# US 2021/0241938 A1 · Electric conductor for use in electric machines > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2021/0241938 A1 - Document ID: US20210241938A1 - Status: Published application - Kind: A1 - Application number: 17/050,912 - Filed: 2019-05-28 - Published: 2021-08-05 - Earliest claimed: 2018-05-29 - Assignees: Miba eMobility GmbH - Applicants: Miba eMobility GmbH - Inventors: Andreas EILENBERGER - Web page: https://patentgrep.com/patent/US20210241938A1 ## CPC - H02K 3/34: between conductors or between conductor and core, e.g. slot insulation - H02K 3/345: {between conductor and core, e.g. slot insulation} - H01B 7/0275: {comprising one or more extruded layers of insulation} - H02K 3/04: Windings characterised by the conductor shape, form or construction, e.g. with bar conductors - H02K 3/24: with channels or ducts for cooling medium between the conductors - H02K 3/30: Windings characterised by the insulating material - H02K 3/32: Windings characterised by the shape, form or construction of the insulation - H02K 2213/03: Machines characterised by numerical values, ranges, mathematical expressions or similar information - H02K: DYNAMO-ELECTRIC MACHINES (dynamo-electric relays H01H53/00; conversion of DC or AC input power into surge output power {H03K3/53}) - H01B: CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES (selection for magnetic properties H01F1/00; waveguides H01P {; printed circuits H05K}) ## Abstract The invention relates to an electric conductor for use in electric machines, more particularly for producing windings for stators or rotors of electric machines, such as electric motors or generators. The conductor comprises an electrically conductive conductor core having a substantially rectangular cross-section and comprises two longitudinal end faces arranged opposite one another and two transverse end faces arranged opposite one another as well as a total longitudinal extension between a first end and a second end. The conductor further comprises at least one insulation layer, which is arranged around the full circumference of the conductor core at least over a predominant part of the total longitudinal extension of the conductor core. The at least one insulation layer predominantly consists of an extrudable, polymer, thermoplastic material selected from the group of aromatic polysulfones (PAES) or mixtures of aromatic polysulfones (PAES). ## Claims ### Claim 1 An electric conductor (1) for use in electric machines, in particular for manufacturing windings for stators of electric machines, such as electric motors or generators, comprising an electrically conductive conductor core (2) having a substantially rectangular cross-section, wherein the conductor core (2) comprises two longitudinal end faces (6, 7) arranged opposite one another and two transverse end faces (8, 9) arranged opposite one another as well as a total longitudinal extension (3) between a first end (4) and a second end (5) of the conductor core (2), at least one insulation layer (10), which insulation layer (10) is arranged around the full circumference of the conductor core (2) at least over a predominant part of the total longitudinal extension (3) of the conductor core (2), wherein the at least one insulation layer (10) predominantly comprises an extrudable, polymer, thermoplastic material selected from the group of aromatic polysulfones (PAES) or mixtures of aromatic polysulfones (PAES). ### Claim 2 (depends on 1) The electric conductor according to claim 1, wherein the at least one insulation layer (10) comprises a material having a relative permittivity of less than 4 at a frequency of 0.1 kHz to 100 kHz and a temperature of −50° C. to 180° C., measured according to IEC 60250. ### Claim 3 (depends on 1) The electric conductor according to claim 1, wherein the material of the at least one insulation layer (10) has a glass transition temperature above 160° C. ### Claim 4 (depends on 1) The electric conductor according to claim 1, wherein the at least one insulation layer (10) comprises a material having a heat deflection temperature according to ISO 75-1, -2, -3, method A of at least 170° C. ### Claim 5 (depends on 1) The electric conductor according to claim 1, wherein the at least one insulation layer (10) has a dielectric strength according to IEC 60243-1 of at least 28 kV/mm at a layer thickness of less than 500 μm. ### Claim 6 (depends on 1) The electric conductor according to claim 1, wherein the at least one insulation layer (10) predominantly comprises polysulfone (PSU), polyethersulfone (PES or PESU) or polyphenylene sulfone (PPSU) or of mixtures of these aromatic polysulfones (PAES). ### Claim 7 (depends on 1) The electric conductor according to claim 1, wherein, in the area of the transverse end faces (8, 9), the at least one insulation layer (10) has a layer thickness (11) which is 2 to 8 times a layer thickness (12) of the at least one insulation layer (10) in the area of the longitudinal end faces (6, 7). ### Claim 8 (depends on 1) The electric conductor according to claim 1, wherein the at least one insulation layer (10) has a total cross-sectional area (13) which is 0.1 to 0.18 times a total cross-sectional area (14) of the conductor core (2). ### Claim 9 (depends on 1) The electric conductor according to claim 1, wherein the at least one insulation layer (10) is applied to the conductor core (2) by means of extrusion. ### Claim 10 (depends on 1) The electric conductor according to claim 1, wherein the at least one insulation layer (10) is completely coated with a support layer (16). ### Claim 11 (depends on 10) The electric conductor according to claim 10, wherein the support layer (16) predominantly comprises an extrudable, polymer, thermoplastic material selected from the group of aromatic polysulfones (PAES) or polyaryletherketone (PAEK) or of mixtures of these materials. ### Claim 12 (depends on 10) The electric conductor according to claim 10, wherein the support layer (16) predominantly comprises polysulfone (PSU), polyethersulfone (PES or PESU), polyphenylene sulfone (PPSU) or polyaryletherketone (PAEK) or of mixtures of these thermoplastic polymers. ### Claim 13 (depends on 10) The electric conductor according to claim 10, wherein the support layer (16) comprises a material having an elongation at break according to ISO 527-1, -2 of 50%) or more. ### Claim 14 (depends on 10) The electric conductor according to claim 10, wherein the support layer (16) comprises a material having a heat deflection temperature according to ISO 75-1, -2, -3, method A of at least 170° C. ### Claim 15 (depends on 10) The electric conductor according to claim 10, wherein a layer thickness (17) of the support layer (16) is substantially uniform around the circumference of the at least one insulation layer (10) and 0.6 to 1.0 times a layer thickness (12) of the at least one insulation layer (10) in the area of the longitudinal end faces (6). ### Claim 16 (depends on 10) The electric conductor according to claim 10, wherein the support layer (16) has a total cross-sectional area (18) which is 0.22 to 0.35 times a total cross-sectional area (13) of the at least one insulation layer (10). ### Claim 17 (depends on 10) The electric conductor according to claim 10, wherein the support layer (16) is applied to the at least one insulation layer (10) by means of extrusion. ### Claim 18 (depends on 1) An electric winding (29) for an electric machine, in particular a stator of a generator or electric motor, wherein the winding is manufactured from the electric conductor (1) configured according to claim 1 or of multiple interconnected electric conductors (1). ### Claim 19 (depends on 1) A stator (30) for an electric machine, such as a generator or electric motor, comprising a laminated core (19) having multiple grooves (20) continuously extending in the circumferential direction (21) around a longitudinal axis (24) of the laminated core (19) and in a longitudinal direction (22) of the laminated core (19), with at least two electric conductors (1) received in each groove (20) for forming an electric winding (29), wherein the electric conductors (1) received in the grooves (20) are configured according to claim 1. ### Claim 20 (depends on 19) The stator according to claim 19, wherein the respective conductors (1) received in the grooves (20) are completely coated with the at least one insulation layer (10) at least over a total longitudinal extension (28) of a respective groove (20).