Coiled Conductive Body Casting With Integrated Insulation
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Solution Overview
Problem
Existing methods for producing coiled electrically conductive bodies with good space utilization are inefficient and costly, particularly when insulation is applied to coils with closely spaced helical turns, as they require complex work steps and limited space utilization due to the need for minimum distance between turns.
Innovation Solution
A method involving the production of a coiled model as a lost mold from a heat-labile material, coated with an insulating layer that adheres well to the cast metal body, embedded in molding sand, and then filled with metallic casting material, allowing for efficient space utilization and simplified insulation application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional casting methods are used to produce coiled electrically conductive bodies, then manufacturing complexity is reduced, but space utilization is limited due to required minimum distance between adjacent turns
Solution Approach 1:
The insulating layer is applied to the coiled model before the casting process, rather than after. This preliminary action allows the insulation to be integrated into the molding process itself, enabling tighter spacing between turns while maintaining manufacturing simplicity. The insulating layer is already in place when the metal is poured, eliminating the need for separate post-casting insulation steps.
2Reliability
If insulation is applied after coil manufacturing, then electrical insulation is achieved, but manufacturing effort increases due to additional work steps
Solution Approach 1:
The insulation application step is merged with the casting process. By applying the insulating layer to the model before casting and having it remain on the cast body, the patent combines what would otherwise be separate operations (insulation application and casting) into a single integrated process, thereby reducing total manufacturing effort while ensuring reliable electrical insulation.
Solution Approach 2:
The insulating layer serves dual purposes: it provides electrical insulation and acts as a release agent during casting. The layer is formulated to adhere to the model initially, facilitate casting, and then remain adhered to the cast body, eliminating the need for separate insulation application steps.
3Volume of moving object
If closely spaced turns are used to improve space utilization, then volume efficiency increases, but manufacturing complexity increases due to difficulty in applying insulation
Solution Approach 1:
The insulating layer is applied to the model before the casting process, when the coil structure is still in model form and more accessible. This preliminary application allows for uniform insulation coverage even on closely spaced turns, avoiding the complexity of applying insulation to the finished tight coil structure.
Solution Approach 2:
The insulating layer is formulated with specific properties (viscosity, adhesion characteristics, thermal stability) that enable it to conform to closely spaced turns and maintain its insulating function. The material parameters are optimized to ensure proper adhesion to the model and subsequent release during casting, while maintaining electrical insulation properties.
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
This method enables the production of coiled electrically conductive bodies with improved space utilization and reduced manufacturing effort, as the insulating layer adheres to the cast body, eliminating the need for additional insulation steps and enhancing the efficiency of space filling within the volume.
Implementation Method 1
a helical model is first produced as a lost mold from a model material that can be liquefied or vaporized under the influence of heat
Implementation Method 2
the insulating layer adheres to the cast body, eliminating the need for additional insulation steps
Data Source
Figure 1~7
Figure 8
AI summary
The invention relates to a method for producing a coiled electrically conductive body (2), in which first a coiled model (3, 8) is produced as a lost mould from a core material that can be liquefied or vaporised under the influence of heat, and then covered with a preferably electrically insulating layer (4, 5) and embedded in a moulding sand, and wherein a metallic casting material is then filled into the lost mould with the displacement of the model and said material connects with the insulating layer, and wherein the cast body (7) is removed from the moulding sand together with the insulating layer (4, 5) adhered to same.