Manufacturing method of special-shaped silk-covered wire

Abstract

The invention discloses a manufacturing method of a special-shaped silk-covered wire, and relates to the technical field of wire and cable manufacturing. The method comprises the steps of providing a special-shaped metal wire, performing surface pretreatment, winding a silk thread on the wire by using a winding device, applying an adhesive, performing curing treatment and the like. The winding device comprises a movable wire guide nozzle, the position can be adjusted in real time according to the shape of the special-shaped section, and it is ensured that the wire is evenly wrapped. By optimizing the winding process and the curing process, the problems of non-uniform silk wrapping and poor adhesive force in the manufacturing of the special-shaped silk-covered wire are solved, and the insulating property and the mechanical strength of the product are improved. The method is suitable for automatic production, high in efficiency and stable in quality.

Description

Technical Field

[0001] This invention relates to the field of wire and cable manufacturing technology, and in particular to a method for manufacturing irregularly shaped wire. Background Technology

[0002] Silk-covered wire is a common type of insulated electrical wire. It consists of a metal conductor wrapped with silk threads as insulation and is widely used in motors, transformers, and electronic equipment. Traditional silk-covered wires mostly use round cross-section conductors, and while the manufacturing process is mature, it has limitations: round conductors have low space utilization and are prone to skin effect in high-frequency applications, affecting performance. With the miniaturization and high performance of electronic equipment, irregularly shaped cross-section silk-covered wires (such as rectangular, trapezoidal, or elliptical wires) are favored due to their better space utilization and electrical performance.

[0003] However, the manufacture of irregularly shaped wires faces numerous challenges. First, the irregular cross-section makes it easy for gaps to form during wire winding, resulting in poor insulation uniformity. Second, the adhesion between the wire and the conductor is insufficient, making it prone to detachment. Furthermore, existing manufacturing methods mostly rely on manual or simple mechanical winding, which is inefficient and produces inconsistent quality. Therefore, there is an urgent need in this field for a method to manufacture irregularly shaped wires that can achieve uniform wrapping, strong adhesion, and high efficiency. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a method for manufacturing irregularly shaped wire. This method achieves uniform wrapping of the wire on the irregularly shaped conductor by adjusting the winding device in real time, applying adhesive, and optimizing the curing process, thereby improving insulation performance and mechanical strength.

[0005] The present invention proposes a method for manufacturing irregularly shaped covered wire, comprising the following steps:

[0006] S1. Provide an irregularly shaped metal wire; S2. Perform surface pretreatment on the irregularly shaped metal wire; S3. Use a winding device to wind the wire onto the irregularly shaped metal wire, wherein the winding device includes a movable guide nozzle, the guide nozzle adjusting its position in real time according to the cross-sectional shape of the irregularly shaped metal wire to maintain constant contact between the wire and the wire surface; S4. Apply adhesive to the wire during the winding process; S5. After winding, perform a curing treatment to cure the adhesive; The core steps of the method include providing an irregularly shaped metal wire, surface pretreatment, winding, applying adhesive, and curing treatment. The irregularly shaped metal wire can be any conductive metal, such as copper, aluminum, or alloy, with a non-circular cross-section, such as polygonal or curved. Surface pretreatment aims to remove oxide layers and contaminants to improve adhesion. The key to the winding device is the mobility of the guide nozzle, which adjusts its position in real time through sensor feedback and a control system to maintain a consistent contact angle between the wire and the wire surface. Adhesive application can be achieved through spraying, dipping, etc., and curing treatment is selected according to the type of adhesive, such as heating or UV irradiation.

[0007] Preferably, the cross-sectional shape of the irregular metal wire is rectangular, trapezoidal, or elliptical; these shapes are common in electrical equipment, with rectangles saving space, trapezoids facilitating stacking, and ellipses reducing edge stress.

