Litz Wire Termination Insulation Removal and Sealing
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Solution Overview
Problem
Current methods for terminating Litz wire bundles are inefficient, as they often damage the wire structure, fail to provide a complete seal, and are prone to corrosion, especially when exposed to bodily fluids, leading to increased electrical resistance and potential wire failure.
Innovation Solution
A method involving a tube with an open end where wires and an insulating material are placed, subjected to pressure and heat, causing the insulating material to melt and solidify, forming a barrier that seals the wires and prevents fluid ingress, while fusing the wires without damaging them.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If insulation is removed by dipping into molten solder, then low temperature film insulation is removed, but high temperature film insulation cannot be removed and the wire structure is damaged
Solution Approach 1:
The patent changes the temperature parameter from molten solder temperatures (low enough to remove old insulation but too low for new insulation) to a higher temperature range that can remove high temperature film insulation while maintaining wire structure integrity through controlled heating
Solution Approach 2:
The patent replaces the mechanical dipping process with a thermal field-based insulation removal method, using controlled heating to eliminate insulation without physical contact that could damage the wire structure
2Ease of operation
If crimp terminals are used, then connection is made, but insulation piercing teeth cannot reach every strand in the Litz wire bundle
Solution Approach 1:
The patent performs preliminary insulation removal and wire strand separation before the connection step, allowing all wire strands to be exposed and accessible for complete contact with the terminal, ensuring every strand makes proper electrical contact
3Ease of manufacture
If fused salts are used to chemically dissolve insulation, then insulation is removed, but chemical residue cannot be completely removed from inside the Litz wire bundle
Solution Approach 1:
The patent replaces the chemical dissolution process with a thermal field-based insulation removal method, using controlled heating to vaporize or eliminate insulation without leaving chemical residues inside the wire bundle
Solution Approach 2:
The patent converts the potential harm of high temperature (which could damage wires) into a benefit by using controlled thermal fields that selectively remove insulation while preserving the wire structure, eliminating the need for harmful chemicals
4Productivity
If tube fusing is used, then large bundles of insulated wire can be terminated, but the process is complex and time-consuming
Solution Approach 1:
The patent segments the insulation removal and wire termination processes into distinct, optimized steps, allowing each to be performed with specialized equipment and parameters, improving overall efficiency while maintaining the ability to handle large wire bundles
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 insulates and seals the wire terminations, preventing corrosion and maintaining the integrity of the wire bundle, even when exposed to bodily fluids, thus reducing the risk of electrical failure.
Implementation Method 1
heating the tube, the plurality of wires, and the insulating material to a temperature above a melting point of the insulating material, wherein the insulating material is melted
Implementation Method 2
the insulating material is melted and driven toward the open end of the tube. Upon removal of the heat, the insulating material solidifies
Implementation Method 3
The applied pressure and heat are sufficient to deform the tube and compress the wires, the insulating material, and the tube together such that the wires are pressed against other wires and the insulating material. The heat is sufficient to fuse the wires to each other
Implementation Method 4
The applied pressure and heat are sufficient to deform the tube and compress the wires, the insulating material, and the tube together
Data Source
AI summary
A method for insulating wires is disclosed. A portion of the plurality of wires and an insulating material are placed in a tube having an open end. Pressure is applied to the tube. During the application of pressure, the tube, the plurality of wires, and the insulating material are heated to a temperature above a melting point of the insulating material. As a result, the insulating material is melted and driven toward the open end of the tube. Upon removal of the heat, the insulating material solidifies and forms a barrier proximal to the open end of the tube.