Insulated Conductor Dual Fluorine Layer Lubricity Adhesion
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Solution Overview
Problem
Existing insulated conductors face issues with lubricity and flexibility, as the lubricative layer and insulating layer do not easily adhere to each other, leading to potential exfoliation when wound in a coil shape, and the addition of fluororesin can result in low affinity with other resins, causing crack generation.
Innovation Solution
An insulated conductor with a low-concentration fluorine layer and a high-concentration fluorine layer, where the high-concentration layer has a higher fluorine atom content, is formed on the surface, enhancing lubricity and adhesion, and the manufacturing method involves electrodeposition and heat treatment to create these layers without a separate lubricative coating step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a lubricative layer including a lubricative component is formed on the insulating layer, then the lubricity of the surface is improved, but the adhesion between the lubricative layer and the insulating layer deteriorates, causing potential exfoliation when wound
Solution Approach 1:
The patent applies local quality by creating a fluororesin layer only on the surface of the insulating layer, rather than making the entire insulating layer lubricative. This surface-only approach provides lubricity where needed (during winding) while maintaining the adhesive properties of the bulk insulating layer material, thus preventing exfoliation.
Solution Approach 2:
The patent uses composite materials by combining the insulating layer material (such as polyamide-imide or polyimide) with a fluororesin coating. This composite structure provides both the adhesive strength of the insulating layer and the lubricative properties of the fluororesin surface layer, resolving the contradiction between lubricity and adhesion.
2Ease of operation
If fluororesin is added to the insulating layer to improve lubricity, then the surface lubricity is improved, but the affinity between fluororesin and other resins deteriorates, causing crack generation
Solution Approach 1:
The patent segments the structure into two distinct parts: a bulk insulating layer made of traditional insulating materials and a surface fluororesin layer. This segmentation allows each layer to perform its specific function optimally - the bulk layer provides structural integrity and adhesion, while the surface layer provides lubricity - without the compatibility issues that would arise from mixing fluororesin throughout the entire insulating layer.
Solution Approach 2:
The fluororesin is applied locally only to the surface of the insulating layer rather than being distributed throughout the entire insulating layer. This localized application ensures that the fluororesin provides lubricity where it is needed (at the surface during winding) while avoiding the affinity problems that would occur if fluororesin were mixed with other resins in the bulk material.
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 provides improved lubricity and flexibility, preventing large crack formation and ensuring the layers do not exfoliate when wound, while being industrially advantageous by eliminating the need for a separate lubricative coating process.
Implementation Method 1
an electrodeposition step of electrodepositing an electrodeposition liquid including thermosetting resin particles and fluororesin particles to a surface of the conductor to obtain an electrodeposition layer-attached conductor
Implementation Method 2
a drying step of heating and drying the electrodeposition layer-attached conductor to obtain a dried electrodeposition layer-attached conductor
Data Source
AI summary
An insulated conductor of the present invention is an insulated conductor having a conductor and an insulating film provided on a surface of the conductor, in which the insulating film has a low-concentration fluorine layer disposed on a surface side of the conductor and a high-concentration fluorine layer disposed on at least a part of an outside surface of the low-concentration fluorine layer, the low-concentration fluorine layer includes a cured product of a thermosetting resin and a fluororesin and has a fluorine atom content relatively lower than that of the high-concentration fluorine layer, and the high-concentration fluorine layer includes a cured product of a thermosetting resin and a fluororesin and has a fluorine atom content relatively higher than that of the low-concentration fluorine layer.