Hexagonal Insulated Wire Chamfered Corners Electrodeposition
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Solution Overview
Problem
The existing methods for forming insulating coatings on hexagonal electric wires, such as the electrodeposition method, result in high void ratios when wound due to swelling at the corner parts, limiting the reduction of voids between adjacent wires.
Innovation Solution
A chamfered part with a length of 1/3 to 1/20 of the flat part is formed on the corner of the hexagonal cross-section wire to suppress swelling, reducing the thickness difference of the coating to 5 µm or less, thereby achieving a void ratio of 5% or less in the wound state.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the electrodeposition method is used to form the insulating coating on hexagonal wire, then the coating thickness can be increased, but the corner part swells due to high electrolytic density
Solution Approach 1:
The patent applies local quality by providing different geometries to different parts of the wire cross-section. The corner parts are given a rounded geometry while the flat parts maintain the hexagonal shape. This local differentiation allows the electrodeposition process to produce uniform coating thickness across the wire surface, preventing the swelling problem at corner parts while maintaining adequate coating thickness.
2Manufacturing precision
If roundness is provided on the corner part to reduce sharpness, then the coating uniformity improves, but voids are formed between adjacent wires in the wound state
Solution Approach 1:
The patent applies local quality by providing different geometries to different parts of the wire cross-section. The corner parts are given a rounded geometry while the flat parts maintain the hexagonal shape. This local differentiation allows the electrodeposition process to produce uniform coating thickness across the wire surface, preventing the swelling problem at corner parts while maintaining adequate coating thickness.
3Reliability
If hexagonal cross section is used, then voids between adjacent wires are reduced, but the coating thickness becomes non-uniform due to corner flow during drying
Solution Approach 1:
The patent applies local quality by providing different geometries to different parts of the wire cross-section. The corner parts are given a rounded geometry while the flat parts maintain the hexagonal shape. This local differentiation allows the electrodeposition process to produce uniform coating thickness across the wire surface, preventing the swelling problem at corner parts while maintaining adequate coating thickness.
Solution Approach 2:
The patent replaces the conventional drying-based coating formation method with electrodeposition. Instead of relying on mechanical drying processes that cause coating flow and non-uniformity, the patent uses electrochemical deposition to form the insulating coating. This substitution eliminates the coating flow problem during drying and achieves uniform coating thickness, particularly at the corner parts of the hexagonal wire.
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 approach significantly reduces voids between adjacent wires, enhancing insulation reliability and allowing for flexible winding directions, making it suitable for high-performance motor manufacturing at a lower cost.
Implementation Method 1
The electrodeposition method is a method in which the insulating coating is formed by electrodepositing a coating component on the surface of copper wire: by passing the copper wire to be the core material of the insulated electric wire through the electrodeposition solution including a coating component; and by applying electrical current on the copper wire.
Data Source
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AI summary
An insulated electric wire and a method of producing the electric wire are provided. The insulated electric wire incudes: a copper wire; and an insulating coating formed on a surface of the copper wire by an electrodeposition method. A cross section shape of the insulated electric wire including the insulating coating is in a hexagonal shape, a chamfered part that suppresses swelling of the insulating coating is formed on each corner part of a hexagonal cross section of the copper wire, a length of the chamfered part is 1/3 to 1/20 of a length of a flat part of the hexagonal cross section, and a void ratio in a wound state is 5% or less.