Rectangular Wire Multilayer Resin Coating for Soot-Free Welding
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Solution Overview
Problem
Conventional high-frequency rectangular wires face issues with rigid welding due to soot formation during the assembly of motors, which affects the mechanical strength and reliability of the wire joints.
Innovation Solution
A rectangular wire design featuring a multilayer conductor member with a thermosetting resin layer having a glass transition temperature of 100°C to 200°C and a urethane bond, combined with a thermoplastic resin layer having a melting point of 300°C or more, which facilitates easy welding without soot formation and maintains high-frequency properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulative enamel film is formed on the outer periphery of rectangular metallic bodies to achieve high-frequency property, then high-frequency performance is improved, but soot formation occurs during welding making rigid welding difficult
Solution Approach 1:
The insulation coating is divided into two distinct layers: an inner thermosetting resin layer (urethane bond with Tg of 100-200°C) that provides high-frequency properties and adhesion, and an outer thermoplastic resin layer (melting point ≥300°C) that prevents soot formation during welding. This segmentation allows each layer to perform its specific function without interfering with the other.
Solution Approach 2:
The patent uses a composite coating structure combining two different resin materials with complementary properties. The thermosetting resin provides electrical insulation and adhesion at high frequencies, while the thermoplastic resin provides welding compatibility and soot prevention. This composite approach resolves the contradiction between high-frequency performance and weldability.
2Loss of energy
If a thermosetting resin layer with urethane bond and glass transition temperature of 100°C to 200°C is formed on the rectangular metallic conductor, then high-frequency losses are reduced, but the complexity of the coating process increases
Solution Approach 1:
The patent specifies precise parameter ranges for the thermosetting resin (urethane bond, Tg of 100-200°C) to optimize high-frequency performance. By controlling the glass transition temperature within this range, the resin maintains appropriate flexibility and electrical properties to minimize high-frequency losses while allowing standard coating processes to be used.
3Ease of manufacture
If a thermoplastic resin layer with melting point of 300°C or more is formed on the outer periphery of the multilayer conductor member, then welding property is improved, but the manufacturing cost increases
Solution Approach 1:
The thermoplastic resin layer is applied only on the outer periphery of the multilayer conductor member, providing welding compatibility exactly where needed (at the surfaces that contact during welding) without unnecessarily coating the entire structure. This localized application reduces material consumption while maintaining the welding benefits.
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 enables robust and reliable wire joints with improved high-frequency performance and ease of welding, reducing high-frequency losses and ensuring excellent adhesion and insulation properties.
Implementation Method 1
the thermosetting resin having a glass transition temperature of 100° C. or more and 200° C. or less and having a urethane bond
Implementation Method 2
a layer of a thermoplastic resin having a melting point of 300° C. or more on the outer periphery of the multilayer conductor member
Data Source
AI summary
A rectangular wire having: a multilayer conductor member constructed by stacking, in a thickness direction, a rectangular metallic conductor that has a layer of a thermosetting resin formed on the outer periphery thereof, the thermosetting resin having a glass transition temperature of 100° C. or more and 200° C. or less and having a urethane bond; and a layer of a thermoplastic resin having a melting point of 300° C. or more on the outer periphery of the multilayer conductor member.