A novel combination paint die and method of use thereof

Abstract

The present application relates to a new type of combined painting mold and its using method, belongs to the technical field of enameled electromagnetic wire production. Technical scheme: the mold cover is composed of a mold core assembly section (1) and a mold support section (2), the mold core assembly section (1) is an elastic cylinder provided with a through type lateral gap one (101), the mold support section (2) is an elastic cylinder provided with a through type lateral gap two (201), the mold support section (2) is sleeved outside the mold core assembly section (1), and the mold cover is formed into a sleeve structure; the mold core is a split type mold core (3) composed of two detachable butt joint split mold cores, the center of the mold core is combined into a mold core hole (302), and the split type mold core can be detachably embedded in the cylinder body of the mold core assembly section (1) of the mold cover. The present application has the characteristics of optimized structure, convenient disassembly and assembly, no need to cut wire and pass through mold, etc., is suitable for the high frequency transformation working condition of multi-specification enameled flat wire for power transformers, and effectively improves the production efficiency and reduces the production loss.

Description

Technical Field

[0001] This invention relates to a novel combined coating mold and its application method, belonging to the field of enameled electromagnetic wire production technology. Background Technology

[0002] Horizontal enameled flat wire production equipment is a core piece of equipment for high-end electromagnetic wire processing, widely used in core fields such as power transformers, new energy vehicle drive motors, and high-end industrial control equipment. With the rapid upgrading of China's high-end equipment manufacturing industry, the expansion of the power grid, and the large-scale development of the new energy vehicle industry, the market demand for specialized enameled flat wire production capacity continues to rise. At the same time, more stringent standardization requirements are being placed on wire insulation performance, dimensional accuracy, and quality stability. Against this industry development backdrop, domestic enameled flat wire production equipment has undergone continuous iteration and optimization, achieving multiple technological breakthroughs in production efficiency, energy conservation and environmental protection, and operational stability. This has effectively improved the overall production quality and production capacity of enameled flat wire, basically meeting the production and usage needs of conventional scenarios.

[0003] Existing technologies for producing enameled flat wires mostly employ mold coating processes. This process offers high coating precision and excellent coating uniformity, making it the mainstream technology for high-end flat wire processing. Examples include Chinese patents CN2020224537743 ("A Combined Enameled Wire Coating Mold") and CN2021216463579 ("A Combined Enameled Wire Coating Mold"). However, in actual industrial production, the existing coating mold structures and supporting processes still have significant technical defects, failing to meet customized production requirements. Large power transformers primarily use a customized order model for enameled flat wires, resulting in numerous specifications and diverse categories, leading to frequent production changes. Existing ordinary coating molds are integrated, fixed structures, making changeover procedures cumbersome: first, the lead wire must be cut, and the entire mold disassembled; then, the new mold is threaded onto the cut lead wire end, aligning the broken lead wire; finally, the new mold is aligned and assembled onto the mold support. Existing technologies are ill-suited for production scenarios involving multiple specifications and frequent changeovers, making it difficult to balance the demands for efficient production with low-consumption processing. In the production of enameled flat wire with multiple specifications and frequent changeovers, it is necessary to cut the wire, disassemble and reassemble the entire mold, and re-thread and reconnect it. This results in cumbersome mold-changing procedures, lengthy changeover times, and a significant amount of effective production time consumed. Furthermore, frequent threading and wire-cutting operations generate a large amount of waste wire, leading to substantial raw material losses and a persistently high waste rate on the production line. This further exacerbates raw material waste and increases production costs. Moreover, traditional mold structures have poor adaptability and cannot simultaneously meet the demands for both high efficiency and low waste in customized enameled flat wire production. Additionally, the numerous coating passes mean that changing the entire mold is time-consuming, consuming a significant amount of effective production time and significantly reducing the overall production line efficiency.

[0004] In summary, in order to address the industry pain points such as low changeover efficiency and high waste rate of existing coating molds, and to further improve the production efficiency and economics of enameled flat wire, the industry urgently needs to develop a new type of coating mold with optimized structure, convenient assembly and disassembly, and wider adaptability, as well as supporting application processes. Summary of the Invention

[0005] This invention proposes a novel combined coating mold and its usage method, which features optimized structure, convenient assembly and disassembly, and no need for wire cutting and mold threading. It is suitable for high-frequency changeover conditions of multi-specification enameled flat wires used in power transformers, effectively improving production efficiency, reducing production losses, and solving the aforementioned technical problems existing in the prior art.