[0008] Preferably, the surface pretreatment in step S2 includes cleaning, polishing, or chemical treatment; specifically, the surface pretreatment includes cleaning (such as ultrasonic cleaning), polishing (such as belt polishing), or chemical treatment (such as pickling or phosphate conversion); cleaning removes oil stains, polishing increases roughness, and chemical treatment forms an activation layer.

[0009] Preferably, the thread material includes natural silk (such as silkworm silk, which has excellent insulation and heat resistance), synthetic silk (such as polyester or nylon silk, which has high strength and low cost), or blends thereof. The thread diameter is preferably 0.01-0.05 mm to ensure wrapping density.

[0010] Preferably, the adhesive is a thermosetting resin, a UV-curable resin, or a solvent-based adhesive; the adhesive is preferably a thermosetting resin (such as epoxy resin, which is resistant to high temperatures after curing), a UV-curable resin (such as acrylate, which cures quickly), or a solvent-based adhesive (such as polyurethane, which has good flexibility), and the adhesive viscosity is controlled at 100-1000 cPs for easy application.

[0011] Preferably, the winding device in step S3 is a multi-axis CNC winding machine, and the guide nozzle is controlled by a servo motor to move in the X, Y, and Z directions with a movement accuracy of ±0.01mm. The CNC system is programmed according to the conductor cross-section model to achieve precise trajectory control.

[0012] Preferably, hot air at a temperature of 50-150°C is applied during the winding process in step S3 to soften the yarn, making it easier to deform and fit irregular surfaces, especially suitable for thermoplastic yarns. The hot air flow rate is 5-20 L / min, and it is blown evenly through a nozzle.

[0013] Preferably, the curing process in step S5 is specifically heat treatment (temperature 100-200°C, time 1-30 minutes), ultraviolet irradiation (intensity 50-200mW / cm², time 1-60 seconds), or air drying (room temperature 2-24 hours), the choice depending on the adhesive properties.

[0014] Preferably, a cooling step is performed after curing in step S5. The cooling method includes natural cooling or forced air cooling to stabilize the product dimensions and prevent deformation.

[0015] Preferably, the irregularly shaped metal wire is made of copper (good conductivity) or aluminum (lightweight), and the wire size is customized according to application requirements, for example, the cross-sectional area is 0.001-55mm².

[0016] Compared with the prior art, the present invention provides a method for manufacturing irregularly shaped covered wire, which has the following beneficial effects:

[0017] 1. By adjusting the guide nozzle in real time, the wire is evenly wrapped on the irregularly shaped conductor without gaps, thus improving the insulation resistance.

[0018] 2. The adhesive cures and enhances adhesion, making the threads less likely to fall off and improving product durability.

[0019] 3. The method is suitable for automated production, with high efficiency, low cost, and good product quality consistency. Detailed Implementation

[0020] Example 1: Manufacturing method of rectangular cross-section wire

[0021] This embodiment uses rectangular cross-section copper wire as an example to describe the manufacturing process in detail. Rectangular cross-section wire is suitable for high-frequency transformers and compact motors, where uniform wire wrapping is crucial for insulation performance.

[0022] Materials preparation:

[0023] Irregularly shaped metal wires: rectangular cross-section oxygen-free copper wires with cross-sectional dimensions of 0.2mm × 0.1mm (width × height), continuous length on a spool, resistivity ≤ 0.01724Ω·mm² / m, the wires are pre-drawn by a wire drawing machine to ensure dimensional tolerance ±0.01mm;

[0024] Thread: Made of polyester synthetic yarn with a diameter of 0.01mm, a breaking strength ≥5cN / dtex, and an elongation of 15-20%. Polyester yarn has high strength and chemical resistance, making it suitable for harsh environments.

[0025] Adhesive: Epoxy resin thermosetting adhesive, model EP-500, viscosity 500 cPs (25°C), temperature resistance grade B (130°C) after curing. 5% silane coupling agent is added to the adhesive to enhance adhesion.

