Manufacturing method for high-temperature-resistant and puncture-resistant enameled square wire

Abstract

Disclosed in the present invention is a manufacturing method for a high-temperature-resistant and puncture-resistant enameled square wire, comprising the following steps: unwinding a wire; drawing the wire to obtain a round wire; performing rolling to preliminarily shape the round wire into a flat wire having semicircular-like cross-sectional R-angles; performing primary shaping to obtain a flat wire having an octagonal-like cross-section; performing secondary shaping to obtain a square wire having a cross-sectional R-angle radius of 0.015±0.005 mm; performing cleaning; performing annealing; performing primary painting, primary baking, and primary cooling; and performing secondary painting, secondary baking, and secondary cooling to obtain an enamelled square wire, wherein a paint for the primary painting is PAI, and a paint for the secondary painting is PI, the ratio of PI to PAI being 1:9. Using the present invention enables products to exhibit good high-temperature resistance and puncture resistance, and to have a low cost. During a mold shaping treatment process, all parts of a conductor are uniformly stressed, and the amount of processing the cross-sectional R-angles of the conduct is increased, improving the uniformity of subsequent paint film coating.

Description

High-temperature-resistant and puncture-resistant enameled square wire manufacturing method TECHNICAL FIELD

[0001] The application belongs to the technical field of enameled wire production, and particularly relates to a high-temperature-resistant and puncture-resistant enameled square wire manufacturing method. BACKGROUND

[0002] The existing enameled square wire is composed of a square conductor and a film, and is widely used in various inductors, electrical appliances, motors, voice coils, vehicle-mounted multimedia products, etc. In recent years, 5G mobile phones, 5G equipment, artificial intelligence machines, new energy and intelligent electrical appliances and automobiles have rapidly grown and demanded, and these high-end products have extremely high added value, bringing a broad field and a bright future to the application of enameled wire. However, the existing enameled square wire product still has poor high-temperature resistance and puncture resistance.

[0003] In addition, in the manufacturing process of the enameled square wire, the conductor is first drawn into a round wire by a wire drawing device, then the round wire is pressed into a flat wire by calendering, and then the flat wire is formed into a square wire by a mold. However, in the existing manufacturing process of the enameled square wire, in order to improve the production efficiency, only one mold shaping treatment is usually performed, that is, the conductor is shaped into a square shape by hard drawing, so that the force on each part of the conductor is uneven, and the conductor is prone to breakage in the subsequent production process, and the overall performance is poor. At the same time, since the conductor only undergoes one mold shaping treatment, the processing amount of the R angle of the cross section of the conductor is not reasonable and sufficient, so that the R angle of the cross section of the conductor is not smooth enough, which is not conducive to the uniformity of subsequent film coating. SUMMARY

[0004] The purpose of the present application is to provide a high-temperature-resistant and puncture-resistant enameled square wire manufacturing method with low cost, which can make the force on each part of the conductor uniform, increase the processing amount of the R angle of the cross section of the conductor, and improve the uniformity of subsequent film coating.

[0005] In order to achieve the above-mentioned purpose, the technical scheme adopted by the present application is as follows:

[0006] A high-temperature-resistant and puncture-resistant enameled square wire manufacturing method comprises the following steps:

[0007] Step S1: The conductor is guided out of the wire laying device and drawn into a round wire by a wire drawing device;

[0008] Step S2: The round wire is subjected to calendering treatment to preliminarily shape the round wire into a flat wire with a cross-sectional R angle in the shape of a semicircle;

[0009] Step S3: The flat wire obtained after the step S2 is subjected to first shaping treatment by a first mold to obtain a flat wire with a cross section in the shape of an octagon;

[0010] Step S4: using a second mold to perform a second shaping treatment on the flat wire obtained after the step S3, to obtain a square wire with a cross-sectional R corner radius of 0.015±0.005mm; the cross-sectional area of the wire passage in the second mold is 5%±3% smaller than that of the wire passage in the first mold;

[0011] Step S5: performing a cleaning treatment on the square wire;

[0012] Step S6: performing an annealing treatment on the square wire after the cleaning treatment;

[0013] Step S7: sequentially performing a first paint coating treatment, a first baking treatment and a first cooling treatment on the square wire after the annealing treatment; wherein the paint for the first paint coating treatment is PAI;

[0014] Step S8: sequentially performing a second paint coating treatment, a second baking treatment and a second cooling treatment on the square wire after the step S7, to obtain an enameled square wire; wherein the paint for the second paint coating treatment is PI; the ratio of the paint for the second paint coating treatment to the paint for the first paint coating treatment is 1:9.

[0015] As a preferred scheme of the present application, the tangent position of the straight edge of the first mold to the R corner arc and the tangent position of the straight edge of the second mold to the R corner arc are provided with a circular arc transition.