[0006] The technical solution of this invention is: A novel combined painting mold includes a mold sleeve and a mold core assembled together. The mold sleeve consists of a mold core assembly section and a mold support section. The mold core assembly section is an elastic cylinder with a through-type lateral slit, and the mold support section is an elastic cylinder with a through-type lateral slit. The mold support section is fitted over the mold core assembly section to form a sleeve structure. The mold core is a split mold core, consisting of two detachable and interlocking split mold cores. The two split mold cores are joined together to form a complete mold core. The center of the mold core forms a mold core hole. The split mold core can be detachably embedded inside the mold core assembly section of the mold sleeve.

[0007] The cross-section of the split mold core is a rounded rectangle one, and the four corners of the rounded rectangle one are provided with mold core rounded corners; the cross-sections of the two split mold cores are joined together to form a mold core hole; the mold core hole is a rounded rectangle two, and the four corners of the rounded rectangle two are provided with mold core hole rounded corners; the mold core hole is a flared hole, the inlet part of the mold core hole is the mold inlet area, the outlet part of the mold core hole is the mold outlet area, the diameter of the mold inlet area is larger than the diameter of the mold outlet area, and the mold inlet area and the mold outlet area smoothly transition into a whole mold core hole.

[0008] The core assembly section has a rectangular mounting slot inside its cylinder, and the split core is embedded in the rectangular mounting slot of the core assembly section.

[0009] The mold support section is positioned and installed on the mold frame of the enameling machine; the mold frame is provided with a mold frame slot hole that matches the outer circle of the mold support section, and the mold support section is embedded and locked in the mold frame slot hole. The enameling machine is a special equipment for producing enameled wire in the electromagnetic wire industry. It is used to manufacture wires for electrical coils such as motors and transformers by coating the surface of copper or aluminum wire with polyester insulating varnish and curing it.

[0010] One end of the mold core assembly section is provided with an annular mold core assembly section boss, and one end of the mold support section is provided with an annular mold support section retainer. The mold core assembly section boss and the mold support section retainer cooperate with each other to position the mold support section to fit the mold core assembly section. The mold support section and the mold core assembly section cannot move axially but can rotate relative to each other.

[0011] The core assembly section and mold support section are made of corrosion-resistant elastic materials, typically fluororubber FKM, polytetrafluoroethylene, or polyetheretherketone, which have elastic adaptability and can meet the requirements of side-entry and non-cutting assembly / disassembly conditions.

[0012] A method for using the aforementioned novel combined coating mold includes the following steps: During mold changing operations, the copper flat wire of the next specification to be processed is connected to the existing copper flat wire on the enameling machine; the through-type lateral slit one and through-type lateral slit two on the mold sleeve of the combined coating mold are aligned and placed in a straight line; the copper flat wire and the split mold core are removed from the mold sleeve, the two separate mold cores of the split mold core are separated from the copper flat wire, and the mold sleeve and the split mold core are removed; a new mold sleeve and the split mold core matching the next specification of copper flat wire are installed on the mold frame; the through-type lateral slit one and through-type lateral slit two on the new combined coating mold are aligned and placed in a straight line; the copper flat wire is laterally embedded into the new combined mold sleeve; and the copper flat wire is then inserted into the mold core hole through the mold core mating interface of the split mold core, thus completing the replacement of the combined coating mold.

[0013] The split mold core and the mold set are assembled into a combined painting mold. The mold support section of the mold set is embedded and locked in the mold frame slot hole of the mold frame, so that the combined painting mold is positioned and fixed on the mold frame as a whole. This ensures the installation stability and concentricity of the combined painting mold during continuous painting operations, avoids shaking and displacement of the combined painting mold, and further ensures the consistency and reliability of painting quality during mass production.

[0014] The through-type lateral gap one and through-type lateral gap two on the mold core assembly section and the mold support section are aligned and are on a straight line, allowing the enameled flat wire to be laterally embedded into the mold sleeve or removed.