[0026] Auxiliary materials: alcohol cleaning agent, deionized water;

[0027] Equipment configuration:

[0028] Winding device: Multi-axis CNC winding machine, including a wire feeding mechanism, a wire guide system, a tension control system, an adhesive spraying system, a heating and curing oven, and a winding mechanism;

[0029] Wire feeding mechanism: adopts active wire feeding, with a wire speed control range of 0-20m / min and an accuracy of ±0.1m / min;

[0030] Guide tip system: The guide tip is controlled by three servo motors (X, Y, Z axes), with a movement range of ±10mm and an accuracy of ±0.01mm. The guide tip is made of ceramic, which is wear-resistant and reduces wire friction.

[0031] Tension control system: uses magnetic powder brake and sensor feedback, tension control range 0-20cN, accuracy ±1cN;

[0032] Adhesive spraying system: including micro nozzles, metering pumps and storage tanks, with a spraying volume control range of 0.05-0.2 g / m and an accuracy of ±0.01 g / m;

[0033] Heating and curing oven: 5m in length, temperature control range 50-300°C, accuracy ±5°C, using hot air circulation;

[0034] Winding mechanism: torque control, winding speed synchronized with unwinding;

[0035] Control system: PLC (Programmable Logic Controller) and HMI (Human Machine Interface) are integrated. The system is programmed based on the cross-sectional shape model of the wire (rectangular in this example). The control algorithm adopts PID (Proportional-Integral-Derivative) regulation. It receives the wire position signal fed back by the encoder in real time and calculates the movement trajectory of the guide nozzle. For example, for a rectangular cross-section, the guide nozzle moves at a constant speed on the straight side and decelerates and pauses briefly at the four corners (pause time 0.1-0.5 seconds) to ensure that the wire fits tightly against the corners.

[0036] Manufacturing steps:

[0037] 1. Provide irregularly shaped metal wires: Rectangular copper wires are released from the wire-laying mechanism at a wire speed of 10m / min. During the wire-laying process, the position of the wires is monitored by a photoelectric sensor to prevent deviation.

[0038] 2. Surface pretreatment:

[0039] Cleaning: The wires are passed through an ultrasonic cleaning tank containing alcohol cleaning agent. The ultrasonic frequency is 40kHz, the power is 500W, and the cleaning time is 30 seconds to remove surface oil and oxides.

[0040] Drying: After cleaning, the wires are placed in the hot air drying zone at 80°C for 10 seconds to ensure that there are no water stains on the surface;

[0041] 3. Winding the silk thread:

[0042] The thread is released from the spool and kept at a constant tension of 8cN (range 5-10cN) by a tension controller. Too high a tension may cause the thread to break, while too low a tension will cause the wrapping to become loose.

[0043] The guide tip adjusts its position in real time according to the rectangular cross-section model: when moving along the wide side (0.2mm), the guide tip moves at a constant speed along the X-axis; when moving along the narrow side (0.1mm), it moves along the Y-axis; at the corner, the guide tip decelerates to 50% of the linear speed, pauses for 0.2 seconds, and at the same time finely adjusts the Z-axis position to maintain the wire contact angle of 45° (the angle between the wire and the conductor axis).

[0044] The adhesive is sprayed onto the filament through a micro-nozzle at a pressure of 0.2 MPa and a coating amount of 0.1 g / m. The nozzle is 10 mm away from the filament to ensure uniform coverage.

[0045] During the wrapping process, the quality of the package is monitored in real time by a camera, and the system automatically adjusts if any abnormalities are found.

[0046] 4. Curing treatment: The wound wires are put into the curing oven, the oven temperature is set to 150°C and the time is 5 minutes. Under these conditions, the epoxy resin is fully cross-linked and cured. The hot air flow rate in the curing oven is 1m / s to ensure uniform temperature.

[0047] 5. Cooling: After curing, the wires pass through the cooling zone and are cooled to room temperature (25°C) by forced air cooling at a speed of 5m / s for about 30 seconds.

