Stranded Wire Insulation Removal via Laser Ablation
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Solution Overview
Problem
Existing methods for producing stranded wires, particularly shaped stranded wires, face challenges with enameled wire insulation that inhibits electrical and mechanical connections, leading to reduced mechanical strength, electrical conductivity, and thermal conductivity, as well as increased waste and processing difficulties due to enamel residues and overhangs.
Innovation Solution
A method involving the application of an insulation layer to wires, followed by individual removal of the insulation layer along partial lengths to form non-insulated contact regions, using techniques like laser ablation for precise and residue-free insulation stripping, allowing for efficient and reliable production of stranded wires with improved mechanical and electrical connections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an insulation layer is applied to wires for electrical isolation, then insulation performance is improved, but electrical and mechanical connection quality deteriorates due to enamel residues
Solution Approach 1:
The insulation layer is removed in advance from specific regions where electrical and mechanical connections are required, before the connection process takes place. This preliminary removal action ensures that no enamel residues interfere with the connection quality, while the insulation layer remains intact in regions where electrical isolation is needed.
Solution Approach 2:
The insulation layer is selectively removed only from specific local regions (contact regions) where connections are needed, while maintaining the insulation layer in other regions. This creates different local properties: insulated regions for electrical isolation and non-insulated regions for high-quality connections.
2Strength
If insulation layer is completely removed for connection, then electrical connection is improved, but insulation performance deteriorates due to loss of insulation coverage
Solution Approach 1:
Instead of complete removal, the insulation layer is selectively removed only from local contact regions where electrical connection is needed. The rest of the wire retains its insulation layer, maintaining overall insulation performance while enabling high-quality local connections.
Solution Approach 2:
Rather than removing the insulation layer completely or uniformly, only a partial removal is performed in specific regions. This partial action is sufficient to achieve the connection goal without compromising the insulation function in other areas.
3Ease of manufacture
If traditional insulation removal methods are used, then processing is simplified, but waste increases due to enamel residues and overhangs
Solution Approach 1:
Traditional mechanical insulation removal methods (such as scraping or cutting) are replaced with laser ablation technology. This substitution enables precise, contactless removal of the insulation layer without generating enamel residues or overhangs, thereby reducing waste while maintaining processing simplicity.
Solution Approach 2:
The laser ablation process creates a precise digital control model of where insulation should be removed, allowing for exact replication of the desired contact regions without material waste. The process follows predetermined patterns that minimize unnecessary material removal.
4Reliability
If insulation layer remains intact for connection, then insulation performance is maintained, but connection quality deteriorates due to enamel interference
Solution Approach 1:
The insulation layer's presence or absence is determined by local requirements: it is removed in contact regions where connection quality is paramount, and maintained in other regions where insulation performance is critical. This spatial differentiation resolves the contradiction between insulation and connection quality.
Solution Approach 2:
The insulation layer is removed in advance from contact regions before the connection process begins. This preliminary action eliminates enamel interference with connection quality while the insulation layer remains intact elsewhere to maintain insulation performance.
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
This approach enables low-waste, high-quality production of stranded wires with enhanced mechanical and electrical connections, reduced enamel residues, and increased processing efficiency, suitable for both continuous and batchwise production methods.
Implementation Method 1
using techniques like laser ablation for precise and residue-free insulation stripping
Data Source
AI summary
The invention relates to a method for producing stranded wires, including the steps of applying an insulation layer to lines, separating the insulated lines, individually removing the insulation layer from the separated lines along a partial length of the lines, and bringing the lines together to form a stranded wire, wherein the partial lengths are arranged at the same level at least in sections for the purpose of forming a non-insulated contact region.