[0015] The core hole size of the split core is designed according to the enameling process ratio of the enameled flat wire, and a margin is reserved for the assembly and docking of the two split cores to eliminate the split assembly error; the split core cross-sections of the two split cores fit tightly together, forming a tightly fitting core interface on the split core cross-sections, and the size of the core hole after assembly is completely matched with the production process standard of enameled wire.

[0016] This invention eliminates the need to cut copper flat wires during mold changing operations, and also eliminates the need for traditional die-threading assistance. After completing the production of the previous specification of enameled flat wire, the next specification of copper flat wire to be processed is simply connected to the existing copper flat wire. The old combined painting mold can then be disassembled directly on the mold frame, followed by the rapid assembly and fixing of the new specification combined painting mold. This method completely eliminates redundant processes such as wire cutting, die threading, and wire end reconnection in traditional processes, significantly shortening mold changing time, greatly improving production line changeover efficiency, and reducing wasted production time. Simultaneously, it avoids the waste wire problem caused by wire cutting and repeated die threading, significantly reducing raw material loss, effectively controlling production costs, and perfectly adapting to multi-specification, high-frequency customized production changeover scenarios, balancing the needs of high-efficiency production and low-loss processing.

[0017] The core innovation of this invention lies in abandoning the traditional mold-changing structure and operation method that relies on threading and cutting wires. Instead, it adopts a split-type modular mold structure design. The new modular painting mold consists of a two-section mold sleeve and a split mold core, enabling rapid mold-changing operations without wire cutting or threading. The two-section mold sleeve is divided into two functional sections along the axial direction: a mold core assembly section and a mold support section. Both sections have through-type lateral slits on their side walls, allowing the enameled flat wire to be directly embedded into the mold sleeve from the side, eliminating the need for axial threading and providing structural support for mold-changing operations without stopping or cutting the wire. Furthermore, the entire mold sleeve is made of corrosion-resistant elastic material, offering excellent structural elasticity, wear resistance, and corrosion resistance, making it suitable for long-term continuous industrial production conditions with superior structural stability and service life.

[0018] Beneficial technical effects of the present invention: 1. The present invention adopts a combination structure of a side-opening through-type lateral gap mold sleeve and a split mold core, which realizes mold changing without shearing or threading, greatly simplifies the mold changing process, shortens the mold changing time, and effectively improves the effective working time of the production line and the overall production efficiency. 2. Completely eliminate waste line generation during mold changing, significantly reduce raw material loss and manufacturing costs, and improve production economy; 3. The split-type modular structure is suitable for high-frequency changeover needs of multi-specification enameled flat wires, and has stronger mold adaptability and versatility, solving the industry pain points of cumbersome changeover and poor adaptability of traditional integrated molds. 4. The combined painting mold has high assembly precision and good structural stability, which can effectively ensure the painting precision and coating uniformity of flat wire, improve product processing quality, and well meet the customized, high-quality and high-efficiency production needs of enameled flat wire for high-end power transformers. Attached Figure Description

[0019] Figure 1 This is a perspective view of the front side of the assembled painting mold according to an embodiment of the present invention; Figure 2 This is a perspective view of the rear side of the assembled painting mold according to an embodiment of the present invention; Figure 3 This is a perspective view of the front side of the mold core assembly section according to an embodiment of the present invention; Figure 4 This is a perspective view of the rear side of the mold core assembly section according to an embodiment of the present invention; Figure 5 This is a perspective view of the front side of the mold support section according to an embodiment of the present invention; Figure 6 This is a perspective view of the rear side of the mold support section according to an embodiment of the present invention; Figure 7 This is a perspective view of the split mold core assembly according to an embodiment of the present invention; Figure 8 This is a perspective view of a single-sided mold core of a split mold core according to an embodiment of the present invention; Figure 9 This is a perspective view of the mold frame from the side, according to an embodiment of the present invention. Figure 10 This is a perspective view of the assembly of the combined mold and mold frame according to an embodiment of the present invention; In the diagram: Mold core assembly section 1, through-type side gap one 101, mold core assembly section boss 102, rectangular mounting hole slot 103, mold core slot 104, mold support section 2, through-type side gap two 201, mold support section slot 202, split mold core 3, mold core mating interface 301, mold core hole 302, mold core fillet 303, split mold core section 304, mold inlet area 305, mold outlet area 306, mold core hole fillet 307, mold frame 4, mold frame slot hole 401. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0021] A novel combined painting mold includes a mold sleeve and a mold core assembled together. The mold sleeve consists of a mold core assembly section 1 and a mold support section 2. The mold core assembly section 1 is an elastic cylinder with a through-type lateral slit 101, and the mold support section 2 is an elastic cylinder with a through-type lateral slit 201. The mold support section 2 is fitted over the mold core assembly section 1 to form a sleeve structure mold sleeve. The mold core is a split mold core 3, which consists of two detachable and interlocking split mold cores. The two split mold cores are joined together to form a complete mold core. The center of the mold core is combined to form a mold core hole 302. The split mold core is detachably embedded inside the cylinder of the mold core assembly section 1 of the mold sleeve.