[0016] As a preferred scheme of the present application, it further includes a step S9: when the enameled square wire needs to be coated with a self-adhesive paint layer, sequentially performing a third paint coating treatment, a third baking treatment, a third cooling treatment, a lubricating treatment and a take-up treatment on the enameled square wire, to obtain an enameled square wire product.

[0017] As a preferred scheme of the present application, it further includes a step S9: when the enameled square wire does not need to be coated with a self-adhesive paint layer, sequentially performing a lubricating treatment and a take-up treatment on the enameled square wire, to obtain an enameled square wire product.

[0018] As a preferred scheme of the present application, the paint in the third paint coating treatment is one of HB, SB or SV.

[0019] As a preferred scheme of the present application, in the step S7, the first paint coating treatment is performed by using high-pressure sealed spraying to perform one or more multi-pass coating on the square wire, so that the thickness of the single-side paint film is 0.3μm-6μm.

[0020] As a preferred scheme of the present application, in the step S8, the second paint coating treatment is performed by using high-pressure sealed spraying to perform one or more multi-pass coating on the square wire, so that the thickness of the single-side paint film is 0.3μm-6μm.

[0021] As a preferred scheme of the present application, in the step S1, the conductor is one of copper, silver, aluminum, aluminum alloy, copper-clad aluminum and tinned copper.

[0022] As a preferred scheme of the present application, the annealing temperature of the square wire in the step S6 is: copper: 400-550℃; silver: 500-650℃; aluminum: 350-450℃; aluminum alloy: 400-500℃; copper-clad aluminum: 300-400℃; tinned copper: 600-700℃.

[0023] The method for manufacturing the high-temperature-resistant and puncture-resistant enameled square wire has the following beneficial effects compared with the prior art:

[0024] 1. After the conductor is drawn into a round wire by a wire drawing device, the conductor is sequentially subjected to calendering treatment, first shaping treatment and second shaping treatment, so that the conductor is gradually shaped into a flat wire with a semi-circular cross section, a flat wire with an octagonal cross section and a square wire with a cross section R corner radius of 0.015±0.005mm. In this way, compared with the prior art in which the conductor is shaped into a square shape by hard drawing, the force on each part of the conductor is uniform, and the conductor is less likely to be broken in the subsequent production process. At the same time, the processing amount of the cross section R corner of the conductor can be reasonably and sufficiently increased, so that the cross section R corner of the conductor is smoother, and the uniformity of the subsequent coating of the paint film is more favorable.

[0025] 2. After the annealing treatment, the square wire is subjected to two times of paint coating treatment. The paint for the first paint coating treatment is PAI, so that the product has better puncture resistance. The paint for the second paint coating treatment is PI, so that the product has better high-temperature resistance. Since the PI material is expensive, has difficulty in uniform coating, has strict storage conditions and has a short shelf life, PAI and PI are combined in the embodiment, the insulating layer of the finished wire is formed by PAI and PI after processing, and the ratio of PI to PAI is 1:9. The cost of the product is lower than that of the product coated with only PI insulating material, and the heat resistance of the product is higher than that of the product coated with only PAI insulating material. The softening breakdown of the product is at least 100℃ higher in the temperature rise test, and the product can withstand harsh working conditions of higher temperature and higher pressure. DETAILED DESCRIPTION

[0026] The specific embodiments of the present application will be further described in detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate the present application, but are not used to limit the scope of the present application.

[0027] In the description of the present application, it should be understood that the terms "upper", "lower", "left", "right", "front", "back", "top", "bottom" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as a limitation on the present application. It should be understood that the terms "first", "second" and the like are used to describe various information in the present application, but these information should not be limited to these terms, and these terms are only used to distinguish the same type of information from each other. For example, the "first" information can also be referred to as "second" information without departing from the scope of the present application, and similarly, the "second" information can also be referred to as "first" information.

[0028] The preferred embodiment of the present application provides a high-temperature-resistant and puncture-resistant enameled square wire manufacturing method, which comprises the following steps:

[0029] Step S1: The conductor is led out from the wire laying device and drawn into a round wire through the wire drawing device. It should be noted that the conductor used in this step is one of copper, silver, aluminum, aluminum alloy, copper-clad aluminum and tinned copper.

[0030] Step S2: The round wire is subjected to calendering treatment to preliminarily form a flat wire with a R angle of a semi-circular shape. It should be noted that in this step, the round wire is subjected to continuous multiple calendering by at least two calendering rollers, which can make the stress more uniform and less likely to break the wire.

