Rectangular Insulated Wire And Electric Generator Coil

Patent metadata

Field	Value
Publication number	US-2016307667-A1
Application number	US-201615181475-A
Country	US
Kind code	A1
Filing date	Jun 14, 2016
Priority date	Jan 10, 2014
Publication date	Oct 20, 2016
Grant date	—

Abstract

A rectangular insulated wire includes a rectangular conductor having a generally rectangular cross section, a thermosetting resin layer provided to cover the rectangular conductor, and a plurality of thermoplastic resin layers provided on the thermosetting resin layer. An adhesion strength between the thermosetting resin layer and the thermoplastic resin layer is 50 gf/mm to 100 gf/mm.

First claim

What is claimed is:

1 . A rectangular insulated wire comprising:
a rectangular conductor having a generally rectangular cross section; a thermosetting resin layer provided to cover the rectangular conductor; and a plurality of thermoplastic resin layers provided on the thermosetting resin layer, an adhesion strength between the thermosetting resin layer and the thermoplastic resin layer being 50 gf/mm to 100 gf/mm.

2 . The rectangular insulated wire according to claim 1 , wherein the thermoplastic resin layer is a crystalline resin layer formed of any of materials selected from the group comprising polyetheretherketone, polyetherketoneketone, polyetherketone, polyphenylene sulfide and thermoplastic polyimide.

3 . The rectangular insulated wire according to claim 1 , wherein adhesion strengths between the plurality of thermoplastic resin layers are 50 gf/mm to 100 gf/mm, respectively.

4 . The rectangular insulated wire according to claim 1 , wherein the thermosetting resin layer is formed of one or a plurality of materials selected from the group comprising polyamide-imide, polyesterimide, polyimide, class H polyester and polyetherimide.

5 . The rectangular insulated wire according to claim 1 , wherein the plurality of thermoplastic resin layers comprises a first thermoplastic resin layer and a second thermoplastic resin layer provided on the first thermoplastic resin layer.

6 . The rectangular insulated wire according to claim 1 , wherein the rectangular conductor is one of aluminum or aluminum alloy and copper or copper alloy.

7 . An electric generator coil formed by winding a rectangular insulated wire comprising:
a rectangular conductor having a generally rectangular cross section; a thermosetting resin layer provided to cover the rectangular conductor; and a plurality of thermoplastic resin layers provided on the thermosetting resin layer, an adhesion strength between the thermosetting resin layer and the thermoplastic resin layer being 50 gf/mm to 100 gf/mm.

8 . A rectangular insulated wire comprising:
a rectangular conductor having a generally rectangular cross section; a thermosetting resin layer provided to cover the rectangular conductor; and a first thermoplastic resin layer provided on the thermosetting resin layer, the first thermoplastic resin layer having a relative crystallinity of greater than or equal to 20% and less than or equal to 50%, the relative crystallinity being calculated based on heat of fusion and heat of crystallization measured by differential scanning calorimetry.

9 . The rectangular insulated wire according to claim 8 , wherein the first thermoplastic resin layer is a crystalline resin layer formed of any of materials selected from the group comprising polyetheretherketone, polyetherketoneketone, polyetherketone, polyphenylene sulfide and thermoplastic polyimide.

10 . The rectangular insulated wire according to claim 8 , wherein an adhesion strength between the thermosetting resin layer and the first thermoplastic resin layer is 50 gf/mm to 100 gf/mm.

11 . The rectangular insulated wire according to claim 10 , further comprising a second thermoplastic resin layer provided on the first thermoplastic resin layer, the second thermoplastic resin layer having a relative crystallinity that is approximately the same as or greater than the relative crystallinity of the first thermoplastic resin layer,
wherein an adhesion strength between the first thermoplastic resin layer and the second thermoplastic resin layer is 50 gf/mm to 100 gf/mm.

12 . The rectangular insulated wire according to claim 11 , wherein the relative crystallinity of the second thermoplastic resin layer is 45% to 100%, and
the relative crystallinity of the second thermoplastic resin layer is within a range of −5% to 60% with respect to the relative crystallinity of the first thermoplastic resin layer.

13 . The rectangular insulated wire according to claim 11 , wherein the second thermoplastic resin layer is a second crystalline resin layer formed of any material selected from the group comprising polyetheretherketone, polyetherketoneketone, polyetherketone, polyphenylene sulfide and thermoplastic polyimide.

14 . The rectangular insulated wire according to claim 8 , wherein the thermosetting resin layer is formed of one or a plurality of materials selected from the group comprising polyamide-imide, polyesterimide, polyimide, class H polyester and polyetherimide.

15 . The rectangular insulated wire according to claim 8 , wherein the thermosetting resin layer is formed on the rectangular conductor by bake-on coating.

16 . The rectangular insulated wire according to claim 8 , wherein the first thermoplastic resin layer is formed on the thermosetting resin layer by extrusion, and further the second thermoplastic resin layer is formed on the first thermoplastic resin layer by extrusion.

17 . The rectangular insulated wire according to claim 8 , wherein the rectangular conductor is one of aluminum or aluminum alloy and copper or copper alloy.

18 . A electric generator coil formed by winding a rectangular insulated wire comprising:
a rectangular conductor having a generally rectangular cross section; a thermosetting resin layer provided to cover the rectangular conductor; and a first thermoplastic resin layer provided on the thermosetting resin layer, the first thermoplastic resin layer having a relative crystallinity of greater than or equal to 20% and less than or equal to 50%, the relative crystallinity being calculated based on heat of fusion and heat of crystallization measured by differential scanning calorimetry.

Assignees

• Furukawa Electric Co Ltd
• Furukawa Magnet Wire Co Ltd

Inventors

• Fukuda Hiedeo
• Oya Makoto
• Ikeda Keisuke
• YAMOTO Satoko
• Aoi Tsuneo

Classifications

• H01B7/0225 Primary

  Three or more layers · CPC title

• H01B3/301

  Macromolecular compounds obtained by reactions forming a linkage containing sulfur with or without nitrogen, oxygen or carbon in the main chain of the macromolecule, not provided for in group H01B3/302 · CPC title

• H01B3/308 Primary

  Wires with resins · CPC title

• H02K3/02

  Windings characterised by the conductor material · CPC title

• H01B3/421

  Polyesters · CPC title