Magnet wire with thermoplastic 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.
1. A magnet wire comprising:
a conductor; and
insulation formed around the conductor, the insulation comprising at least one layer of extruded insulation comprising a blend of:
a first polymeric material comprising polyetheretherketone, wherein the first polymeric material comprises no more than forty percent by weight of the blend;
a second polymeric material comprising polyphenylsulfone; and
a third polymeric material comprising polyethersulfone.
2. The magnet wire of claim 1 , wherein:
the first polymeric material comprises between twenty percent and forty percent by weight of the blend;
the second polymeric material comprises between thirty percent and seventy percent by weight of the blend; and
the third polymeric material comprises between ten percent and forty percent by weight of the blend.
3. The magnet wire of claim 1 , wherein:
the first polymeric material comprises between twenty-five percent and thirty-five percent by weight of the blend;
the second polymeric material comprises between forty-five percent and fifty-five percent by weight of the blend; and
the third polymeric material comprises between fifteen percent and twenty-five percent by weight of the blend.
4. The magnet wire of claim 1 , wherein the extruded insulation has a thickness between 51 microns and 610 microns.
5. The magnet wire of claim 1 , wherein the blend further comprises a compatibilizer.
6. The magnet wire of claim 1 , wherein the blend further comprises a filler material.
7. The magnet wire of claim 6 , wherein the filler material comprises at least one of titanium(IV) oxide, boron nitride, silica dioxide, or chromium(III) oxide.
8. The magnet wire of claim 1 , wherein the extruded insulation is formed directly on the conductor.
9. The magnet wire of claim 1 , wherein the insulation further comprises:
base insulation formed around the conductor, wherein the extruded insulation is formed around the base insulation.
10. The magnet wire of claim 9 , wherein the base insulation comprises at least one layer of polymeric enamel.
11. The magnet wire of claim 10 , wherein the at least one layer of enamel comprises one of polyimide or polyamideimide.
12. The magnet wire of claim 1 , wherein the insulation comprises a partial discharge inception voltage at 25° C. of at least 1900 volts.
13. A magnet wire comprising:
a conductor; and
insulation formed around the conductor, the insulation comprising at least one layer of extruded insulation comprising a blend of:
a first polymeric material having a thermal index greater than 250° C., wherein the first polymeric material comprises no more than forty percent by weight of the blend;
a second polymeric material having a thermal index below 200° C.; and
a third polymeric material different than the second polymeric material and having a thermal index below 200° C.
14. The magnet wire of claim 13 , wherein the first polymeric material comprises at least one of polyetheretherketone, polyaryletherketone, or polyetherketoneketone.
15. The magnet wire of claim 13 , wherein the first polymeric material comprises polyetheretherketone.
16. The magnet wire of claim 13 , wherein the second polymeric material comprises polyphenylsulfone and the third polymeric material comprises polyethersulfone.
17. The magnet wire of claim 13 , wherein:
the first polymeric material comprises between twenty percent and forty percent by weight of the blend;
the second polymeric material comprises between thirty percent and seventy percent by weight of the blend; and
the third polymeric material comprises between ten percent and forty percent by weight of the blend.
18. The magnet wire of claim 13 , wherein:
the first polymeric material comprises between twenty-five percent and thirty-five percent by weight of the blend;
the second polymeric material comprises between forty-five percent and fifty-five percent by weight of the blend; and
the third polymeric material comprises between fifteen percent and twenty-five percent by weight of the blend.
19. The magnet wire of claim 13 , wherein the extruded insulation has a thickness between 51 microns and 610 microns.
20. The magnet wire of claim 13 , wherein the blend further comprises a compatibilizer.
21. The magnet wire of claim 13 , wherein the blend further comprises a filler material, the filler material comprising at least one of titanium(IV) oxide, boron nitride, silica dioxide, or chromium(III) oxide.
22. The magnet wire of claim 13 , wherein the extruded insulation is formed directly on the conductor.
23. The magnet wire of claim 13 , wherein the insulation further comprises:
base insulation formed around the conductor, wherein the extruded insulation is formed around the base insulation.
24. The magnet wire of claim 23 , wherein the base insulation comprises at least one layer of polymeric enamel.
25. The magnet wire of claim 13 , wherein the insulation comprises a partial discharge inception voltage at 25° C. of at least 1900 volts.