Abstract: 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.

Abstract: 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.

Abstract: Magnet wire with thermoplastic insulation that reduces copper poisoning may include a conductor, and at least one layer of thermoplastic insulation formed around the conductor. Additionally, the thermoplastic insulation may include a matrix polymeric material and one or more additives incorporated into the matrix polymeric material, wherein the one or more additives mitigate copper poisoning, such as migration of copper ions from the conductor into the insulation layer, decomposition of the insulation layer as a result of copper ions, and/or oxidation on the surface of the conductor.

Abstract: Magnet wire with low-permittivity insulation includes a conductor and at least one insulation layer formed around the conductor. The insulation layer includes a base polymeric material, and one or more additives incorporated into the base polymeric material. The one or more additives include at least one of (i) a polycyclic aromatic hydrocarbon or (ii) a partially or fully hydrogenated compound of a polycyclic aromatic hydrocarbon. Additionally, the one or more additives lower the permittivity of the insulation layer relative to a control insulation layer formed solely from the base polymeric material.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: 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.