[0022] The cross-section of the split mold core 3 is a rounded rectangle, and the four corners of the rounded rectangle are provided with mold core rounded corners 303; the split mold core cross-sections 304 of the two split mold cores are spliced ​​to form a mold core hole 302; the mold core hole 302 is a rounded rectangle, and the four corners of the rounded rectangle are provided with mold core hole rounded corners 307; the mold core hole 302 is a flared hole, the inlet part of the mold core hole 302 is the mold inlet area 305, the outlet part of the mold core hole 302 is the mold outlet area 306, the diameter of the mold inlet area 305 is larger than the diameter of the mold outlet area 306, and the mold inlet area 305 and the mold outlet area 306 smoothly transition into a whole mold core hole 302.

[0023] The core assembly section 1 has a rectangular mounting slot 103 inside its cylinder, and the split core 3 is embedded in the rectangular mounting slot 103 of the core assembly section 1.

[0024] The mold support section 2 is positioned and installed on the mold frame 4 of the enameling machine; the mold frame 4 is provided with a mold frame slot hole 401 that matches the outer circle of the mold support section 2, and the mold support section 2 is embedded and locked in the mold frame slot hole 401. The enameling machine is a special equipment for producing enameled wire in the electromagnetic wire industry. It is used to manufacture wires for electrical coils such as motors and transformers by coating the surface of copper or aluminum wire with polyester insulating varnish and curing it.

[0025] One end of the mold core assembly section 1 is provided with an annular mold core assembly section boss 102, and one end of the mold support section 2 is provided with an annular mold support section slot 202. The mold core assembly section boss 102 and the mold support section slot 202 cooperate with each other to position the mold support section 2 to fit the mold core assembly section 1. The mold support section 2 and the mold core assembly section 1 cannot move axially but can rotate relative to each other.

[0026] The core assembly section 1 and the mold support section 2 are made of corrosion-resistant elastic materials, generally fluororubber FKM, polytetrafluoroethylene or polyetheretherketone, which have elastic adaptability and can meet the requirements of side-entry and non-cutting disassembly and assembly conditions.

[0027] A method for using the above-mentioned novel combined coating mold includes the following steps: During mold changing operations, the copper flat wire of the next specification to be processed is connected to the original copper flat wire on the enameling machine; the through-type lateral slit one 101 and through-type lateral slit two 201 on the mold sleeve of the combined coating mold are aligned and placed in a straight line; the copper flat wire and the split mold core 3 are taken out from the mold sleeve, the two separate mold cores of the split mold core 3 are separated and detached from the copper flat wire, and the mold sleeve and the split mold core 3 are removed; a new mold sleeve and the split mold core matching the next specification of copper flat wire are installed on the mold frame; the through-type lateral slit one 101 and through-type lateral slit two 201 on the new combined coating mold are aligned and placed in a straight line; the copper flat wire is laterally embedded into the new combined mold sleeve; and the copper flat wire is then inserted into the mold core hole 302 through the mold core interface 301 of the split mold core 3, thus completing the replacement of the combined coating mold.

[0028] The split mold core 3 and the mold set are assembled into a combined painting mold. The mold support section 2 of the mold set is embedded and locked in the mold frame slot 401 of the mold frame 4, so that the combined painting mold is positioned and fixed on the mold frame as a whole. This ensures the installation stability and concentricity of the combined painting mold during continuous painting operations, avoids shaking and displacement of the combined painting mold, and further ensures the consistency and reliability of painting quality during mass production.

