Electrical wire insulation and electromagnetic coil

Claim 2

An insulated electrical conductor comprising, in combination, a metallic conductor and an insulating coating applied to the metallic conductor, the coating having been derived by applying to the conductor a liquid slurry comprising: (A) 15-55 solids weight percent a glass powder having a composition of: 40-60 wt.% SiO 2 ; 6-13 wt.% Na 2 O; 2-6 wt.% Al 2 O 3 ; 3-10 wt.% CaO; 15-25 wt.% BaO; and 2-10 wt.% Y 2 O 3 ; (B) 15-65 solids weight percent an inorganic filler selected from the group consisting of alumina, magnesia, zirconia or silica; (C) 30-50 solids weight percent of an organic binder; and (D) sufficient organic solvent to dissolve the organic binder; and by exposing said coated conductor to heat whereby said solvent and said organic binder are evaporated and further heating said conductor causing said coating to adhere to said conductor.

Claim 3

An insulated electrical conductor comprising, in combination, a metallic conductor and an insulating coating applied to the metallic conductor, the coating having been derived by applying to the conductor a liquid slurry comprising: (A) 15-55 solids weight percent a glass powder having a composition of: 40-60 wt.% SiO 2 ; 6-13 wt.% MgO; 2-6 wt.% Al 2 O 3 ; 3-10 wt.% CaO; 15-25 wt.% BaO; and 2-10 wt.% Y 2 O 3 ; (B) 15-65 solids weight percent an inorganic filler selected from the group consisting of alumina, magnesia, zirconia or silica; (C) 30-50 solids weight percent of an organic binder; and (D) sufficient organic solvent to dissolve the organic binder; and by exposing said coated conductor to heat whereby said solvent and said organic binder are evaporated and further heating said conductor causing said coating to adhere to said conductor.

Claim 4

An insulated electrical conductor comprising, in combination, a metallic conductor and an insulating coating applied to the metallic conductor, the coating having been derived by applying to the conductor a liquid slurry comprising: (A) 15-55 solids weight percent a glass powder having a composition of: 40-60 wt.% SiO 2 ; 6-13 wt.% MgO; 2-6 wt.% Al 2 O 3 ; 3-10 wt.% CaO; 15-25 wt.% BaO; and 2-10 wt.% Y 2 O 3 ; (B) 15-65 solids weight percent an inorganic filler selected from the group consisting of alumina, magnesia, zirconia or silica; (C) 30-50 solids weight percent of an organic binder; and (D) sufficient organic solvent to dissolve the organic binder; and by exposing said coated conductor to heat whereby said solvent and said organic binder are evaporated and further heating said conductor causing said coating to adhere to said conductor.

Claim 5

An insulated electrical conductor comprising, in combination, a metallic conductor and an insulating coating applied to the metallic conductor, the coating having been derived by applying to the conductor a liquid slurry comprising: (A) 15-55 solids weight percent a glass powder having a composition of: 40-60 wt.% SiO 2 ; 14-26 wt.% BaO; 3-12 wt.% Na 2 O; 3-12 wt.% CaO; 2-7 wt.% B 2 O 3 ; 2-8 wt.% Al 2 O 3 ; and 2-10 wt.% Y 2 O 3 ; (B) 15-65 solids weight percent an inorganic filler selected from the group consisting of alumina, magnesia, zirconia or silica; (C) 30-50 solids weight percent of an organic binder; and (D) sufficient organic solvent to dissolve the organic binder; and by exposing said coated conductor to heat whereby said solvent and said organic binder are evaporated and further heating said conductor causing said coating to adhere to said conductor.

Claim 6

An insulated electrical conductor comprising, in combination, a metallic conductor and an insulating coating applied to the metallic conductor, the coating having been derived by applying to the conductor a liquid slurry comprising: (A) 15-55 solids weight percent a glass powder having a composition of: 40-60 wt.% SiO 2 ; 14-26 wt.% BaO; 3-12 wt.% Na 2 O; 3-12 wt.% CaO; 2-7 wt.% B 2 O 3 ; 2-8 wt.% Al 2 O 3 ; and 2-10 wt.% Y 2 O 3 ; (B) 15-65 solids weight percent an inorganic filler selected from the group consisting of alumina, magnesia, zirconia or silica; (C) 30-50 solids weight percent of an organic binder; and (D) sufficient organic solvent to dissolve the organic binder; and by exposing said coated conductor to heat whereby said solvent and said organic binder are evaporated and further heating said conductor causing said coating to adhere to said conductor.

Claim 7

The electrical conductor of claim 1, 2 or 3 wherein the organic binder is a liquid copolymer which reduces on being heated to a volatile monomer.

Claim 8

The electrical conductor of claim 1, 2 or 3 wherein the organic binder is a polymer derived from methyl methacrylate.

Claim 9

The electrical conductor of claim 1, 2 or 3 wherein the organic solvent is xylene.

Claim 10

An electromagnetic coil in which the electrical conductor used is that as described in claim 1, 2, or 3.

Claim 11

An electromagnetic coil having insulated electrical conductor wire as described in claim 1, 2 or 3 wherein adjacent layers of said coil are separated by a potting compound.

Claim 12

A process for the preparation of a conductor as described by claim 1, 2 or 3 which process is substantially: (A) maintaining the slurry coated conductor at room temperature for 6 hours to dry out water and to allow the potting compound to dry; (B) heating the conductor at 2° C. per minute or less to 100° C. to vaporize all residual moisture; (C) maintaining said conductor at 100° C. for 16 hours; (D) heating said conductor at 2° C. per minute or less to 125° C.; (E) maintaining said conductor at 125° C. for 8 hours; (F) heating said conductor at 2° C. per minute or less to a temperature between 370° to 375° C. to reduce the organic binder to the monomer state and to vaporize the monomer; (G) maintaining said conductor at 370° to 375° C. for 16 to 20 hours; (H) heating said conductor at 2° C. per minute or less to 450° C.; (I) maintaining said conductor at 450° C. for 4 hours to eliminate any carbonaceous material present; (J) heating said conductor to 750° C. to 790° C. at 2° C. per hour or less; (K) maintaining said conductor at 750° C. to 790° C. for 8 to 10 hours to vitrify the glass; (L) cooling said conductor to 450° C.; (M) maintaining said conductor at 450° C. for 16 hours; and (N) cooling said conductor to room temperature.