office: 1,457 Days
• Field of Search: 174/110.R, 174/110.N, 174/116, 174/118, 174/106.SC, 174/127, 428/372, 428/379, 428/380, 428/383, 428/384, 428/385, 428/386, 428/389
• US Class Current: 174/110.00R
• CPC Class Codes: H01B 3/30 plastics; resins; waxes
• CPC Class Codes: H02K 3/30 Windings characterised by the insulating material
• CPC Class Codes: Y10T 428/2927 including structurally defined particulate matter

Abstract

A pulsed voltage surge resistant magnet wire having a conductor and a continuous and concentric and flexible uniform coat of insulation material superimposed on the conductor. The insulation material has an effective amount of a particulate filler material dispersed throughout the material to increase the pulsed volt surge resistance of the insulation material by at least ten-fold in comparison testing at 20 kHz, 0.721 kV per mil, 50% duty cycle from about 30° C. to about 130° C. with rise times of about 83 kV per microsecond. The particulates of the filler have a size from about 0.005 microns to about 1.0 microns.

Claims

1. A pulsed voltage surge resistant magnet wire comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material being an insulative polymeric material and having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mill, 50% duty cycle, from about 30°

to 130°

C. and a rate of rise of about 83 kV per microsecond, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof, said shielding particulate filler material having particulates of a size from about 0.005 microns to about 1.0 microns.

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

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

4. The magnet wire of claim 1 wherein said conductor is chosen from the group of copper and aluminum conductors, and said magnet wire meets all of the dimensional specifications of the ANSI/NEMA MW1000 standards 1993.

5. The magnet wire of claim 1 wherein said filler material is dispersed throughout said coat of insulation material.

6. The magnet wire of claim 1 wherein said filler material is present in the insulation material from about 1% to about 65% by weight of said insulation material.

7. The magnet wire of claim 1 wherein said filler material is a metallic oxide having a particulate size from about 0.01 to about 0.8 microns in an amount of less than 20% weight of said insulation material.

8. A pulsed voltage surge resistant magnet wire comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C., and a rate of rise of about 83 kV per microsecond, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof, and having particulates of a size from about 0.005 microns to about 1.0 microns, said insulation material is chosen from a group of polymeric materials consisting of polyamide, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof.

9. A pulsed voltage surge resistant magnet wire comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material having an effective amount of particulate non-conductive shielding filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C., and a rate of rise of about 83 kV per microsecond, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof, said shielding particulate filler material having particulates of a size from about 0.005 microns to about 1.0 microns, said insulation material being chosen from the group of polymeric materials consisting of polyamide, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof, said shielding particulate filler material being present in the insulation material from about 1% to about 65% by weight of said insulation material.

10. A pulsed voltage surge resistant magnet wire comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material being an insulative polymeric material and having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C., and a rate of rise of about 83 kV per microsecond, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof, said shielding particulate filler material having particulates of a size from about 0.01 to about 0.8 microns, said shielding particulate filler material being present in the insulation material from about 1% to about 65% by weight of said insulation material.

11. A pulsed voltage surge resistant magnet wire comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C. and a rate of rise of about 83 kV per microsecond, said insulation material is chosen from the group of polymeric materials consisting of polyamides, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof, said shielding particulate filler material is chosen from the group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof.

12. A pulsed voltage surge resistant magnet wire comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C. and a rate of rise of about 83 kV per microsecond, said insulation material being chosen from a group of polymeric materials consisting of polyamide, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof, said shielding particulate filler material being metallic oxide having a particulate size from about 0.01 to about 0.8 microns in an amount of less than 20% weight of said insulation material, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof.

13. A magnet wire for use in PWM, variable frequency motors comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C. and a rate of rise of about 83 kV per microsecond, said particulates of said shielding particulate filler material having a size from about 0.005 microns to about 1.0 microns.

14. The magnet wire of claim 13 wherein said insulation material is chosen from the group of polymeric materials consisting of polyamides, polyimides, polyvinyl acetals, polyurethanes, polyetherimides epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof.

15. The magnet wire of claim 13 wherein said filler material has a particulate size from about 0.01 to about 0.8 microns.

16. The magnet wire of claim 13 wherein said conductor is chosen from the group of copper and aluminum conductors, and said magnet wire meets all of the dimensional specifications of the ANSI/NEMA MW1000 standards 1993.

17. The magnet wire of claim 13 wherein said filler material is dispersed throughout said coat of insulation material.

18. The magnet wire of claim 13 wherein said filler material is present in the insulation material from about 1% to about 65% by weight of said insulation material.

19. The magnet wire of claim 13 wherein said filler material is a metallic oxide having a particulate size from about 0.01 to about 0.8 microns in an amount of less than 20% weight of said insulation material.

20. A magnet wire for use in PWM, variable frequency motors comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C., and a rate of rise of about 83 kV per microsecond, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof, said shielding particulate filler material having particulates of a size from about 0.005 microns to about 1.0 microns, said insulation material being chosen from a group of polymeric materials consisting of polyamide, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof.