[0048] 6. Winding: The finished product is wound onto the reel, with the winding tension controlled at 5cN to avoid damage to the yarn.

[0049] Quality Inspection: Insulation Resistance: Measured using a megohmmeter, value ≥1000MΩ·m (standard requirement ≥500MΩ·m); Adhesion Test: By cross-cut test, after applying 3M tape and tearing it, no threads fall off; Appearance Inspection: Observed under a microscope, the threads are evenly wrapped without gaps or overlaps; Withstand Voltage Test: Apply AC 1kV voltage for 1 minute, no breakdown.

[0050] The product in this embodiment conforms to the GB / T 6109 series standards, is suitable for high-frequency electrical appliances, and the entire process is continuous, with an hourly output of up to 600m³, resulting in high efficiency.

[0051] Example 2: Manufacturing method of trapezoidal cross-section wire

[0052] This embodiment takes trapezoidal cross-section aluminum wire as an example to focus on the chemical pretreatment and UV curing process. Trapezoidal wire is often used in special motor slots, where the wire wrapping needs to adapt to the slope change.

[0053] Materials preparation:

[0054] Irregularly shaped metal wire: trapezoidal cross-section aluminum wire, top diameter 0.15mm, bottom diameter 0.2mm, height 0.1mm, conductivity ≥61% IACS;

[0055] Thread: Nylon synthetic filament, diameter 0.02mm, tensile strength ≥6cN / dtex, abrasion resistant;

[0056] Adhesive: UV-cured acrylic resin, viscosity 300 cPs, good flexibility after curing;

[0057] Auxiliary materials: phosphate solution (conversion membrane treatment agent), deionized water.

[0058] Equipment configuration:

[0059] Winding device: Based on Example 1, a UV curing device (high-pressure mercury lamp, intensity 100mW / cm², wavelength 365nm) and an impregnation adhesive application system are added. The guide nozzle movement algorithm is optimized for trapezoidal cross-section: the speed is different when the upper and lower bottoms move to maintain uniform wrapping.

[0060] Manufacturing steps:

[0061] 1. Provide irregularly shaped metal wires: linear speed 8m / min;

[0062] 2. Surface pretreatment:

[0063] Chemical treatment: The wires are immersed in a phosphate solution (50°C) for 1 minute to form an aluminum phosphate conversion film, which enhances the adhesion of the adhesive.

[0064] Wash with water: Rinse with deionized water for 30 seconds to remove residual reagents;

[0065] Drying: Hot air drying, temperature 100°C, time 15 seconds.

[0066] 3. Winding the silk thread:

[0067] Tension control 10cN;

[0068] Guide tip movement: According to trapezoidal programming, the upper bottom moves faster (to compensate for the short side), and the lower bottom moves slower, maintaining a contact angle of 50°;

[0069] Adhesive application: The thread passes through the adhesive in the impregnation tank for 0.5 seconds, and excess adhesive is removed by a scraper.

[0070] 4. Curing treatment: UV irradiation, intensity 100mW / cm², time 10 seconds, irradiation distance 100mm, to ensure complete curing;

[0071] 5. Cooling: Allow to cool naturally to room temperature for 2 minutes;

[0072] 6. Winding: The winding speed is synchronized with the unwinding speed.

[0073] Quality inspection: Insulation resistance ≥800MΩ·m; Adhesion test: No peeling; Damp heat resistance test: No change in performance after being placed in an environment of 85°C and 85%RH for 168 hours.

[0074] The product in this embodiment is suitable for humid environments, has a fast UV curing speed, and is energy-saving.

[0075] Example 3: Method for manufacturing elliptical cross-section wire

[0076] This embodiment uses elliptical cross-section copper wire as an example to illustrate the application of hot air-assisted winding and solvent-based adhesives. Elliptical wire is used in high-frequency coils to reduce the skin effect.

