Rectangular Conductor Insulating Film Removal Method
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Solution Overview
Problem
The existing methods for removing insulating films from rectangular conductors often result in burr formation, which can lead to unstable welding quality and reduced thickness of the insulating coating, compromising the joint quality of the conductors.
Innovation Solution
A method involving specific steps to remove the insulating film from the junction surface, opposed surface, and corners of rectangular conductors, forming burrs on the junction surface side, while ensuring the insulating film is removed from the side surfaces to prevent burr protrusion on other surfaces, using cutting means and positioning mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the insulating film is cut from the four surfaces on the short sides and the long sides in the cross section of the joint lead wire, then the insulating film removal is achieved, but the peripheral surface of the rectangular conductor is also cut and the conductor becomes thinner, reducing the welding cross section and causing deformation after welding
Solution Approach 1:
The cutting depth is made different for different surfaces: the first surface (junction surface) is cut to a greater depth to remove the insulating film completely, while the second surface (opposed surface) is cut to a lesser depth that does not penetrate the conductor. This local differentiation allows complete insulating film removal at the junction surface while preserving the conductor thickness at the opposed surface, thus maintaining welding cross section strength.
2Reliability
If the insulating film is cut from the side surfaces of the rectangular conductor toward the junction surface, then the welding quality is improved by sandwiching burrs between junction surfaces, but burrs may still protrude from the periphery and cause unstable welding contact
Solution Approach 1:
The insulating film removal process is divided into multiple sequential cutting steps with different cutting depths. The first cutting step removes the insulating film from the junction surface with a first cutting depth. The second cutting step removes the insulating film from the opposed surface with a second cutting depth that is less than the first cutting depth, preventing conductor penetration and burr formation on the periphery.
Solution Approach 2:
Different cutting depths are applied to different surfaces based on their functional requirements. The junction surface receives deeper cutting to ensure complete insulating film removal and proper burr positioning for welding. The opposed surface receives shallower cutting to maintain conductor integrity and prevent peripheral burr protrusion, thus ensuring both welding quality and manufacturing precision.
3Ease of manufacture
If only two corners on the junction surface side are chamfered, then the insulating film removal is simplified, but burrs may still form on sides other than the junction surface side and deteriorate joint quality
Solution Approach 1:
The insulating film removal is segmented into multiple cutting steps with progressively different cutting depths. The first cutting step addresses the junction surface, and the second cutting step addresses the opposed surface with reduced depth. This segmentation ensures complete insulating film removal while controlling burr formation location, achieving both ease of manufacture and joint quality reliability.
Data Source
AI summary
An insulating film removal method according to the present disclosure includes first, second, and third removal steps. In the first removal step, an insulating film coated on a junction surface and an opposed surface opposed to the junction surface is removed, the junction surface being a surface where a rectangular conductor is joined with another rectangular conductor. In the second removal step, a corner of the rectangular conductor is removed so that a burr is formed on the junction surface and a side surface, the side surface adjoining the junction surface and the opposed surface. In the third removal step, the insulating film coated on the side surface is removed so that a burr is formed on the junction surface side.