UV-Curing Resin Coating for Terminal-Equipped Electric Wire
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Solution Overview
Problem
Current methods for manufacturing terminal-equipped electric wires are inefficient, requiring excessive man-hours for corrosion preventive treatments, which hinders productivity due to lengthy resin coating formation processes.
Innovation Solution
A method involving the use of ultraviolet-curing resin, where a discharge port intermittently ejects droplets orthogonal to the movement of a terminal-equipped electric wire, forming a coating that covers the core wire and terminal, and is then irradiated with ultraviolet rays to cure, reducing processing time and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional resin coating methods are used, then corrosion prevention is achieved, but manufacturing time and man-hours are excessive
Solution Approach 1:
The patent replaces conventional mechanical brush coating or spray coating methods with an ultraviolet curing system. The resin is applied and then rapidly cured using UV irradiation, eliminating the need for lengthy drying or curing processes required by traditional methods. This substitution of the curing mechanism dramatically reduces manufacturing time while maintaining corrosion prevention effectiveness.
Solution Approach 2:
The patent utilizes the phase transition of the ultraviolet-curing resin from liquid to solid state through photopolymerization. When UV light is applied, the resin rapidly transitions from a liquid coating state to a solid cured state, providing immediate corrosion protection without requiring extended drying times. This phase change process enables fast curing and significantly improves productivity.
2Manufacturing precision
If conventional coating methods are used, then coverage is achieved, but processing time is excessive
Solution Approach 1:
The patent employs periodic or intermittent ultraviolet irradiation to cure the resin coating. The UV curing process can be applied in pulses or continuously as the wire passes through, enabling rapid and uniform curing across the entire coating surface. This periodic action ensures complete coverage and uniform thickness while minimizing the total processing time required for coating formation.
Solution Approach 2:
The resin is applied to the wire in a liquid state that allows for uniform distribution and complete coverage of the surface before curing. This preliminary coating application ensures that all surfaces are properly covered, and then the UV curing process immediately follows to lock in this coverage. The preliminary liquid state application combined with immediate curing achieves both complete coverage and rapid processing.
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 method significantly reduces the time required for coating formation, enhances precision in resin application, and improves the reliability of corrosion prevention, thereby increasing the productivity of terminal-equipped electric wire manufacturing.
Implementation Method 1
irradiating the coating with ultraviolet rays
Data Source
AI summary
A method for manufacturing a terminal-equipped electric wire includes a coating forming process for forming, on a terminal-equipped electric wire having a terminal including a core wire crimping part that holds a core wire of an electric wire and a covering crimping part crimped to a covering of the electric wire, a coating of an ultraviolet-curing resin that integrally covers the core wire and the terminal, and an irradiating process for irradiating the coating with ultraviolet rays. At the coating forming process, while a discharge port that intermittently ejects droplets of the ultraviolet-curing resin and the terminal-equipped electric wire are moved relative to each other, the coating is formed from the ultraviolet-curing resin ejected from the discharge port. A direction of the relative movement of the discharge port and the terminal-equipped electric wire at the coating forming process includes directions orthogonal to an ejection direction of the droplets.