Flat Electric Wire Multilayer Resin Coating Soot-Free Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional high-frequency rectangular wires with insulative enamel films face difficulties in rigid welding due to soot formation during motor assembly, affecting the integrity of the weld.
Innovation Solution
A rectangular wire design featuring a multilayer conductor member with a non-crystalline or crystalline thermoplastic resin layer on the outer periphery, including a second thermoplastic resin with a melting point of 300°C or more, selected from specific polymers like polyetherimide and polyetheretherketone, to facilitate easy welding without soot generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If an insulative enamel film is formed on the outer periphery of rectangular metallic bodies, then high-frequency property is improved, but welding quality deteriorates due to soot formation
Solution Approach 1:
The patent applies composite materials by forming a multilayer coating structure consisting of a first thermoplastic resin layer (non-crystalline or crystalline with amide bond) and a second thermoplastic resin layer (melting point ≥300°C) on the rectangular metallic conductor. This composite structure combines the high-frequency loss reduction capability of thermoplastic resins with the soot-free welding property of the second resin layer, resolving the contradiction between high-frequency performance and welding quality.
Solution Approach 2:
The patent changes the material parameters by selecting specific thermoplastic resins with defined properties: the first resin is chosen from polyetherimide, polyphenylsulfone, polyethersulfone, polyamide 66, polyamide 46, or polyamide 6, while the second resin has a melting point of 300°C or higher. These parameter specifications ensure both low high-frequency loss and clean welding without soot formation.
2Ease of manufacture
If a thermoplastic resin layer is formed on the outer periphery of rectangular metallic conductors, then welding ease is improved, but high-frequency property may deteriorate
Solution Approach 1:
The patent uses composite materials with a specific two-layer thermoplastic resin structure where the first layer (non-crystalline or crystalline with amide bond) maintains high-frequency properties by having appropriate dielectric characteristics, while the second layer (melting point ≥300°C) provides easy welding. This composite approach ensures both welding ease and high-frequency performance are achieved simultaneously.
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 inhibits high-frequency loss and ensures reliable, soot-free welding, maintaining high-frequency properties and mechanical strength in electrical equipment.
Implementation Method 1
a layer of a non-crystalline resin having no melting point or a crystalline resin having an amide bond
Implementation Method 2
a layer of a second thermoplastic resin having a melting point of 300°C or more on the outer periphery of the multilayer conductor member
Data Source
Figure 1
Figure 2(a)~2(b)
Figure 3(a)~3(d)
AI summary
A rectangular wire having: a multilayer conductor member constructed by stacking, in a thickness direction, a rectangular metallic conductor that has a layer of a first thermoplastic resin formed on the outer periphery thereof, the first thermoplastic resin being a non-crystalline resin having no melting point or a crystalline resin having an amide bond; and a layer of a second thermoplastic resin having a melting point of 300°C or more on the outer periphery of the multilayer conductor member.