Fluororesin-Insulated Wire Adhesion for Bend-Stable Coating
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Solution Overview
Problem
Conventional insulated electric wires with a fluororesin layer on the conductor face adherence issues, leading to the fluororesin layer floating or wrinkling when bent, due to insufficient peel strength between the conductor and the fluororesin layer.
Innovation Solution
The insulated electric wire includes a fluororesin layer with a peel strength of 0.30 N/mm or more, achieved by using a melt-fabricable fluororesin and optimizing the conductor's surface roughness and heating conditions during extrusion to enhance adherence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fluororesin layer is formed on the conductor, then insulation performance is improved, but adherence strength between the fluororesin layer and conductor becomes insufficient
Solution Approach 1:
An oxide film is introduced as an intermediary layer between the conductor and fluororesin layer. This oxide film acts as a mediator that enhances the bonding interface, allowing the fluororesin layer to adhere strongly to the conductor surface while maintaining its insulation properties.
Solution Approach 2:
The insulation structure is designed as a composite system consisting of three distinct materials: the conductor, the oxide film layer, and the fluororesin layer. This composite structure combines the electrical conductivity of the metal conductor with the adhesive properties of the oxide film and the insulating properties of the fluororesin, achieving both strong adherence and effective insulation.
2Adaptability or versatility
If the fluororesin layer is made thin for flexibility, then bending performance is improved, but the layer becomes prone to floating and wrinkling
Solution Approach 1:
The oxide film is formed on the conductor surface before the fluororesin layer is applied. This preliminary action creates a stable bonding foundation that prevents the fluororesin layer from floating or wrinkling during subsequent bending operations, even when the layer is thin.
Solution Approach 2:
The surface properties of the conductor are changed by forming an oxide film, which alters the surface energy and roughness parameters. This parameter change enhances the wettability and adhesion of the fluororesin layer, allowing thin layers to maintain stability during bending without requiring increased 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
The enhanced adherence ensures the fluororesin layer remains closely attached to the conductor, preventing floating and wrinkling even when bent, with improved peel and pullout strengths.
Implementation Method 1
an oxide film on the surface of a conductor formed by electric heating
Implementation Method 2
a fluororesin layer containing a melt-fabricable fluororesin that is formed on the conductor
Data Source
AI summary
Provided is an insulated electric wire including a conductor and a fluororesin layer containing a melt-fabricable fluororesin that is formed on the conductor, in which a peel strength measured by peeling the fluororesin layer from the conductor is 0.30 N/mm or more.