[0029] The through-type lateral slot 101 and through-type lateral slot 201 on the mold core assembly section 1 and the mold support section 2 are aligned on a straight line, allowing the enameled flat wire to be laterally embedded into the mold sleeve or removed.

[0030] The core hole 302 of the split core 3 is designed according to the enameling process ratio of the enameled flat wire, and a margin is reserved for the assembly and docking of the two split cores to eliminate the split assembly error; the split core cross-sections 304 of the two split cores fit tightly together, forming a tightly fitting core interface 301 on the split core cross-sections 304, and the size of the core hole 302 after assembly is completely matched with the production process standard of enameled wire.

[0031] In this embodiment, the present invention is applicable to continuous changeover operations of enameled flat wire with multiple specifications. The specific operation steps are as follows: The first step is wire connection and material preparation. After the production of the previous specification of enameled flat wire is completed, keep the equipment in standby mode. Without cutting the original copper flat wire on the enameling machine, firmly connect the next specification of copper flat wire to be processed with the end of the original copper flat wire. Ensure that the wire runs smoothly, the connection is flat, and there are no protrusions or misalignments. This provides the basis for the operation of wire-free die change.

[0032] The second step is to disassemble the old combined painting mold. Utilizing the lateral slotted structure on the side wall of the mold sleeve, align the through-type lateral slot 101, through-type lateral slot 201, and mold core interface 301 on the old mold sleeve so that they are in a straight line. Remove the copper flat wire from inside the old mold sleeve and mold core, and complete the disassembly of the old mold core and old mold sleeve in sequence. The entire process does not require axial wire pulling or wire cutting, and the disassembly and cleaning of the old combined painting mold is completed quickly.

[0033] The third step is to pre-assemble and align the new combined painting mold. According to the specifications of the flat wire to be produced, select a brand-new split mold core 3 of corresponding size, along with mold core assembly section 1 and mold support section 2. Align and splice the two separate mold cores of the split mold core 3, so that the split mold core cross-sections 304 of the two separate mold cores fit tightly together to form an integral mold core. The hole diameter 302 of the assembled mold core meets the process requirements. Then, insert the assembled mold core into the rectangular mounting slot 103 inside the mold core assembly section 1 from the side through the through-type lateral gap 101, ensuring that the outer wall of the mold core fits tightly with the inner wall of the mold core assembly section 1 without gaps or offset. Fit the mold support section 2 onto the outside of the mold core assembly section 1. The boss 102 of the mold core assembly section and the bayonet 202 of the mold support section cooperate with each other to position the mold support section 2 onto the mold core assembly section 1. The mold support section 2 and the mold core assembly section 1 cannot move axially but can rotate relative to each other. The alignment and pre-assembly of the new combined painting mold is completed.

[0034] The fourth step is to position and fix the combined painting mold. Align the through-type side gap 101, through-type side gap 201 and mold core interface 301 of the combined painting mold so that they are in a straight line. Insert the joined copper flat wire into the pre-assembled combined painting mold from the outside, so that the copper flat wire is placed in the mold core hole 302 in the center of the mold core, ensuring that the copper flat wire is centered and without deviation. Then, insert the mold support section 2 into the mold frame slot hole 401 on the mold frame 4 to complete the limiting and fixing of the entire mold, ensuring that the combined painting mold is firmly installed and accurately positioned.

[0035] Step 5: Start-up. After all the molds for all passes on the production line have been replaced and installed, check the wire routing and mold assembly accuracy. Once it is confirmed that there are no issues such as wire jamming, misalignment, or looseness, the equipment can be started to begin continuous painting production of the next specification of enameled flat wire.

[0036] The above description is merely the basic principle and preferred embodiment of the present invention. Improvements and substitutions made by those skilled in the art based on the present invention are within the scope of protection of the present invention.