[0077] Materials preparation:

[0078] Irregularly shaped metal conductor: elliptical cross-section copper wire, major axis 0.2mm, minor axis 0.1mm;

[0079] Silk thread: Natural silkworm silk, 0.01mm in diameter, with excellent insulation properties;

[0080] Adhesive: Solvent-based polyurethane adhesive, viscosity 400 cPs, flexible after curing;

[0081] Auxiliary material: Plasma treatment gas (argon).

[0082] Equipment configuration:

[0083] Winding device: Add hot air nozzles (temperature adjustable), guide nozzles are programmed for elliptical trajectories; add hot air control module to control system.

[0084] Manufacturing steps:

[0085] 1. Provide irregularly shaped metal wires: linear speed 5m / min;

[0086] 2. Surface pretreatment: Plasma treatment, power 500W, time 5 seconds, to improve surface energy in an argon atmosphere;

[0087] 3. Winding the silk thread:

[0088] Tension control 7cN;

[0089] Hot air application: temperature 100°C, flow rate 10L / min, softens the silk and makes it easier to fit curved surfaces;

[0090] Guide tip movement: Move at a constant speed along an elliptical trajectory, maintaining a contact angle of 40°;

[0091] Adhesive spraying: pressure 0.15MPa, spraying amount 0.08g / m.

[0092] 4. Curing treatment: First, dry with hot air (80°C, 2 minutes), then cure at room temperature for 24 hours to allow the solvent to evaporate.

[0093] 5. Cooling: Natural cooling.

[0094] 6. Winding up.

[0095] Quality inspection: Insulation resistance ≥1200MΩ·m; Flexibility test: Bending radius 5mm, repeated bending 10 times, no cracks; High frequency test: Q value ≥100 at 1MHz.

[0096] The product in this embodiment is suitable for high-frequency inductor components, and the natural insulation properties of silk enhance its performance.

[0097] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. A method for manufacturing irregularly shaped covered wire, characterized in that, Includes the following steps: Step S1: Provide irregularly shaped metal wires; Step S2: Perform surface pretreatment on the irregularly shaped metal wire; Step S3: Use a winding device to wind the wire onto the shaped metal wire. The winding device includes a movable wire guide nozzle, which adjusts its position in real time according to the cross-sectional shape of the shaped metal wire to maintain constant contact between the wire and the wire surface. Step S4: Apply adhesive to the yarn during the winding process; Step S5: After wrapping, perform a curing process to cure the adhesive.

2. The method for manufacturing irregularly shaped covered wire according to claim 1, characterized in that, The cross-sectional shape of the irregular metal wire is rectangular, trapezoidal, or elliptical.

3. The method for manufacturing irregularly shaped covered wire according to claim 1, characterized in that, The surface pretreatment in step S2 includes cleaning, polishing, or chemical treatment.

4. The method for manufacturing irregularly shaped covered wire according to claim 1, characterized in that, The thread is natural silk, synthetic silk, or a combination thereof.

5. The method for manufacturing irregularly shaped covered wire according to claim 1, characterized in that, The adhesive is a thermosetting resin, a UV-curable resin, or a solvent-based adhesive.

6. The method for manufacturing irregularly shaped covered wire according to claim 1, characterized in that, The winding device in step S3 is a multi-axis CNC winding machine, and the guide nozzle is moved by a servo motor.

7. The method for manufacturing irregularly shaped covered wire according to claim 1, characterized in that, During the winding process in step S3, hot air is also applied to the thread to soften it.

8. The method for manufacturing irregularly shaped covered wire according to claim 1, characterized in that, The curing process in step S5 is heat treatment, ultraviolet irradiation, or air drying.

9. The method for manufacturing irregularly shaped covered wire according to claim 1, characterized in that, After the curing process in step S5, a cooling step is also performed.

10. The method for manufacturing irregularly shaped covered wire according to claim 1, characterized in that, The irregularly shaped metal wire is a copper wire or an aluminum wire.