Phenoxy Resin Fusion Layer for Uniform Wire Bundle Insulation
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Solution Overview
Problem
Existing self-fusing insulated electric wires face issues with non-uniform fusion resin distribution leading to insufficient insulation voltage and varying distances between wires, which affects the partial discharge inception voltage (PDIV), and the manufacturing process is complex and costly.
Innovation Solution
A resin composition comprising a phenoxy resin with specific molecular weight and structural units, along with optional blowing agents and curing agents, forms a heat fusion layer that ensures uniform adhesion and improved insulation properties after fusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a blowing agent is added to the heat fusion layer to foam the heat fusion layer after the winding process, then the fusion property between electric wires is improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The patent applies preliminary action by incorporating the blowing agent into the heat fusion layer before the winding process. The blowing agent is already present in the resin composition, so it automatically foams during the heating process after winding, eliminating the need for separate post-winding foaming operations and reducing manufacturing complexity
Solution Approach 2:
The patent extracts the foaming function from a separate post-winding process and integrates it into the heat fusion layer material itself. By taking out the blowing agent and incorporating it into the resin composition, the foaming action becomes an inherent property of the material rather than a separate process step
2Reliability
If the heat fusion layer is thickened to improve fusion property, then the fusion property between electric wires is improved, but the volumetric efficiency of the coil is lowered
Solution Approach 1:
The patent applies phase transitions by using a blowing agent that undergoes phase change from solid/liquid to gas during heating. This generates foam in situ within the heat fusion layer, creating voids that reduce the effective thickness of the layer while maintaining or improving fusion properties through the expanded foam structure
Solution Approach 2:
The patent creates porous materials by generating foam structure within the heat fusion layer through the blowing agent. The resulting porous foam structure provides adequate fusion property while occupying less volume than a solid layer of equivalent thickness, thereby improving volumetric efficiency
3Reliability
If the coating thickness of the electric wire is increased to improve fusion property, then the fusion property is improved, but the workability when the electric wire is inserted into the motor is deteriorated
Solution Approach 1:
The patent uses phase transitions of the blowing agent during heating to create foam expansion that improves fusion property without requiring increased initial coating thickness. The in-situ foaming occurs after winding, so the wire maintains its original dimensions during insertion, preserving workability
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 resin composition achieves a self-fusing insulated electric wire with enhanced insulation properties and uniform fusion, maintaining consistent wire spacing and improving PDIV, while simplifying the manufacturing process.
Implementation Method 1
a blowing agent is added to the heat fusion layer to foam the heat fusion layer after the winding process
Implementation Method 2
a heat fusion layer to be fused to each other is formed on an outer periphery of a conductor
Data Source
AI summary
A resin composition includes a phenoxy resin as a principal component. The phenoxy resin has a weight-average molecular weight of 40,000 or more. The phenoxy resin has, in the same or different molecules, a first structural unit derived from bisphenol S phenoxy and a second structural unit derived from a bisphenol epoxy other than the first structural unit. A content ratio of the first structural unit in the phenoxy resin is 20 mol % to 80 mol % relative to a total content of the first structural unit and the second structural unit constituting the phenoxy resin.