Claims

1. A novel combined painting mold, characterized in that: The mold sleeve and the mold core are combined together. The mold sleeve is composed of a mold core assembly section (1) and a mold support section (2). The mold core assembly section (1) is an elastic cylinder with a through-type lateral slit one (101). The mold support section (2) is an elastic cylinder with a through-type lateral slit two (201). The mold support section (2) is fitted outside the mold core assembly section (1) to form a sleeve structure. The mold core is a split mold core (3), which is composed of two split mold cores that can be separated and joined together. After the two split mold cores are joined together, a complete mold core is formed. The center of the mold core is combined to form a mold core hole (302). The split mold core can be detachably embedded inside the cylinder of the mold core assembly section (1) of the mold sleeve.

2. The novel combined painting mold according to claim 1, characterized in that: The cross-section of the split mold core (3) is a rounded rectangle, and the four corners of the rounded rectangle are provided with mold core rounded corners (303); the split mold core cross-sections (304) of the two split mold cores are spliced ​​to form a mold core hole (302); the mold core hole (302) is a rounded rectangle, and the four corners of the rounded rectangle are provided with mold core hole rounded corners (307); the mold core hole (302) is a horn hole, the inlet part of the mold core hole (302) is the mold inlet area (305), the outlet part of the mold core hole (302) is the mold outlet area (306), the hole diameter of the mold inlet area (305) is larger than the hole diameter of the mold outlet area (306), and the mold inlet area (305) and the mold outlet area (306) smoothly transition into a whole mold core hole (302).

3. The novel combined painting mold according to claim 2, characterized in that: The core assembly section (1) has a rectangular mounting slot (103) inside its cylinder, and the split core (3) is embedded in the rectangular mounting slot (103) of the core assembly section (1).

4. A novel combined painting mold according to claim 1 or 2, characterized in that: The mold support section (2) is positioned and installed on the mold frame (4) of the enameling machine; the mold frame (4) is provided with a mold frame slot hole (401) that matches the outer circle of the mold support section (2), and the mold support section (2) is embedded and locked in the mold frame slot hole (401).

5. A novel combined painting mold according to claim 1 or 2, characterized in that: One end of the mold core assembly section (1) is provided with an annular mold core assembly section boss (102), and one end of the mold support section (2) is provided with an annular mold support section slot (202). The mold core assembly section boss (102) and the mold support section slot (202) cooperate with each other to position the mold support section (2) to fit the mold core assembly section (1). The mold support section (2) and the mold core assembly section (1) cannot move axially but can rotate relative to each other.

6. A novel combined painting mold according to claim 1 or 2, characterized in that: The core assembly section (1) and the mold support section (2) are made of corrosion-resistant elastic material.

7. A method of using the novel combined painting mold according to any one of claims 1-6, characterized in that... The process includes the following steps: During the mold change operation, the copper flat wire of the next specification to be processed is connected to the original copper flat wire on the enameling machine; the through-type side gap one (101) and through-type side gap two (201) on the mold sleeve of the combined painting mold are aligned and placed on a straight line; the copper flat wire and the split mold core (3) are taken out from the inside of the mold sleeve; the two separate mold cores of the split mold core (3) are separated and detached from the copper flat wire; the mold sleeve and the split mold core (3) are removed. 3) Install the new mold sleeve and split mold core that match the next specification of copper flat wire on the mold frame, align the through side gap one (101) and through side gap two (201) of the new combined painting mold and place them on a straight line, insert the copper flat wire laterally into the new combined mold sleeve, and then insert the copper flat wire into the mold core hole (302) through the mold core interface (301) of the split mold core (3) to complete the replacement of the combined painting mold.

8. The method of using the novel combined painting mold according to claim 7, characterized in that: The split mold core (3) and the mold set are assembled into a combined painting mold. The mold support section (2) of the mold set is embedded and locked in the mold frame slot (401) of the mold frame (4), so that the combined painting mold is positioned and fixed on the mold frame as a whole.

9. A practical method for a novel combined painting mold according to claim 7, characterized in that: The core hole (302) of the split core (3) is designed according to the enameling process ratio of the flat wire coating process, and a margin is reserved for the assembly and docking of the two split cores to eliminate the split assembly error; the split core cross-section (304) of the two split cores fits tightly, and a tightly fitted core interface (301) is formed on the split core cross-section (304). After assembly, the size of the core hole (302) is completely matched with the production process standard of enameled wire.

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