Bonded Individually Coated Wires for Continuous Multiwire Insulation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing stator designs for electric machines require improvements in efficiency and manufacturing processes, particularly in the formation of insulated conductive wires for enhanced electromagnetic performance.
Innovation Solution
A method for forming a multiwire structure by applying fluid coating materials containing insulating precursors to conductive wires, which are then advanced through dies to create electrically insulated and bonded wires, allowing for the formation of complex wire configurations efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If traditional separate insulation and bonding processes are used for wire formation, then manufacturing complexity increases, but production efficiency decreases
Solution Approach 1:
The patent combines the insulation coating and bonding processes into a single integrated die structure. The die simultaneously applies insulating material to individual wires and bonds multiple wires together, eliminating the need for separate insulation and bonding steps. This merging of operations directly increases productivity while reducing manufacturing process complexity.
Solution Approach 2:
The die structure is designed to perform multiple functions simultaneously: it coats wires with insulating material, bonds wires together, and shapes the multiwire structure all in one operation. This multi-functional approach eliminates the need for multiple specialized equipment, thereby improving production efficiency and simplifying the manufacturing process.
2Reliability
If multiple separate coating processes are applied to each wire, then insulation quality improves, but manufacturing time increases
Solution Approach 1:
The patent implements continuous coating of insulating material on multiple wires simultaneously as they pass through the die. The process maintains continuous motion without stopping between wires or between coating and bonding operations, ensuring consistent insulation quality while minimizing manufacturing cycle time. The continuous action eliminates idle time between operations.
Solution Approach 2:
The die structure pre-positioning and pre-coats all wires with insulating material before the bonding operation occurs. This preliminary insulation application ensures that electrical insulation is established before wires are bonded together, maintaining insulation quality while reducing total process time by overlapping operations.
3Manufacturing precision
If wires are coated and bonded separately in multiple steps, then bonding precision improves, but production speed decreases
Solution Approach 1:
The die structure merges the coating and bonding operations into a single integrated process. Insulating material is applied and wires are bonded simultaneously in one location, ensuring precise wire positioning and bonding while maintaining high production speed. The integrated structure eliminates positioning errors that could occur during transfer between separate operations.
Solution Approach 2:
The die structure acts as an intermediary device that simultaneously performs coating and bonding functions. It provides a controlled environment where insulating material is applied and wires are bonded in precise alignment, ensuring bonding precision while enabling continuous high-speed production through its integrated design.
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 method enables the efficient formation of multiwire structures with enhanced electrical insulation and bonding, improving the efficiency and performance of stator designs in electric machines.
Implementation Method 1
applying a first fluid coating material to a first conductive wire wherein the first fluid coating material includes a precursor to or a fluid form of a first insulating material. The first conductive wire with the first fluid coating material is advanced through a first die and forms a first electrically insulated conductive wire having a solid layer of the first insulating material on the first conductive wire
Implementation Method 2
form a multiwire structure having two conductive wires electrically insulated from each other and bonded to each other by the first and second insulating materials
Data Source
AI summary
A method for forming a multiwire structure having two conductive wires insulated from and bonded to each other by insulating material includes applying a first fluid coating material to a first conductive wire. The first conductive wire bearing the first fluid coating material is advanced through a first die forming a first electrically insulated conductive wire comprising a solid layer of a first insulating material on the first conductive wire. A second conductive wire is provided adjacent to the first electrically insulated conductive wire, and a second fluid coating material is applied to the second conductive wire. The first electrically insulated conductive wire and the adjacent second conductive wire bearing the second fluid coating material are then advanced through a second die to form a multiwire structure having two conductive wires electrically insulated from each other and bonded to each other by the first and second insulating materials.