Pivotable Wire Coating Unit for Uniform Thickness Across Geometries
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Solution Overview
Problem
Existing systems for producing coated wires struggle to achieve a homogeneous coating thickness due to varying wire cross-sections and geometries, leading to issues like inhomogeneous curing, blistering, and voltage breakdowns, and are difficult to adjust to changing requirements.
Innovation Solution
A coating device with a pivotally mounted application unit around a support roller axis, allowing for flexible adjustment to different wire properties, combined with micrometer screws for fine tuning, and a system that includes an oven for drying and curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a fixed coating device is used for producing coated wires, then the device structure is simple and easy to manufacture, but the device cannot adapt to varying wire cross-sections and geometries, resulting in inhomogeneous coating thickness
Solution Approach 1:
The application unit is made dynamically adjustable through pivotal mounting about the support roller axis, allowing the wire guiding elements to be repositioned according to different wire cross-sections and geometries. This dynamic configuration enables the device to adapt to various wire characteristics while maintaining a relatively simple overall structure.
Solution Approach 2:
The support roller serves multiple functions: it supports the wire, provides an axis for pivotal mounting of the application unit, and acts as a reference for positioning wire guiding elements. This multi-functionality reduces the need for additional components, maintaining structural simplicity while enhancing adaptability.
2Manufacturing precision
If conventional coating devices are used, then the device is easy to manufacture, but the coating thickness becomes inhomogeneous due to varying wire cross-sections
Solution Approach 1:
Wire guiding elements with different geometries are provided to match specific wire cross-sections and shapes. These elements are positioned in the application unit to ensure homogeneous coating thickness for each wire type. The localized adaptation of guiding elements achieves precise coating control without requiring complete device redesign.
Solution Approach 2:
The pivotal mounting of the application unit allows dynamic adjustment of wire guiding elements to achieve optimal positioning for homogeneous coating. This dynamic capability enables precise coating thickness control while maintaining a simple, easily manufacturable device structure.
3Productivity
If the application unit is fixed in position, then the device structure is simple, but the system cannot be adjusted to different wire properties, reducing productivity
Solution Approach 1:
The application unit is pivotal mounted about the support roller axis, enabling quick adjustment to different wire properties without complex reconfiguration. This dynamic design allows the system to adapt to varying production requirements efficiently, enhancing productivity while keeping the device structure relatively simple.
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
Enables the production of coated wires with consistent coating thickness and improved curing, reducing the risk of defects and enhancing system adaptability to varying wire characteristics.
Implementation Method 1
at least one wetting unit for applying the coating material, wherein the wetting unit has a wetting unit base body with a wetting passage for the wire
Implementation Method 2
applying a layer of the coating material to the wire
Implementation Method 3
at least one stripping unit for stripping excess coating material from the wire, wherein the stripping unit has a stripping unit base body and a stripping passage for the wire
Implementation Method 4
a furnace for solidifying the applied layer, wherein the furnace is arranged downstream of the at least one application unit in the wire conveying direction
Implementation Method 5
drying and/or curing the coating material in the oven
Data Source
Figure 1A
Figure 1B
Figure 2
AI summary
The invention relates to a coating device (1) for applying at least one layer of a coating material to a wire (2), comprising a support roller (3) for supporting and conveying the wire (2) in a wire conveying direction (4), wherein the support roller (3) is mounted so as to be rotatable about a support roller axis (5), and at least one application unit (6) arranged downstream of the support roller (2) in the wire conveying direction (4), wherein the application unit (6) is mounted so as to be pivotable about the support roller axis (5).