[0031] Step S3: The flat wire obtained after the step S2 is subjected to first shaping treatment by using a first mold to obtain a flat wire with a cross section of an octagon shape. It should be noted that in this step, it is a preferred choice to use the first mold to form the flat wire with a cross section of an octagon shape, if the deformation amount of the flat wire is small (such as forming a flat wire with a cross section of a decagon), it is close to a round wire, which is not conducive to subsequent processing; if the deformation amount of the flat wire is large (such as forming a flat wire with a cross section of a hexagon), the flat wire is easily damaged and broken.

[0032] Step S4: The flat wire obtained after the step S3 is subjected to second shaping treatment by using a second mold to obtain a square wire with a R angle radius of 0.015±0.005mm; the cross-sectional area of the wire passage in the second mold is 5%±3% smaller than that of the wire passage in the first mold. It should be noted that in this step, it is a preferred choice that the cross-sectional area of the wire passage in the second mold is 5%±3% smaller than that of the wire passage in the first mold, if it is greater than 5%±3%, it will lead to the phenomenon of insufficient processing, and it is more difficult to obtain a wire with a square cross section; if it is less than 5%±3%, the flat wire is easily damaged, and the service life of the mold is affected.

[0033] Step S5: cleaning treatment is performed on the square wire, which can clean the oil stains and powder on the surface of the conductor. Generally, the ultrasonic cleaning method is used, which can make the surface of the conductor smoother, the adhesion of the product stronger, and the subsequent paint coating step more convenient.

[0034] Step S6: annealing treatment is performed on the square wire after the cleaning treatment, which can eliminate the organizational defects and internal stress caused by the wire in the previous steps, and make the conductor R angle more smooth and flat. It should be noted that in this step, the annealing temperature corresponding to each conductor is as follows: copper: 400-550℃; silver: 500-650℃; aluminum: 350-450℃; aluminum alloy: 400-500℃; aluminum-clad copper: 300-400℃; and tin-plated copper: 600-700℃.

[0035] Step S7: the square wire after the annealing treatment is sequentially subjected to first paint coating treatment, first baking treatment and first cooling treatment; the paint for the first paint coating treatment is PAI. It should be noted that the first paint coating treatment is performed by using high-pressure sealed spraying to coat the square wire for one or more times, so that the thickness of the single-side paint film is 0.3-6μm.

[0036] Step S8: the square wire after the step S7 is sequentially subjected to second paint coating treatment, second baking treatment and second cooling treatment to obtain the enameled square wire. The paint for the second paint coating treatment is PI; the ratio of the paint for the second paint coating treatment to the paint for the first paint coating treatment is 1:9. It should be noted that the second paint coating treatment is preferably performed by using high-pressure sealed spraying to coat the square wire for one or more times, so that the thickness of the single-side paint film is 0.3-6μm.

[0037] According to the high-temperature-resistant and puncture-resistant enameled square wire manufacturing method, after the conductor is drawn into a round wire through a wire drawing device, the conductor is sequentially subjected to calendering treatment, first shaping treatment and second shaping treatment, and is gradually shaped into a flat wire with a R angle being a semi-circular shape, a flat wire with a section being an octagon shape and a square wire with a section R angle radius being 0.015±0.005 mm. Thus, compared with the prior art in which the conductor is shaped into a square shape through hard drawing, the conductor is gradually shaped, the force on each part of the conductor is uniform, and the conductor is not easy to break in the subsequent production process. Meanwhile, the processing amount of the conductor section R angle can be reasonably and fully increased, the conductor section R angle is smoother, and the uniformity of subsequent paint film coating is more favorable. In addition, after annealing treatment, the square wire is subjected to two times of paint coating treatment, the paint for the first paint coating treatment is PAI, so that the product has better puncture resistance, and the paint for the second paint coating treatment is PI, so that the product has better high-temperature resistance. Since the PI material is expensive, uniformity of coating is difficult, storage conditions are harsh and shelf life is short, PAI and PI are combined in the embodiment, the insulating layer of the finished wire is formed by PAI and PI after processing, and the ratio of PI to PAI is 1:9. The product has lower cost than that of a product coated with only PI insulating material and higher heat resistance than that of a product coated with only PAI insulating material, and the softening breakdown temperature is at least 100 DEG C higher in the temperature rise test, so that the product can withstand harsh working conditions of higher temperature and higher pressure.

[0038] Exemplarily, the tangent position of the straight edge of the first die to the R angle arc and the tangent position of the straight edge of the second die to the R angle arc are provided with a circular arc transition, so that the section R angle of the conductor is smoother, and the uniformity of paint film coating is favorable, and the overall performance of the product is improved.

