Optimization of Insulation Structure Design for Enameled Wires Based on Molecular Structure Design

Area of Science:

• Materials Science
• Electrical Engineering
• Polymer Science

Background:

• Enameled wire performance is critical for new energy vehicle motors.
• Current methods to improve partial discharge inception voltage (PDIV), such as powder doping and increased varnish thickness, have limitations including dispersion instability and reduced power density.

Purpose of the Study:

• To design a novel insulation structure for enameled wires to enhance corona voltage and PDIV.
• To control electronic field stress by utilizing materials with adjustable dielectric constants.
• To improve the performance of enameled wires without negatively impacting their breakdown margin.

Main Methods:

• A novel insulation structure was designed to control electronic field stress.
• Dielectric constants were adjusted by modifying the free volume of the polymer.
• A preparation scheme was developed to increase corona voltage and PDIV.

Main Results:

• The outermost electric field strength of the enameled wire model decreased by 22.11%.
• The enameled wire breakdown margin increased by 26.85%.
• The new design successfully increased corona voltage and PDIV without compromising the breakdown margin.

Conclusions:

• The novel insulation structure offers a superior alternative to conventional methods for enhancing enameled wire performance in electric motors.
• Adjusting polymer free volume to control dielectric constants is an effective strategy for improving electrical insulation properties.
• This advancement contributes to the development of more reliable and powerful new energy vehicle motors.