Insulated Conductor Fluorine Gradient Adhesion
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Insulated conductors face issues with adhesion between the conductor and insulating film, leading to potential degradation and crack generation, especially due to the low affinity between fluororesins and other resins, which can result in partial discharge and reduced durability.
Innovation Solution
An insulated conductor design featuring a fluorine-containing resin composition layer with a cured product of thermosetting resin and fluororesin, accompanied by a fluorine concentration gradient layer that decreases fluorine atom content towards the conductor, enhancing adhesion and preventing crack formation, along with a manufacturing method involving electrodeposition and controlled drying to achieve a sea-island structure and optimal fluorine content distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a fluororesin is added to the insulating layer to improve lubricity, then the surface lubricity is improved, but a large crack is easily generated between the fluororesin and other resins due to low affinity
Solution Approach 1:
The patent applies local quality by creating a fluorine concentration gradient layer where the fluorine content varies spatially - higher near the insulating film surface for lubricity, and lower near the conductor for adhesion. This gradient structure allows different regions to serve different functions: the high-fluorine region provides surface lubricity while the low-fluorine region ensures strong bonding to the conductor, thereby preventing crack generation at interfaces.
Solution Approach 2:
The patent changes the concentration parameter of fluorine atoms spatially within the insulating film. By controlling the fluorine concentration to decrease from the insulating film side toward the conductor, the material properties transition smoothly, maintaining both surface lubricity and interfacial adhesion, thus preventing crack formation while preserving lubricity.
2Reliability
If an insulating coating containing a thermosetting resin and a bubble forming agent is baked to achieve high partial discharge inception voltage, then the partial discharge inception voltage is improved, but pores are formed in the insulating film which degrades adhesion between the conductor and insulating film
Solution Approach 1:
The patent changes the chemical composition parameter by introducing a fluorine-containing resin alongside the thermosetting resin. The fluororesin forms a low-fluorine region near the conductor that does not create pores during baking, thereby maintaining adhesion strength while the overall composition still achieves high partial discharge inception voltage through the fluororesin's inherent electrical properties.
3Reliability
If the fluorine atom content is increased to suppress partial discharge, then the partial discharge inception voltage is improved, but the adhesion to the conductor deteriorates due to low affinity between fluororesin and conductor
Solution Approach 1:
The patent applies local quality by creating spatial variation in fluorine concentration within the insulating film. The high-fluorine region near the insulating film surface provides high partial discharge inception voltage and surface lubricity, while the low-fluorine region near the conductor maintains good adhesion to the conductor. This local differentiation resolves the contradiction between achieving high voltage resistance and maintaining conductor adhesion.
Solution Approach 2:
The patent changes the fluorine concentration parameter gradientically from the insulating film side to the conductor side. This continuous parameter change allows the material to exhibit high fluorine content (for voltage resistance) in the outer region while maintaining low fluorine content (for adhesion) near the conductor interface, thereby simultaneously achieving both objectives.
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 effectively increases the partial discharge inception voltage, improves adhesion between the insulating film and conductor, and maintains stability even at high temperatures, reducing the likelihood of crack formation and ensuring long-term insulating performance.
Implementation Method 1
an electrodeposition step of electrodepositing an electrodeposition liquid including thermosetting resin particles and fluororesin particles to a surface of the conductor
Implementation Method 2
a drying step of heating and drying the electrodeposition layer-attached conductor
Data Source
AI summary
An insulated conductor having a conductor and an insulating film provided on a surface of the conductor, in which the insulating film has a fluorine-containing resin composition layer including a cured product of a thermosetting resin and a fluororesin and a fluorine concentration gradient layer which is disposed between the conductor and the fluorine-containing resin composition layer. The fluorine-containing resin composition layer includes a cured product of a thermosetting resin and a fluororesin, and is provided with a concentration gradient in which a fluorine atom content decreases from the fluorine-containing resin composition layer side toward the conductor.