Manufacturing method of enameled wire
By employing a discontinuous coating method in the manufacturing of enameled wires, and performing a cooling operation between each two adjacent coating cycles, the problem of wire breakage due to reduced thermal stability was solved, thereby enhancing the thermal stability of the wires and ensuring manufacturing quality.
Patent Information
- Application Number
- CN202410511117.X
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-04-26
- Publication Date
- 2025-10-28
AI Technical Summary
In existing technologies, when a thick coating is formed using continuous coating methods, the wires are prone to breakage due to reduced thermal stability.
A non-continuous coating method is adopted, and a cooling operation is performed between each two adjacent coating cycles to enhance the thermal stability of the wires and prevent breakage.
Cooling operations enhance the thermal stability of the conductors, ensure the effective execution of the coating cycle, prevent conductor breakage, and ensure qualified manufacturing quality.
Smart Images
Figure CN120854071A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of enameled wire processing technology, and more specifically, to a method for manufacturing enameled wire. Background Technology
[0002] Enameled wire consists of a conductor and an insulating coating covering the conductor. During the manufacturing process of enameled wire, the conductor needs to be coated with enamel to form an insulating coating on its surface.
[0003] Current enameled wire processing technology typically employs a continuous coating method to form a coating of predetermined thickness on the conductor surface. Continuous coating refers to a cyclical process of repeatedly dipping the conductor in enamel, baking, dipping again, baking again, and so on, until the coating on the conductor surface reaches the predetermined thickness.
[0004] For example, for aluminum wires that need to form a coating with a thickness of 160μm on the surface, the current method of impregnation is to continuously perform a cycle of impregnation → baking → impregnation → baking... about 30 times (one "impregnation → baking" is one cycle) to form a coating with a thickness of 160μm on the surface of the aluminum wire.
[0005] The current continuous coating method has a problem that the wires are prone to breakage as the number of dipping and baking cycles increases, especially for wires that require a thicker coating (usually more than 150 μm).
[0006] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of the present invention, and therefore may include information that does not constitute prior art known to those skilled in the art. Summary of the Invention
[0007] In view of this, the present invention provides a method for manufacturing enameled wire using a non-continuous coating method. By cooling between two adjacent coating cycles, the thermal stability of the wire is enhanced, thus solving the problem of wire breakage due to reduced thermal stability after multiple immersion and baking.
[0008] According to one aspect of the present invention, a method for manufacturing enameled wire is provided, comprising: a discontinuous coating step, the discontinuous coating step comprising at least two sets of coating cycles and a cooling operation performed between each pair of adjacent coating cycles; wherein each set of coating cycles comprises multiple coating operations, each coating operation comprising impregnating and baking the wire.
[0009] In some embodiments, the number of coating operations in each coating cycle is determined at least based on the thermal stability of the conductor.
[0010] In some embodiments, the number of painting operations in each painting cycle may be the same or different.
[0011] In some embodiments, the conductor is an aluminum wire; the number of coating operations in each coating cycle is between 15 and 22, and / or, each coating cycle increases the coating thickness on the surface of the aluminum wire by 80 μm to 100 μm.
[0012] In some embodiments, the cooling operation includes allowing the wire to cool naturally or sending the wire into a cooling device for cooling.
[0013] In some embodiments, the cooling operation includes winding the wire that has completed the previous set of painting cycles around the booster guide wheel; after the cooling operation, the wire wound around the booster guide wheel is subjected to the next set of painting cycles.
[0014] In some embodiments, impregnating the wire with varnish includes feeding the wire into an impregnation apparatus for impregnation.
[0015] In some embodiments, baking the wire includes feeding the wire into a baking device for baking.
[0016] In some embodiments, the method for manufacturing enameled wire further includes an annealing step, which is performed after the discontinuous coating step.
[0017] In some embodiments, the conductor is an aluminum wire; the annealing step includes annealing the aluminum wire at an annealing temperature between 200°C and 300°C.