[0039] Exemplarily, the embodiment further includes a step S9. When the enameled square wire needs to be coated with a self-adhesive paint layer, the enameled square wire is sequentially subjected to third paint coating treatment, third baking treatment, third cooling treatment, lubricating treatment and take-up treatment, and an enameled square wire product is obtained. The paint for the third paint coating treatment is preferably one of HB, SB or SV. When the enameled square wire does not need to be coated with a self-adhesive paint layer, the enameled square wire is sequentially subjected to lubricating treatment and take-up treatment, and an enameled square wire product is obtained.

[0040] In the description of the present application, it should be noted that unless otherwise explicitly specified and limited, the terms "connected", "connected" should be understood in a broad sense, for example, it can be fixedly connected, or detachably connected, or integrally connected, it can be mechanically connected, or electrically connected, it can be directly connected, or indirectly connected through an intermediate medium, or it can be the communication inside two elements. For those skilled in the art, the specific meaning of the above terms in the present application can be understood according to the specific circumstances.

[0041] The above merely describes the preferred embodiments of the present application, and it should be pointed out that those skilled in the art can make several improvements and replacements without departing from the technical principles of the present application, and these improvements and replacements should also be considered as the protection scope of the present application.

Claims

1. A method for making a high temperature resistant puncture resistant enameled round wire, characterized by, The method comprises the following steps: Step S1: a conductor is drawn out from a pay-off device and drawn into a round wire by a wire drawing device; Step S2: the round wire is subjected to a calendering treatment to preliminarily form a flat wire with a cross-section R angle in a semi-circular shape; Step S3: a first die is used to perform a first shaping treatment on the flat wire obtained after the step S2 to obtain a flat wire with a cross-section in an octagonal shape; Step S4: a second die is used to perform a second shaping treatment on the flat wire obtained after the step S3 to obtain a square wire with a cross-section R angle radius of 0.015±0.005mm; the cross-sectional area of the wire passage in the second die is 5%±3% smaller than that of the wire passage in the first die; Step S5: the square wire is subjected to a cleaning treatment; Step S6: the square wire after the cleaning treatment is subjected to an annealing treatment; Step S7: the square wire after the annealing treatment is sequentially subjected to a first paint coating treatment, a first baking treatment and a first cooling treatment; the paint for the first paint coating treatment is PAI; Step S8: the square wire after the step S7 is sequentially subjected to a second paint coating treatment, a second baking treatment and a second cooling treatment to obtain an enameled square wire; the paint for the second paint coating treatment is PI; the ratio of the paint for the second paint coating treatment to the paint for the first paint coating treatment is 1:

9.

2. The method for manufacturing high-temperature resistant and puncture-resistant enameled square wire according to claim 1, characterized in that, The tangent position of the straight edge of the first die to the R angle arc and the tangent position of the straight edge of the second die to the R angle arc are provided with a circular arc transition.

3. The method for manufacturing high-temperature resistant and puncture-resistant enameled square wire according to claim 2, characterized in that, Further comprising a step S9: when the enameled square wire needs to be coated with a self-adhesive paint layer, the enameled square wire is sequentially subjected to a third paint coating treatment, a third baking treatment, a third cooling treatment, a lubricating treatment and a winding treatment to obtain an enameled square wire product.

4. The method for manufacturing high-temperature resistant and puncture-resistant enameled square wire according to claim 2, characterized in that, Further comprising a step S9: when the enameled square wire does not need to be coated with a self-adhesive paint layer, the enameled square wire is sequentially subjected to a lubricating treatment and a winding treatment to obtain an enameled square wire product.

5. The method for manufacturing high-temperature resistant and puncture-resistant enameled square wire according to claim 3, characterized in that, The paint in the third paint coating treatment is one of HB, SB or SV.

6. The method for manufacturing high-temperature resistant and puncture-resistant enameled square wire according to claim 1, characterized in that, In the step S7, the first paint coating treatment is performed by using a high-pressure sealed spray to coat the square wire in one or more passes to make the thickness of the single-side paint film 0.3μm-6μm.

7. The method for manufacturing high-temperature resistant and puncture-resistant enameled square wire according to claim 1, characterized in that, In the step S8, the second paint coating treatment is performed by using a high-pressure sealed spray to coat the square wire in one or more passes to make the thickness of the single-side paint film 0.3μm-6μm.

8. The method for manufacturing high-temperature resistant and puncture-resistant enameled square wire according to claim 1, characterized in that, In the step S1, the conductor is one of copper, silver, aluminum, aluminum alloy, copper-clad aluminum and tin-plated copper.

9. The method for manufacturing high-temperature resistant and puncture-resistant enameled square wire according to claim 7, characterized in that, In the step S6, the annealing temperature of the square wire is: copper: 400-550℃; silver: 500-650℃; aluminum: 350-450℃; aluminum alloy: 400-500℃; copper-clad aluminum: 300-400℃; tin-plated copper: 600-700℃. ​ ​ ​