21. A magnet wire for use in PWM, variable frequency motors comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material having an effective amount of shielding particulate non-conductive filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C., and a rate of rise of about 83 kV per microsecond, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof, said shielding particulate filler material having particulates of a size from about 0.005 microns to about 1.0 microns, said insulation material being chosen from a group of polymeric materials consisting of polyamide, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof, said shielding particulate filler material being present in the insulation material from about 1% to about 65% by weight of said insulation material.

22. A magnet wire for use in PWM, variable frequency motors comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C., and a rate of rise of about 83 kV per microsecond, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof, said shielding particulate filler material having particulates of a size from about 0.01 to about 0.8 microns, said shielding particulate filler material is present in an insulation material from about 1% to about 65% by weight of said insulation material.

23. A magnet wire for use in PWM, variable frequency motors comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C. and a rate of rise of about 83 kV per microsecond, said insulation material is chosen from a group of polymeric materials consisting of polyamides, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof, said shielding particulate filler material has a particulate size from about 0.01 to about 0.8 microns, said shielding particulate filler material is chosen from the group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof.

24. A magnet wire for use in PWM, variable frequency motors comprising a conductor and a continuous and concentric and uniform and flexible coat of insulation material superimposed on said conductor, said insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C. and a rate of rise of about 83 kV per microsecond, said insulation material is chosen from a group of polymeric materials consisting of polyamide, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof, said shielding particulate filler material is a metallic oxide having a particulate size from about 0.01 to about 0.8 microns in an amount of less than 20% weight of said insulation material, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof.

25. A pulsed voltage surge resistance insulation material comprising an insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C. and a rate of rise of about 83 kV per microsecond, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof, said shielding particulate filler material having particulates of a size from about 0.005 to about 1.0 microns.

26. The insulation material of claim 25 wherein said insulation material is chosen from the group of polymeric materials consisting of polyamides, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof.

27. The insulation material of claim 25 wherein said filler material has a particulate size from about 0.01 to about 0.8 microns.

28. The insulation material of claim 25 wherein said conductor is chosen from the group of copper and aluminum conductors, and said magnet wire meets all of the dimensional specifications of the ANSI/NEMA MW1000 standards 1993.

29. The insulation material of claim 25 wherein said filler material is dispersed throughout said coat of insulation material.

30. The insulation material of claim 25 wherein said filler material is present in the insulation material from about 1% to about 65% by weight of said insulation material.

31. The insulation material of claim 25 wherein said filler material is a metallic oxide having a particulate size from about 0.01 to about 0.8 microns in an amount of less than 20% weight of said insulation material.

32. A pulsed voltage surge resistant insulation material comprising an insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C., and a rate of rise of about 83 kV per microsecond, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof, said shielding particulate filler material having particulates of a size from about 0.005 microns to about 1.0 microns, said insulation material being chosen from a group of polymeric materials consisting of polyamide, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof.

33. A pulsed voltage surge resistant insulation material comprising an insulation material having an effective amount of shielding particulate non-conductive filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C., and a rate of rise of about 83 kV per microsecond, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof, said shielding particulate filler material having particulates of a size from about 0.005 microns to about 1.0 microns, said insulation material being chosen from a group of polymeric materials consisting of polyamide, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof, said shielding particulate filler material being present in an insulation material from about 1% to about 65% by weight of said insulation material.

34. A pulsed voltage surge resistant insulation material comprising an insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C., and a rate of rise of about 83 kV per microsecond, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof, said shielding particulate filler material having particulates of a size from about 0.01 to about 0.8 microns, said shielding particulate filler material being present in an insulation material from about 1% to about 65% by weight of said insulation material.

35. A pulsed voltage surge resistant insulation material comprising an insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C. and a rate of rise of about 83 kV per microsecond, said insulation material is chosen from the group of polymeric materials consisting of polyamides, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof, said shielding particulate filler material has a particulate size from about 0.01 to about 0.8 microns, said shielding particulate filler material is chosen from the group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof.

36. A pulsed voltage surge resistant insulation material comprising an insulation material having an effective amount of shielding particulate filler material dispersed throughout said coat to increase the pulsed voltage surge resistance of said insulation material by at least ten-fold in comparison testing at 20 kHz, 0.7 to 1 kV per mil, 50% duty cycle, from about 30°

to 130°

C. and a rate of rise of about 83 kV per microsecond, said insulation material being chosen from a group of polymeric materials consisting of polyamide, polyimides, polyvinyl acetals, polyurethanes, polyetherimides, epoxies, acrylics, polyamideimides, polyesters, polyesterimide, polyamide esters, polyesteramideimides, polyimide esters and combinations thereof, said shielding particulate filler material is a metallic oxide having a particulate size from about 0.01 to about 0.8 microns in an amount of less than 20% weight of said insulation material, said shielding particulate filler material being chosen from a group of metal oxides consisting of titanium dioxide, alumina, silica, zirconium oxide, zinc oxide, iron oxide and combinations thereof.