[0018] The beneficial effects of this invention compared to the prior art include at least the following:
[0019] The method for manufacturing enameled wire of the present invention adopts a non-continuous coating method of "one set of coating cycles → one cooling operation → one set of coating cycles...". The cooling operation between two adjacent sets of coating cycles enhances the thermal stability of the wire, avoids the wire from breaking due to reduced thermal stability after multiple immersion and baking, ensures the effective execution of subsequent coating cycles, and thus ensures the manufacture of qualified enameled wire.
[0020] It should be understood that the above general description and the following detailed description are exemplary and explanatory only, and are not intended to limit the invention. Attached Figure Description
[0021] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the invention and, together with the description, serve to explain the principles of the invention. It is obvious that the drawings described below are merely some embodiments of the invention, and those skilled in the art can obtain other drawings based on these drawings without any inventive effort.
[0022] Figure 1 This diagram illustrates the main steps of the method for manufacturing enameled wire in an embodiment of the present invention.
[0023] Figure 2 and Figure 3 A schematic diagram illustrating an implementation scenario of the method for manufacturing enameled wire according to an embodiment of the present invention is shown;
[0024] Figure 4 This diagram illustrates the implementation flow of the method for manufacturing enameled aluminum wire in an embodiment of the present invention. Detailed Implementation
[0025] Exemplary embodiments will now be described more fully with reference to the accompanying drawings. However, these exemplary embodiments can be implemented in many forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided to fully and completely convey the concept of the exemplary embodiments to those skilled in the art.
[0026] The accompanying drawings are merely illustrative of the invention and are not necessarily drawn to scale. The same reference numerals in the drawings denote the same or similar parts, and therefore, repeated descriptions of them will be omitted.
[0027] The flowchart shown in the accompanying diagram is merely illustrative and does not necessarily include all steps. For example, some steps may be broken down, some steps may be combined or partially combined, and the actual execution order may change depending on the actual situation. Furthermore, the term "multiple" means two or more, unless otherwise explicitly specified.
[0028] It should be noted that, unless otherwise specified, the embodiments of the present invention and the features in different embodiments can be combined with each other.
[0029] The method for manufacturing enameled wire provided by the present invention includes a discontinuous coating step, which includes at least two sets of coating cycles and a cooling operation performed between each pair of adjacent coating cycles; wherein each set of coating cycles includes multiple coating operations, and each coating operation includes immersing the wire in enamel and baking.
[0030] The method for manufacturing enameled wire of the present invention adopts a non-continuous coating method of "one set of coating cycles → one cooling operation → one set of coating cycles...". The cooling operation between two adjacent sets of coating cycles enhances the thermal stability of the wire, avoids the wire from breaking due to reduced thermal stability after multiple immersion and baking, ensures the effective execution of subsequent coating cycles, and thus ensures the manufacture of qualified enameled wire.
[0031] Figure 1 The main steps of the method for manufacturing enameled wire in an embodiment of the present invention are illustrated. Figure 2 and Figure 3 This illustration depicts an implementation scenario of the enameled wire manufacturing method according to an embodiment of the present invention. Combined with... Figures 1 to 3 As shown, in some embodiments, the discontinuous coating step of the enameled wire manufacturing method includes:
[0032] S210, Perform the first set of painting cycles on wire 100;
[0033] S220, Cooling operation is performed on the wire 100 that has completed the first set of painting cycles;
[0034] S230, the second set of painting cycle is performed on the wire 100 after the cooling operation is completed.
[0035] Both the first and second painting cycles include multiple painting operations, each of which involves immersing the conductor 100 in paint and baking it.
[0036] The material of conductor 100 can be copper, aluminum, alloy, etc.; the enameled wire made from it can be used in motors, electrical appliances, etc., for example, it can be used in drive motors of new energy vehicles.
[0037] Impregnating the conductor 100 with varnish includes: feeding the conductor 100 into an impregnation apparatus 120 for impregnation. The impregnation apparatus 120 is, for example, a varnish bath; feeding the conductor 100 into the impregnation apparatus 120 so that the surface of the conductor 100 is wetted with varnish. The varnish has insulating properties, and may also have properties such as moisture resistance, corrosion resistance, and heat resistance.
