Driving the New Energy Grid—Electrical Materials and Power Equipment
Research Background
The new-type power grid, dominated by new energy sources, features a large number of medium- and high-frequency power equipment systems, such as wind turbines, high-frequency transformers, high-frequency switching power supplies, dynamic reactive power compensation devices, high-frequency circuit breakers, capacitors, and reactors. Moreover, as the pulse-width modulation (PWM) technology for variable-frequency motors and the gradual adoption of SiC power devices—characterized by their high switching speeds and high-frequency operating capabilities—continue to enhance efficiency, they also intensify partial discharge and corona effects. This poses new challenges to the design and selection of insulation materials as well as to the overall system stability.
Using TECO technology, the surface of electrical-grade aluminum wire (as well as aluminum strips and aluminum foil) is subjected to functional ceramic treatment, producing electromagnetic wires with outstanding overall performance—either ceramic-insulated or composite-insulated. These electromagnetic wires are then applied in new types of power equipment suitable for next-generation renewable energy grids.
Ceramic insulation – high-performance aluminum-based electromagnetic wire/foil
Ceramic-insulated aluminum electromagnetic wire/foil, including flat aluminum wire, round aluminum wire, aluminum strip, and aluminum foil.
Polyimide film-covered/Polyimide and polyester enameled composite insulated electromagnetic wire, including flat aluminum wire and round aluminum wire.
Flattened aluminum wire, round aluminum wire, aluminum strip, narrow/wide aluminum foil—covering more than 20 national standards.
Specifications: Various round and flat wires (round wires: 0.1–3.5 mm; flat wires: 2–13 mm², with a wider side ≤6 mm), aluminum strips/foils (10 mm–600 mm).
Features: High thermal conductivity, resistance to electromagnetic radiation, and mechanical flexibility; enameled/membrane-coated products are resistant to corona discharge, refrigerants, oils, radiation, and extreme cold, as well as to partial discharge.
Applications: Can be used in high-temperature environments in specialized fields such as aerospace and nuclear power, as well as in windings of motors, medium-frequency transformers, electromagnets, and other equipment that experience large inrush currents and operate under harsh environmental conditions.
Ceramic-insulated aluminum flat wire
Ceramic-insulated aluminum round wire
Ceramic-insulated aluminum strip/foil
Ceramic Insulated Coil
Composite Insulation – High-Performance Film-Coated Enameled Electromagnetic Wire
The structure and properties of DuPont’s corona-resistant polyimide film demonstrate that inorganic nanoparticles are key to its corona resistance. The mechanism underlying this corona resistance is explained as follows:
① The bond energies of inorganic nanoparticles are higher than those of organic compounds, making them more resistant to corona-induced corrosion.
② Doping with inorganic nanoparticles introduces more shallow traps, which helps to enhance corona resistance.
③ Inorganic nanoparticles have a higher thermal conductivity, enabling them to quickly dissipate heat from the material and thus providing an anti-corona effect.
By combining the TECO ceramic layer with domestically produced anti-corona materials and adopting a ceramic-based composite insulation structure, it is possible to enhance the anti-corona performance of domestically produced electromagnetic wires, significantly extend the anti-corona life of winding insulation, and reduce costs—thereby breaking the domestic reliance on foreign counterparts for anti-corona electromagnetic wires.
Benchmarking DuPont’s “Golden Film”
During the accelerated corona resistance test at 250℃, its performance metrics exceeded those of DuPont PI film by 66% to 181% (depending on the ceramic film thickness). Under the same conditions, DuPont PI film outperformed domestically produced corona-resistant films by 37%.
According to the national standard GB 4074-2008 “Test Methods for Winding Wire,” Jingshang Electric conducted corona resistance tests and achieved no breakdown after 1,000 hours (20 kHz, bipolar square wave, 155℃), far exceeding the national standard requirement of ≥20 hours (and also significantly surpassing the special user’s requirement of ≥150 hours).
Ceramic-coated electromagnetic wire
Ceramic-coated enameled electromagnetic wire
The world’s first “roll-to-roll” automated and intelligent aluminum-based ceramic production line.
The “Mobile Floating Potential” method achieves adaptive voltage regulation based on different growth stages of ceramic membranes.
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