Aluminum Insulated Wire Coating With CO2 Plasma Adhesion Boost
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Solution Overview
Problem
The adhesion between aluminum conductors and insulating films coated with polyaryletherketone (PAEK) or polyphenylene sulfide (PPS) resins is inferior when directly extrusion-coated, which affects the performance of insulated wires in miniaturized electrical and electronic equipment.
Innovation Solution
Subjecting the aluminum conductor to CO2 plasma treatment improves the adhesion between the conductor and the resin coating layer, which includes PAEK or PPS resins, by modifying the conductor surface and enhancing the affinity with the resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If aluminum conductor is directly extrusion-coated with PAEK or PPS resin, then manufacturing process is simple, but adhesion between conductor and insulating film is inferior
Solution Approach 1:
The aluminum conductor surface is subjected to plasma treatment or chemical conversion coating before extrusion-coating with the resin. This preliminary surface modification creates a surface that enhances adhesion to the insulating film, resolving the contradiction by preparing the surface in advance to achieve both strong adhesion and manufacturing efficiency.
2Weight of moving object
If aluminum conductor is used to reduce weight, then weight reduction is achieved, but adhesion between conductor and insulating film deteriorates due to chemically stable oxide film
Solution Approach 1:
The surface properties of the aluminum conductor are modified through plasma treatment or chemical conversion coating, changing the chemical and physical parameters of the surface to improve adhesion while maintaining the weight advantage of aluminum conductors.
Solution Approach 2:
A composite structure is created by forming a conversion coating layer or plasma-treated surface layer on the aluminum conductor, combining the lightweight property of aluminum with enhanced surface adhesion properties to resolve the contradiction between weight reduction and adhesion improvement.
3Volume of moving object
If insulating film is bent with small bending radius for miniaturized equipment, then equipment miniaturization is achieved, but insulating film peels off when adhesion is insufficient
Solution Approach 1:
The conductor surface is pre-treated with plasma or chemical conversion coating to enhance adhesion before the insulating film is formed and bent. This preliminary surface preparation ensures that the insulating film maintains strong adhesion even when bent with small radii in miniaturized equipment, preventing peeling and maintaining reliability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The CO2 plasma treatment significantly improves the adhesion strength between the aluminum conductor and the resin coating layer, achieving high dielectric breakdown voltage and excellent heat resistance while maintaining strong adhesion even after heat treatment.
Implementation Method 1
subjecting the aluminum conductor to CO2 plasma treatment improves the adhesion between the conductor and the resin coating layer, which includes PAEK or PPS resins, by modifying the conductor surface and enhancing the affinity with the resins
Data Source
AI summary
An insulated wire including a conductor and a resin coating layer covering a periphery of the conductor, wherein the conductor is an aluminum conductor surface-treated with CO2 plasma, and at least a portion of the resin coating layer in contact with the conductor includes at least one kind of a polyaryletherketone resin and a polyphenylene sulfide resin.