Fluororesin-Insulated Wire With Oxide Film Adhesion Layer
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Solution Overview
Problem
Existing insulated electric wires with fluororesin coatings suffer from insufficient adherence strength between the conductor and the fluororesin layer, leading to issues such as the fluororesin layer floating or wrinkling when the wire is bent.
Innovation Solution
The insulated electric wire includes a conductor coated with a fluororesin layer containing a melt-fabricable fluororesin, achieving a peel strength of 0.30 N/mm or more, ensuring the conductor and fluororesin layer are in close contact and preventing the fluororesin layer from floating or wrinkling during bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a fluororesin layer is formed on the conductor, then the insulating performance is improved, but the adherence strength between the fluororesin layer and conductor becomes insufficient
Solution Approach 1:
An oxide film is formed on the conductor surface to serve as an intermediary layer between the conductor and the fluororesin layer. This oxide film acts as a mediator that enhances the bonding between the metal conductor and the fluororesin coating, achieving both good insulating performance and sufficient adherence strength.
Solution Approach 2:
The surface properties of the conductor are changed by forming an oxide film on it. This chemical modification of the conductor surface alters its reactivity and bonding characteristics, enabling better adhesion of the fluororesin layer while maintaining the insulating function.
2Ease of manufacture
If the fluororesin layer is directly disposed on the conductor, then the manufacturing process is simplified, but the fluororesin layer floats or wrinkles when the wire is bent
Solution Approach 1:
The oxide film serves as a mediator that provides mechanical interlocking and chemical bonding between the conductor and fluororesin layer. This intermediate structure prevents the fluororesin layer from floating or wrinkling during bending operations, improving dimensional stability.
Solution Approach 2:
The structure comprises a composite system with three layers: conductor, oxide film, and fluororesin layer. This composite structure combines the electrical conductivity of the metal conductor with the insulating properties of the fluororesin, while the oxide film provides the bonding interface that ensures structural integrity during deformation.
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 improved adherence strength between the conductor and fluororesin layer prevents the fluororesin layer from floating or wrinkling, even when the wire is bent, maintaining a stable and durable insulation.
Implementation Method 1
an oxide film on the surface of a conductor formed by electric heating
Implementation Method 2
heating the fluororesin to melt the fluororesin, and extruding the fluororesin in a melted state onto 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.