Electrodeposition Liquid for Heat-Resistant Insulated Wire
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Solution Overview
Problem
Existing insulated wire manufacturing methods, such as the immersion method, face challenges in achieving uniform layer thickness, especially at corners, and lack sufficient heat resistance, while electrodeposition methods require suitable coating materials that are not environmentally friendly.
Innovation Solution
An electrodeposition liquid with heat-resistant particles dispersed in a suspension of resin particles, having a viscosity of 100 cP or less and turbidity of 1 mg/L to 600 mg/L, allows for the formation of an insulating layer with densely dispersed heat-resistant particles on the surface, enhancing heat resistance and achieving uniform thickness in a single electrodeposition treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the immersion method is used to form an insulating layer, then the process is simple, but the layer thickness at corners is thinner than at flat portions and multiple immersions are required
Solution Approach 1:
The patent replaces the mechanical immersion method with an electrodeposition method that uses electrical fields to deposit coating material. This substitution enables uniform coating thickness including at corner portions, as the electrical field distributes the coating material evenly across the wire surface during the electrodeposition process
2Manufacturing precision
If the immersion method is used repeatedly to achieve desired layer thickness, then coating thickness can be increased, but productivity decreases due to multiple immersion cycles
Solution Approach 1:
The patent replaces the iterative mechanical immersion process with a single electrodeposition cycle that achieves the desired coating thickness in one operation. The electrodeposition method allows for precise control of layer thickness through electrical parameters, eliminating the need for repeated immersion and drying cycles
3Ease of manufacture
If organic solvent is used as dispersion medium for resin and oxide fine particles, then coating material can be effectively applied, but environmental burden increases
Solution Approach 1:
The patent changes the fundamental parameter of the dispersion medium from organic solvent to water. This parameter change maintains the effectiveness of the coating material application while eliminating the environmental burden associated with organic solvents, as the electrodeposition process can effectively utilize water-based dispersion media
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 solution provides excellent heat resistance at the surface of the insulating layer, increasing the cut-through temperature and enabling uniform coating at corners, while reducing environmental impact by using water as a dispersion medium.
Implementation Method 1
the wire material is placed in an electrodeposition liquid including a coating material component such as a resin varnish, the wire material is used as an anode or a cathode to apply an electric current between the wire material and a counter electrode, and the coating material component is electrodeposited on the wire material surface
Implementation Method 2
an electrodeposition liquid with heat-resistant particles dispersed in a suspension of resin particles, having a viscosity of 100 cP or less and turbidity of 1 mg/L to 600 mg/L
Implementation Method 3
heat-resistant particles are dispersed in a suspension in which resin particles are dispersed
Data Source
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AI summary
The present invention provides an insulated wire having a heat-resistant insulating layer, wherein heat-resistant particles are contained in the insulating layer, and the heat-resistant particles are densely dispersed in a surface region of the insulating layer. For example, the concentration of heat-resistant particles included in a layer thick portion of 0.5 µm from the surface of the insulating layer is two times the concentration of heat-resistant particles included in a central portion of the insulating layer. An electrodeposition liquid used to form the insulating layer is formed by dispersing the heat-resistant particles in a suspension in which resin particles are dispersed, the viscosity is 100 cP or less, and the turbidity is 1 mg/L or more.