Insulated Wire Multi-Layer Coating Diameter Reduction
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Solution Overview
Problem
Existing insulated wires face challenges in reducing their outer diameter while maintaining high insulation and flame-retardant properties, as thick layers are required for direct-current stability and flame-retardant properties, leading to moisture infiltration and low insulation reliability.
Innovation Solution
The insulated wire structure is optimized by forming a coating layer with a first flame-retardant layer, an insulating layer, and a second flame-retardant layer, where the insulating layer suppresses water infiltration into the first flame-retardant layer, allowing for a thinner overall structure and improved mechanical strength, with the second flame-retardant layer maintaining high flame-retardant properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the thickness of the coating layer is reduced to decrease the outer diameter of the insulated wire, then the outer diameter is reduced, but the flame-retardant property and direct-current stability deteriorate
Solution Approach 1:
The coating layer is divided into multiple functional layers: a flame-retardant layer containing flame retardant for flame resistance, an insulating layer for electrical insulation and moisture barrier, and optionally a protective layer. This segmentation allows each layer to specialize in one function, enabling thin overall structure while maintaining high performance in each specific property.
Solution Approach 2:
The patent uses composite material structures where the flame-retardant layer contains flame retardant additives mixed with resin, the insulating layer uses high-resistivity materials, and these layers are combined to create a multi-functional coating system. This composite approach allows simultaneous achievement of flame retardancy, insulation, and moisture resistance in a thin structure.
2Reliability
If a thick coating layer is used to ensure flame-retardant property and direct-current stability, then these properties are maintained, but moisture infiltration increases and insulation reliability decreases
Solution Approach 1:
The coating is segmented into distinct functional layers where the insulating layer specifically addresses moisture infiltration with its high volume resistivity and moisture barrier properties, while the flame-retardant layer handles flame resistance. This functional separation prevents moisture from reaching the conductor while maintaining flame retardancy, solving the problem of moisture infiltration in thick coatings.
3Weight of moving object
If the thickness of the insulating layer and flame-retardant layer is reduced to decrease weight, then weight is reduced, but the balance between insulation property and flame-retardant property becomes difficult to maintain
Solution Approach 1:
The coating structure is segmented into specialized layers where the insulating layer thickness is optimized for electrical insulation and moisture barrier (can be very thin with high-resistivity materials), while the flame-retardant layer thickness is optimized for flame resistance. This allows weight reduction by eliminating redundant material in each layer while maintaining the required balance between insulation and flame-retardant properties.
Solution Approach 2:
The patent changes material parameters by selecting insulating materials with very high volume resistivity (≥5.0×10^15 Ωcm) that allow ultra-thin insulating layers, and optimizing flame-retardant resin compositions to achieve high flame resistance with minimal thickness. These parameter optimizations enable weight reduction while maintaining property balance.
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 configuration enables a reduced outer diameter of the insulated wire while ensuring high direct-current stability and flame-retardant properties, enhancing mechanical strength and preventing moisture infiltration, thus achieving both diameter reduction and performance enhancement.
Implementation Method 1
an insulating layer exists between the plurality of flame-retardant layers
Data Source
AI summary
An insulated wire having an electrical wire structure capable of reducing an outer diameter while an insulating property and a flame-retardant property are highly kept is provided. In the insulated wire including: a conductor; and a coating layer arranged on an outer periphery of the conductor, the insulated wire has a flame-retardant property that allows the insulated wire to pass a vertical tray flame test (VTFT) on the basis of EN 50266-2-4, has a direct-current stability that allows the insulated wire to pass a direct-current stability test in conformity to EN 50305.6.7, has a diameter of the conductor that is equal to or smaller than 1.25 mm, and has a thickness of the coating layer that is smaller than 0.6 mm.