Continuous Insulation Application on Conductors
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Solution Overview
Problem
Current methods for insulating electrical conductors, such as coil wires and Roebel bars, are time-consuming, prone to void formation, and pose health and safety risks due to the use of liquid resins, and involve multiple steps and interfaces that can lead to weak spots in the insulation.
Innovation Solution
An apparatus and method that applies a composition of thermosetting material and solid electrically insulating elements directly onto the conductor, eliminating the need for mica tapes and allowing for continuous application and curing, thereby reducing the number of interfaces and potential weak spots.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mica tape impregnation is used, then insulation is achieved, but void formation occurs leading to partial discharge problems
Solution Approach 1:
The patent changes the physical state of the insulation material from solid tape to liquid composition, enabling it to flow and fill all gaps and voids completely, then transforms it to solid state through curing. This parameter change eliminates void formation while maintaining insulation reliability.
Solution Approach 2:
The patent uses a composite composition of thermosetting material and solid electrically insulating elements (such as mica particles) suspended in the liquid. This composite approach provides both complete void filling and the desired electrical insulation properties, resolving the contradiction between reliability and manufacturing precision.
2Reliability
If conventional insulation processes are used, then insulation is provided, but the process is time-consuming and involves multiple steps
Solution Approach 1:
The patent merges multiple separate steps (tape wrapping, resin impregnation, curing) into a single integrated process where liquid composition is applied and cured in one continuous operation. This eliminates the need for precise tape positioning and multiple handling steps, significantly reducing process time while maintaining insulation quality.
Solution Approach 2:
The patent enables continuous application and curing of the insulation composition along the conductor length, eliminating interruptions and discrete steps. The liquid composition continuously flows to cover the conductor surface and is continuously cured, maintaining uninterrupted insulation application and reducing total process time.
3Reliability
If liquid resin impregnation is used, then insulation is achieved, but health and safety issues arise due to chemical fume evaporation
Solution Approach 1:
The patent changes the curing mechanism from thermal curing (which requires high temperatures and causes fume evaporation) to UV光固化 (which occurs at room temperature). This parameter change eliminates harmful chemical fume evaporation while maintaining the effectiveness of the thermosetting insulation material.
Solution Approach 2:
The patent replaces the thermal curing system with a UV光固化 system. Instead of using heat to cure the resin (which causes fume evaporation), UV light is used to initiate polymerization. This substitution eliminates the harmful thermal effects and chemical fume evaporation while achieving the same insulation effectiveness.
4Manufacturing precision
If mica tape is precisely positioned, then thickness variations are avoided, but the process becomes complex and time-consuming
Solution Approach 1:
The patent uses a spray application system that delivers liquid insulation composition through pneumatic or hydraulic means. The liquid is atomized and sprayed uniformly onto the conductor surface, automatically achieving consistent thickness coverage without requiring precise mechanical positioning of tapes. This eliminates the complexity of tape positioning mechanisms while maintaining manufacturing precision.
Solution Approach 2:
The patent changes the insulation application from solid tape placement to liquid spray deposition. The liquid composition flows and self-levels to achieve uniform thickness, eliminating the need for precise positioning. This parameter change from solid to liquid state simplifies the application process while maintaining consistent insulation thickness.
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 approach simplifies the insulation process, reduces void formation, enhances safety, and provides a more reliable insulation layer that can function as both turn and groundwall insulation, decreasing the risk of electrical failures.
Implementation Method 1
The UV irradiation unit is configured to cure the thermosetting material
Data Source
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AI summary
An apparatus (100, 200) and a method for applying an insulation layer (20) onto a conductor (15-1, 15-2, 15-3, 15-4) to obtain a conductor arrangement (10) for an electrical appliance are described. The apparatus (100, 200) comprises a treatment device having at least an application unit (110, 210) and a curing unit (120, 220), the curing unit (120, 220) being arranged downstream of the application unit (110, 210); an advancement device (150) configured to perform a relative movement of the conductor (15-1, 15-2, 15-3, 15-4) with respect to the treatment device in an advancement direction (A), wherein the application unit (110, 210) is configured to apply a composition of a thermosetting material and solid insulating elements onto the conductor, and wherein the curing unit (210, 220) is configured to activate a curing process of the thermosetting material to obtain the insulation layer (20) on the conductor (15-1, 15-2, 15-3, 15-4). The method comprises applying continuously in a longitudinal direction of the conductor (15-1, 15-2, 15-3, 15-4) a composition of a thermosetting material and solid insulating elements onto the conductor, an activating continuously in the longitudinal direction a curing process of the applied thermosetting material to obtain the insulation layer (20) on the conductor (15-1, 15-2, 15-3, 15-4).