Essex Furukawa Magnet Wire USA LLC

Essex Group, Inc.

Essex Solutions USA LLC

Matthew E Leach

Mohammad Mazhar Said

Allan R Knerr

James J Connell

Christopher Paul Richardson

Frederick Marshall McFarland

Tamanna Ferdous McFarland

Allen Roe Guisinger

Zhiyang Zhao

Guadalupe Arambula

M Mazhar Said

Rakshit Amba

Marvin Bradford DeTar

Gregory S Caudill

David Marshall Cain

Bogdan Gronowski

Jason Dennis Stephens

Baber Inayat

Russell Glenn Post

Mohammed Ibrahim Ali

John M Swihart

Christian Reece Grover

Greg S Caudill

A fault detection system for use with wire includes an outer housing and a detection component positioned within the housing. The detection component includes a plurality of emitters and a plurality of detectors positioned around an examination area through which a wire is traversed. Each adjacent pair of emitters is spaced no more than 30 degrees apart, and each of the plurality of detectors is positioned across the examination area from a corresponding emitter. Each of the emitters is configured to emit a signal that is measured by a corresponding detector, and the detection component is configured to detect one or more defects on a surface of the wire based upon changes in the signals measured by one or more of the plurality of detectors.

Systems and methods for detecting defects in magnet wire insulation

Magnet wire including extruded insulation formed from a blend of different polymeric materials is described. A magnet wire may include a conductor and insulation formed around the conductor. The insulation may include at least one layer of extruded insulation formed from a blend of at least three different polymeric materials. A first polymeric material, such as polyetheretherketone, may have a thermal index above 250° C. Second and third polymeric materials, such as polyphenylsulfone and polyethersulfone, may have lower thermal indexes.

Magnet wire with thermoplastic insulation

A method for forming magnet wire includes co-extruding multiple layers of different insulating materials. A conductor may be provided, and extruded insulation may be formed around the conductor by co-extruding both a first layer of thermoplastic insulation and a second layer of thermoplastic insulation with the second layer formed around the first layer. The first layer may include a first polymeric material having a first thermal index, and the second layer may include a second polymeric material having a second thermal index higher than the first thermal index.

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 corona resistant polyimide insulation

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

Insulating films suitable for use in magnet wire, electrical machines, and other applications may include at least one layer formed from extruded material. The extruded material may include a blend of a first polymeric material and a second polymeric material different than the first polymeric material. The first polymeric material may include one of polyetheretherketone, polyaryletherketone, polyetherketoneketone, polyphenylsulfone, polyphenylene sulfide, or polybenzimidazole, and the second polymeric material may include one of polyphenylsulfone, polyetherimide, polyethersulfone, polyphenylene sulfide, polycarbonate, or polyester.

Polymeric insulating films

Magnet wire including extruded insulation formed from multiple layers of different materials is described. A magnet wire may include a conductor and insulation formed around the conductor. The insulation may include a first layer of extruded thermoplastic insulation formed around the conductor and a second layer of extruded thermoplastic insulation formed around the first layer of extruded thermoplastic insulation. The first layer may be formed from a first polymeric material having a first thermal index, and the second layer may be formed from a second polymeric material having a second thermal index higher than the first thermal index.

Magnet wire included extruded insulation formed from a blend of two or more different polymeric materials is described. A magnet wire may include a conductor and insulation formed around the conductor. The insulation may include at least one layer of extruded insulation formed from a blend of a first polymeric material and a second polymeric material different than the first polymeric material. The first polymeric material may include one of polyetheretherketone, polyaryletherketone, polyetherketoneketone, polyphenylsulfone, polyphenylene sulfide, or polybenzimidazole. The second polymeric material may include one of polyphenylsulfone, polyetherimide, polyethersulfone, polyphenylene sulfide, polycarbonate, or polyester.

Systems and methods for forming insulation on magnet wire are provided. An extruder that includes one or more rotating screws may receive a plurality of ingredients for a polymeric insulation material and process the plurality of ingredients to facilitate polymerization of the polymeric insulation material within the extruder. An application assembly in fluid communication with the extruder may apply the polymeric insulation material onto a wire. A curing device may then cure the polymeric insulation material.

Systems and methods for forming magnet wire insulation

Systems and methods for forming insulation on magnet wire are provided. An extruder that includes one or more rotating screws may receive a thermoset polymeric material and process the thermoset polymeric material to increase its pressure and temperature. An extrusion crosshead assembly in fluid communication with the extruder may receive the thermoset polymeric material and press extrude the thermoset polymeric material as insulation onto a magnet wire. A curing device may then cure the extruded insulation material.

Systems and methods for forming magnet wire insulation with thermoset material

Winding wire articles may include a conductor formed into a predefined shape having at least one bend. Additionally, a plurality of cavities may be formed within the conductor. Insulation may also be formed around the conductor.

Winding wire articles having internal cavities

A continuously transposed conductor (CTC) cable may include a plurality of electrically insulated strands arranged in first and second stacks with the plurality of strands successively transposed between the first and second stacks. The plurality of strands may include at least one strand having a plurality of component strands that are arranged in third and fourth stacks with the plurality of component strands successively transposed between the third and fourth stacks. Each of the components strands may include a conductor and insulation formed at least partially around the conductor.

Continuously transposed conductors and assemblies

Continuously transposed conductor ('CTC') cables are described. A CTC cable may include a plurality of electrically insulated strands connected in parallel at their ends. Additionally, each strand may include one or more conductors and an extruded insulation layer formed at least partially around the one or more conductors.

Continously transposed conductor

A system of rollers can transfer fluid from a reservoir to an electrically conductive wire feeding past the reservoir. The system can include a first cylinder that contacts the reservoir and rotates to pick up fluid from the reservoir. A second cylinder can contact the first cylinder and rotate. Fluid can transfer between the first cylinder and the second cylinder. The second cylinder can contact the feeding wire such that the second cylinder applies the fluid to the wire as the wire feeds past the second cylinder. Accordingly, two rotating cylinders can cooperatively transfer fluid from the reservoir to the moving wire.

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Fort Wayne, IN, United States of America

Matthew E Leach