Essex Group, Inc.

Essex Furukawa Magnet Wire USA LLC

Phelps Dodge Industries, Inc.

Essex Solutions USA LLC

Allan R Knerr

Gregory S Caudill

Won Seok Lee

Jason Dennis Stephens

David Marshall Cain

Baber Inayat

Bogdan Gronowski

Frederick Marshall McFarland

Koji Nishibuchi

Joonhee Lee

James J Connell

Matthew E Leach

Marvin Bradford DeTar

George H Sollner

Mohammad Mazhar Said

Allen Roe Guisinger

Tamanna Ferdous McFarland

Michael W Lindvay

Christopher Paul Richardson

Donny R Disque

Daniel M Saban

Vanessa Jean Scott

David Mykel Geng

Magnet wire with corona resistant enamel insulation may include a conductor, and at least one layer of polymeric enamel insulation may be formed around the conductor. The polymeric enamel insulation may include a filler dispersed in a base polyimide material. Additionally, the polymeric enamel insulation may have a thermal index of at least 260° C.

Magnet wire with corona resistant polyimide insulation

Magnet wire with corona resistant enamel insulation may include a conductor and a multi-layer insulation system formed around the conductor. The insulation system may include a basecoat formed from a first polymeric enamel insulation. A midcoat formed from a second polymeric enamel insulation may be formed around the basecoat, and the second polymeric enamel insulation may include a filler dispersed in a base polyimide material. The filler may include between 20 percent and 80 percent by weight of silica dioxide and between 20 and 80 percent by weight of titanium dioxide. Additionally, the insulation system may include a topcoat formed from third polymeric enamel insulation formed around the midcoat.

Magnet wire with flexible corona resistant enamel insulation may include a conductor and a multi-layer insulation system formed around the conductor. The insulation system may include a basecoat formed from first polymeric enamel insulation, a midcoat formed from second polymeric enamel insulation, and a topcoat formed from third polymeric enamel insulation. The midcoat may include a filler containing silica dioxide and chromium oxide dispersed in a base polyamideimide material. Additionally, the magnet wire may exhibit few or no cracks in the topcoat when the wire is bent 180 degrees around a 4 mm mandrel.

Magnet wire with flexible corona resistant insulation

Electric machines, such as motors, may include an armature and a field component, and at least one of the armature or the field component may include a laminated structure having a plurality of slots into which a plurality of conductive elements are positioned. Additionally, a polymeric insulation layer may be formed directly on the laminated structure at least within the plurality of slots.

Electric machines having insulation formed on laminated structures

Magnet wire with corona resistant enamel insulation may include a conductor, and at least one layer of polymeric enamel insulation may be formed around the conductor. The polymeric enamel insulation may include a filler dispersed in a base polyamideimide material. The filler may include between 20 percent and 80 percent by weight of silica dioxide and between 20 and 80 percent by weight of titanium dioxide. Additionally, the polymeric enamel insulation may have a thermal index of at least 230&#xb0; C. and a thermal index that is at least twice that of the base polymeric material.

Magnet wire with corona resistant polyamideimide insulation

Magnet wire with corona resistant enamel insulation may include a conductor, and at least one layer of polymeric enamel insulation may be formed around the conductor. The polymeric enamel insulation may include a filler dispersed in a base polyimide material. The filler may include between 20 percent and 80 percent by weight of silica oxide and between 20 and 80 percent by weight of titanium oxide. Additionally, the polymeric enamel insulation may have a thermal index of at least 260&#xb0; C. and a thermal index that is at least twice that of the base polymeric material.

Insulated winding wires, winding wire articles, and associated formation methods are described. An insulated winding wire may include a conductor and insulation formed around the conductor. In certain embodiments, the insulation may include a first layer including a first parylene material and a second layer including a second parylene material different from the first parylene material. In other embodiments, the insulation may include one or more layers containing parylene formed over base insulation.

Insulated winding wire with conformal coatings

Magnet wire with corona resistant enamel insulation may include a conductor, and at least one layer of polymeric enamel insulation may be formed around the conductor. The polymeric enamel insulation may include a filler dispersed in polyimide and an additive formed by reacting an amine moiety with a formaldehyde material. The filler may include between 20 percent and 80 percent by weight of silica oxide and between 20 and 80 percent by weight of titanium oxide.

Insulated winding wire articles and associated formation methods are described. An insulated winding wire article may include a conductor and optional base insulation formed around the conductor. The conductor may be formed into a predefined shape having at least one bend, such as a U-shaped bend. A coating comprising parylene may be formed around the conductor and any base insulation.

Insulated winding wire articles having conformal coatings

Insulated winding wires and associated methods for forming winding wires are described. A winding wire may include a conductor and insulation formed around the conductor. The insulation may provide a partial discharge inception voltage greater than approximately 1,000 volts and a dielectric strength greater than approximately 10,000 volts. Additionally, the insulation may be capable of withstanding a continuous operating temperature of approximately 220&#xb0; C. without degradation. The insulation may include at least one base layer formed around an outer periphery of the conductor, and an extruded thermoplastic layer formed around the base layer. The extruded layer may include at least one of polyetheretherketone (PEEK) or polyaryletherketone (PAEK).

Insulated winding wire

An insulated winding wire may include a conductor and insulation formed around the conductor. The insulation may include a base insulation layer formed around the conductor and having a first dielectric constant (&#x3b5;). The insulation may further include an extruded thermoplastic layer formed around the base insulation layer and having a second dielectric constant (&#x3b5;). The extruded thermoplastic layer may include (i) at least one polymer comprising a ketone group and (ii) at least one fluoropolymer. A ratio of the dielectric constant (&#x3b5;) of the extruded thermoplastic layer to the dielectric constant (&#x3b5;) of the base layer at 250&#xb0; C. may be less than or equal to approximately 1.0.

A magnet wire insulation material having combined therewith a magnet wire winding lubricant having the formula of ##STR1## where n is from about 0 to about 26, m is from about 1 to about 35 and R is a hydrogen atom or any alkyl or acyl radical or a ##STR2## radical, and R.sup.1 is a hydrogen atom or an alkyl or an acyl radical and a magnet wire having superimposed on a base insulation material a coating of a lubricant having the formula of ##STR3## where n is from about 0 to about 26, m is from about 0 to about 35 and R is a hydrogen atom or any alkyl or acyl radical or a ##STR4## radical, and R.sup.1 is a hydrogen atom or an alkyl or an acyl radical.

Solid magnet wire winding lubricants

A composition of matter comprising the reaction product of a cyanuric acid reactant, an aliphatic vicinal diol reactant and a carboxyl reactant, a method for producing the same, a magnet wire coated therewith and an electromagnetic device utilizing the same.

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Fort Wayne, IN, United States of America

Allan R Knerr