Hydrodynamic Wire Coating With Solvent-Free Thickness Control
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Solution Overview
Problem
Existing wire coating techniques face issues such as the use of carcinogenic solvents, high energy consumption, uneven coating, difficulty in controlling coating thickness, and the inability to produce coated wire efficiently on an industrial scale without reducing wire diameter.
Innovation Solution
A solvent-free hydrodynamic coating method and apparatus that utilizes hydrodynamic forces generated by the motion of the wire to apply thermosetting polymer coatings, controlling temperature and pressure to achieve uniform and adherent coatings without solvent use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional coating techniques (extrusion or enameling) are used, then coating can be applied to wire, but the process uses carcinogenic solvents and consumes high energy
Solution Approach 1:
The patent changes the physical and chemical parameters of the coating material by using thermosetting polymers that can be applied in a liquid state and then cured through chemical reaction, eliminating the need for carcinogenic solvents and reducing energy consumption compared to conventional high-temperature firing processes
Solution Approach 2:
The patent utilizes phase transitions of the thermosetting polymer material, transitioning from liquid coating application to solid cured coating through chemical cross-linking, eliminating solvent evaporation and reducing energy requirements
2Manufacturing precision
If conventional coating techniques are used, then coating can be applied, but the coating thickness is difficult to control and coating is uneven
Solution Approach 1:
The patent implements feedback control by monitoring the quantity of coating material in the coating chamber and adjusting pressurization accordingly, maintaining consistent coating thickness and uniformity throughout the wire coating process
Solution Approach 2:
The patent uses a dynamic system where the wire moves through the coating chamber and the coating material is pressurized to match wire speed, creating adaptive control that maintains precise coating thickness despite variations in wire velocity
3Productivity
If multiple passes are used to achieve sufficient coating thickness, then coating can be built up, but production efficiency decreases and time increases
Solution Approach 1:
The patent enables continuous single-pass coating by maintaining a steady supply of liquid coating material through pressurization while wire moves continuously through the coating chamber, eliminating the need for multiple passes and significantly improving production efficiency
Solution Approach 2:
The patent applies preliminary action by pre-pressurizing the coating material before wire contact, ensuring sufficient coating material is available in advance to achieve complete coverage in a single pass, eliminating the need for repeated coating cycles
4Reliability
If coating material is pressurized to flow into coating chamber, then coating can be applied, but pressure control must be precise to avoid defects
Solution Approach 1:
The patent uses feedback control by monitoring coating material quantity in the coating chamber and automatically adjusting pressurization levels, maintaining optimal pressure conditions without requiring manual intervention and ensuring consistent coating quality
Solution Approach 2:
The system performs self-service by automatically regulating its own pressurization based on coating material consumption, adjusting pressure in response to wire speed and coating chamber material levels without external control input
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 method enables efficient, safe, and cost-effective industrial production of coated wire with precise control over coating thickness and uniformity, eliminating the need for multiple passes and reducing environmental impact.
Implementation Method 1
heating the coating material in the injection channel to a first temperature, pressurizing the coating material in the injection channel such that the coating material flows into the coating chamber, and heating the coating material to a second temperature, higher than the first temperature, such that the coating material has an appropriate viscosity for being applied to the wire
Implementation Method 2
a coating principle called hydrodynamic coating... combining the speed of the wire passing through the coating chamber and density, temperature and viscosity of the coating material in the coating chamber is configured to generate hydrodynamic forces within the coating chamber to adhere the coating material to the wire
Implementation Method 3
pressurizing the coating material in the injection channel such that the coating material flows into the coating chamber
Implementation Method 4
the wire may be centered by hydrodynamic forces generated by the nozzle
Data Source
AI summary
A method of applying a polymer coating material to a wire using a coating apparatus and/or a control system. The method may include receiving coating material input to the coating apparatus at a first end of an elongate injection channel of the coating apparatus and supplying the received coating material to a coating chamber that is arranged at a second end of the injection channel. The method may include feeding wire through the coating chamber of the coating apparatus so as to apply the coating material to the wire in the coating chamber through the movement of the wire through the coating chamber.