Electrostatic Wire Coating Device for Corrosion Protection
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Solution Overview
Problem
Existing methods for coating electrical wires with anticorrosion material face issues such as surface tension causing the material to flow from aluminum surfaces and require complex dispenser setups for multiple wires, leading to incomplete coating and increased complexity.
Innovation Solution
A coating device with a metal jetting unit, voltage application, and moving mechanism that electrifies the jetting outlet and conductor, allowing the jetting outlet to move relative to the wires, ensuring the liquid is drawn to the conductor without being repelled by surface tension, and using a controller to manage the process for efficient coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If liquid anticorrosion material is sprayed onto aluminum conductor surface, then coating is applied, but surface tension causes the liquid to be repelled and flow from the surface, resulting in incomplete coating
Solution Approach 1:
The patent converts the harmful surface tension effect into a beneficial electrostatic attraction. By applying positive voltage to the nozzle and negative voltage to the conductor, the liquid coating material becomes electrified and is attracted to the conductor surface, transforming the repulsive surface tension force into an attractive electrostatic force that ensures complete coating coverage
Solution Approach 2:
The patent changes the electrical parameter of the system by applying voltage to both the nozzle and conductor. This creates an electrostatic field that modifies the interaction between the liquid coating material and the conductor surface, overcoming the surface tension barrier and enabling effective coating
2Manufacturing precision
If a dispenser is provided for each aluminum electrical wire to coat multiple wires, then coating coverage is improved, but device complexity increases
Solution Approach 1:
The patent makes a single nozzle serve multiple functions by enabling it to coat multiple electrical wires simultaneously. The electrostatic attraction mechanism allows the liquid coating material to be drawn to multiple conductors from a single nozzle position, eliminating the need for multiple dispensers and simplifying the device structure while maintaining comprehensive coating coverage
Solution Approach 2:
The patent merges the function of multiple dispensers into a single nozzle by utilizing electrostatic field effects. The electrified liquid coating material can be attracted to multiple conductors from one source, combining what would traditionally require separate dispensers for each wire into a unified coating system
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 prevents the anticorrosion material from being repelled by surface tension, allows for efficient coating of multiple wires with a simple configuration, and ensures complete coverage of the conductor without exposing it, while also suppressing corrosion and maintaining conductivity.
Implementation Method 1
a voltage application unit for applying a voltage to the jetting outlet and the conductor and electrifying the jetting outlet and the conductor
Implementation Method 2
applying voltage to and electrifying the jetting outlet and the conductor of the electrical wire makes the liquid jetted from the jetting outlet electrified and drawn near the conductor
Data Source
AI summary
Provided is a coating device and a method capable of coating a conductor of a plurality of electrical wires with coating material with simple configuration and of coating without exposing the conductor. A nozzle and a coating area of a terminal-equipped electrical wire are applied to voltage by a voltage applying unit such as to be electrified with polarity different from each other, and jetting jet liquid forms jet liquid over the whole coating area, forms the coating layer with anticorrosion material on a surface of the terminal-equipped electrical wire, and coats the coating area including a conductor with anticorrosion material without being exposed. Furthermore, it is possible to allow the nozzle jet the jet liquid and to move the nozzle in an arranging direction of the terminal-equipped electrical wire, and also to coat the coating area of the terminal-equipped electrical wire with anticorrosion material.