[0038] Baking the wire 100 includes: feeding the wire 100 into a baking apparatus 130 for baking. The baking apparatus 130 is, for example, a high-temperature oven; feeding the wire 100 into the baking apparatus 130 to allow the paint on the surface of the wire 100 to cure and adhere, forming a coating uniformly coated on the surface of the wire 100.
[0039] The operation of feeding the wire 100 into the impregnation equipment 120 can be achieved by means of rollers / guide rollers 110, etc. Rollers / guide rollers 110, etc. can also be provided in the impregnation equipment 120 and the baking equipment 130 to help transport the wire 100.
[0040] The impregnation equipment 120 and the baking equipment 130 can be two separate devices or an integrated device. Figure 3 For the sake of simplicity, the baking equipment is not shown in detail.
[0041] Each dip-and-baking process, i.e., each coating operation, forms a coating of a certain thickness on the surface of the conductor 100. After the first coating cycle, due to the increased number of dip-and-baking cycles, the thermal stability of the conductor 100 continuously decreases. If the coating operation continues, the conductor 100 is prone to breakage. Therefore, after the first coating cycle, the coating operation is paused, and the conductor 100 is cooled to restore its thermal stability to a safe range before proceeding to the second coating cycle. This avoids the conductor 100 breaking during the second coating cycle.
[0042] In the above embodiments, after the first set of painting cycle → cooling operation → second set of painting cycle, a paint coating of predetermined thickness is formed on the surface of the conductor 100, and the conductor 100 is structurally stable and avoids breakage throughout the manufacturing process, so that the enameled wire produced is of qualified quality and has stable performance.
[0043] In other embodiments, the number of painting cycles can be adjusted as needed, and correspondingly, the number of cooling operations can be adjusted to form a paint coating of the required thickness on the surface of the conductor 100.
[0044] In some embodiments, the number of painting operations per painting cycle is determined at least based on the thermal stability of the wire 100.
[0045] The thermal stability of conductor 100 is as follows: when the thermal stability of conductor 100 is within a safe range, conductor 100 will not break; as the number of painting operations increases, the thermal stability of conductor 100 gradually decreases, and the risk of conductor 100 breaking increases; when the thermal stability of conductor 100 is below the critical value, conductor 100 breaks.
[0046] In practice, through simulation, experimental testing, and other methods, continuous coating operations can be performed on the conductor 100 to obtain the maximum number of coating operations that would cause the conductor 100 to break. This maximum number of coating operations serves as a quantitative indicator of the thermal stability of the conductor 100. Subtracting a certain number of reserved operations from this maximum number of coating operations yields the number of coating operations per coating cycle. This ensures that the thermal stability of the conductor 100 is above the critical value during each coating cycle, preferably within a safe range, thus preventing breakage.
[0047] In addition to thermal stability, the number of coating operations in each coating cycle can also take into account factors such as efficiency, as long as it is ensured that the wire 100 will not break during the entire manufacturing process.
[0048] In some embodiments, the number of coating operations in each coating cycle may be the same or different. Having the same number of coating operations in each coating cycle facilitates control during the manufacturing process. As the coating operation is performed, the performance of the wire 100 may change, or manufacturing requirements may change. Therefore, the number of coating operations in each coating cycle may also be different. Specifically, it can be adjusted according to the performance of the wire 100 / manufacturing requirements, as long as it is ensured that after a certain number of coating operations are performed on the wire 100, the thermal stability of the wire 100 is restored to a safe range through a cooling operation before subsequent coating operations are performed, to avoid wire 100 breakage.
[0049] In some embodiments, when the conductor 100 is an aluminum wire, the number of coating operations per coating cycle is between 15 and 22, and / or, each coating cycle increases the coating thickness on the surface of the conductor 100 by 80 μm to 100 μm.
[0050] According to experimental tests, after 15 coating operations, the paint film thickness on the aluminum wire surface reaches approximately 80 μm. During subsequent impregnation, the reduced thermal stability of the aluminum wire leads to a decrease in its tensile strength. The resistance generated during impregnation may exceed the tensile strength of the aluminum wire, increasing the risk of breakage. During subsequent baking, the reduced thermal stability makes the aluminum wire prone to breakage at high temperatures. Furthermore, according to experimental tests, after 22 coating operations, the paint film thickness on the aluminum wire surface reaches approximately 100 μm, at which point the aluminum wire will break.
[0051] Therefore, when the conductor 100 is an aluminum wire, the number of coating operations in each coating cycle can be set between 15 and 22 times, so that the coating thickness on the surface of the aluminum wire increases by 80μm to 100μm after each coating cycle. This avoids aluminum wire breakage while also taking into account manufacturing efficiency.
[0052] In a preferred embodiment, when either of the following conditions occurs, the number of coating operations in the coating cycle reaches 15 to 22 times (the number of coating operations can be monitored in real time during the coating cycle) or the coating cycle increases the coating thickness on the aluminum wire surface by 80 μm to 100 μm (the coating thickness can be monitored in real time or intermittently during the coating cycle), it indicates that the thermal stability of the aluminum wire is approaching the critical value and there is a risk of breakage. At this time, the current group of coating cycles can be stopped, the aluminum wire can be cooled, and then the next group of coating cycles can be performed to ensure that the aluminum wire will not break.
[0053] In other embodiments, when the conductor 100 is a copper wire or other type of conductor, the number of coating operations in each coating cycle can be adjusted according to factors such as the performance of the conductor 100 / manufacturing requirements, as long as it is ensured that the conductor 100 does not break during each coating cycle.
[0054] In some embodiments, the cooling operation includes allowing the wire 100 to cool naturally or sending the wire 100 into a cooling device for cooling. Natural cooling means cooling in ambient air; the cooling device can be an industrial device such as a cooling box. In a specific implementation, the next coating operation can be performed after the wire 100 has completely exited the baking equipment of the previous coating operation and has been sufficiently cooled in ambient air / cooling equipment.
[0055] In some embodiments, the cooling operation includes wrapping the wire 100, which has completed the previous set of painting cycles, around the booster guide wheel 160; after the cooling operation, the wire 100 wrapped around the booster guide wheel 160 is subjected to the next set of painting cycles. The wire 100 may be partially wrapped around the booster guide wheel 160, for example, it may be "draped" on the booster guide wheel 160; the wire 100 may also be completely wrapped around the booster guide wheel 160.
[0056] By placing the wire 100 around the guide wheel 160, the painting operation on the wire 100 is paused to allow the wire 100 to cool down and restore its thermal stability. On the other hand, the guiding effect of the guide wheel 160 can reduce the tensile resistance on the wire 100, ensuring that the wire will not break during the subsequent painting operation.
[0057] In some embodiments, the method for manufacturing enameled wire further includes an annealing step, performed after a discontinuous coating step.
[0058] Existing enameled wire processing techniques typically involve annealing the wire before the enameling process to improve its internal stress and facilitate subsequent continuous enameling. However, annealing reduces the wire's tensile strength, increasing the risk of breakage during the enameling process. In this embodiment of the invention, annealing is not performed before the discontinuous enameling step to ensure that the tensile strength of the wire 100 is not affected; after the discontinuous enameling step, the wire 100 is annealed to improve its internal stress and enhance the quality and performance of the finished enameled wire.
[0059] In some embodiments, when the conductor 100 is an aluminum wire, the annealing step includes annealing the conductor 100 at an annealing temperature between 200°C and 300°C. This effectively eliminates the internal stress of the aluminum wire, improving the quality and performance of the manufactured enameled wire.
[0060] Figure 4 This diagram illustrates the implementation flow of the aluminum enameled wire manufacturing method in an embodiment of the present invention; see reference. Figure 4 As shown, and in conjunction with the above embodiments, the manufacturing method of aluminum enameled wire can be implemented using the following process in specific implementation.
[0061] S410, the first 15 coating operations are performed on the aluminum wire (each coating operation includes dipping → baking);
[0062] S420: The aluminum wire that has completed the first 15 painting operations is wound around the auxiliary guide wheel for natural cooling or sent into a cooling device.
[0063] S430, the last 15 painting operations are performed on the aluminum wire wound around the booster guide wheel and cooled.
[0064] S440 is used to anneal aluminum wires that have undergone 15 coating operations at 200℃~300℃.
[0065] Through the above process, a varnish coating of about 160μm is formed on the surface of the aluminum wire. The aluminum wire maintains structural stability and will not break throughout the manufacturing process, thus producing an aluminum wire enameled wire with qualified quality and performance.
[0066] In summary, the enameled wire manufacturing method of the present invention adopts a non-continuous coating method of "one coating cycle → one cooling operation → one coating cycle...". The cooling operation between adjacent coating cycles enhances the thermal stability of the wire, preventing breakage due to reduced thermal stability after multiple immersions and baking, ensuring the effective execution of subsequent coating cycles, and thus ensuring the manufacture of qualified enameled wire. The manufacturing method of the present invention can also utilize a guide roller between two coating cycles to cool the wire while reducing its subsequent tensile resistance, ensuring smooth operation of subsequent coating processes. Furthermore, the manufacturing method of the present invention, by performing an annealing step after the non-continuous coating step, ensures the tensile strength of the wire during the coating process and improves the quality and performance of the wire after coating. The manufacturing method of the present invention is particularly suitable for manufacturing thick-coated aluminum wire enameled wire, ensuring that the aluminum wire maintains structural stability and does not break throughout the manufacturing process, thereby producing qualified aluminum wire enameled wire.
[0067] The above description, in conjunction with specific preferred embodiments, provides a further detailed explanation of the present invention. It should not be construed that the specific implementation of the present invention is limited to these descriptions. For those skilled in the art, various simple deductions or substitutions can be made without departing from the concept of the present invention, and all such modifications and substitutions should be considered within the scope of protection of the present invention.
Claims
1. A method for manufacturing enameled wire, characterized in that, include: A discontinuous painting step, the discontinuous painting step comprising at least two sets of painting cycles and a cooling operation performed between each two adjacent sets of painting cycles; Each painting cycle includes multiple painting operations, and each painting operation includes dipping the wires in varnish and baking them.
2. The method for manufacturing enameled wire as described in claim 1, characterized in that, The number of coating operations in each coating cycle is determined at least based on the thermal stability of the conductor.
3. The method for manufacturing enameled wire as described in claim 1, characterized in that, The number of painting operations in each painting cycle may be the same or different.
4. The method for manufacturing enameled wire according to any one of claims 1 to 3, characterized in that, The conductor is an aluminum wire; The number of coating operations in each coating cycle is between 15 and 22, and / or, each coating cycle increases the coating thickness on the aluminum wire surface by 80 μm to 100 μm.
5. The method for manufacturing enameled wire as described in claim 1, characterized in that, The cooling operation includes allowing the wire to cool naturally or sending the wire into a cooling device for cooling.
6. The method for manufacturing enameled wire as described in claim 1 or 5, characterized in that, The cooling operation includes winding the wire that has completed the previous painting cycle around the booster guide wheel; After the cooling operation, the wires wound around the booster guide wheel are subjected to the next set of painting cycles.
7. The method for manufacturing enameled wire as described in claim 1, characterized in that, Impregnating the wire with varnish includes: feeding the wire into an impregnation device for impregnation.
8. The method for manufacturing enameled wire as described in claim 1, characterized in that, Baking the wire includes: feeding the wire into a baking device for baking.
9. The method for manufacturing enameled wire as described in claim 1, characterized in that, Also includes: An annealing step, which is performed after the discontinuous coating step.
10. The method for manufacturing enameled wire as described in claim 9, characterized in that, The conductor is an aluminum wire; The annealing step includes annealing the aluminum wire at an annealing temperature between 200°C and 300°C.