Water-Dispersed Electrodeposition Solution for Insulating Film
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Solution Overview
Problem
Conventional electrodeposition methods for forming insulating films on electrical wires face challenges such as high production costs due to limited monomer options and the need for thermal dissolution, and issues with electrodeposition efficiency and film thickness uniformity.
Innovation Solution
A water-dispersed electrodeposition solution comprising polymer particles made of polyamide-imide or polyester-imide without anionic groups, with controlled median diameter and particle distribution, and a basic compound, which allows for the use of various monomers and eliminates the need for thermal dissolution, enabling easy production at low cost and excellent storage stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyimide particles with anionic groups are used to improve storage stability, then storage stability is improved, but the type of monomers is limited and production cost increases
Solution Approach 1:
The invention changes the chemical parameter of the polymer particles by using polyamide-imide or polyester-imide without anionic groups in the main chain, replacing the conventional polyimide with anionic groups. This parameter change allows the use of various monomers (including diamines without carboxyl or sulfonic acid groups, and tetra-carboxylic acid anhydrides without carboxyl or sulfonic acid groups) while maintaining storage stability through controlled particle size distribution and the addition of basic compounds to neutralize carboxyl groups.
2Stress or pressure
If thermal dissolution is performed to lower viscosity of polyimide varnish, then viscosity is reduced, but accurate temperature control is required and production cost increases
Solution Approach 1:
The invention extracts the thermal dissolution step from the manufacturing process. By using pre-synthesized polyamide-imide or polyester-imide particles with controlled size distribution, the patent eliminates the need for thermal dissolution of polyimide varnish, thereby removing the requirement for accurate temperature control and reducing production costs while achieving the desired viscosity through particle dispersion in water.
3Productivity
If water-soluble polyamide-imide is used to form continuous film, then coating proceeds, but electrodeposition efficiency deteriorates and desired film thickness is difficult to achieve
Solution Approach 1:
The invention segments the coating material into discrete polymer particles (0.05-2.0 μm diameter) rather than using water-soluble polyamide-imide that forms continuous films. This segmentation maintains electrodeposition efficiency by allowing charged particles to be deposited on the cathode surface without forming a continuous insulating layer during the deposition process, enabling achievement of desired film thickness through controlled particle accumulation.
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 allows for the formation of thick, uniformly thickened insulating films with improved electrodeposition efficiency and storage stability, reducing production costs and enhancing the dispersibility of polymer particles, even with a relatively low surface potential.
Implementation Method 1
an electrodeposition method (electrodeposition coating), and the like are known. In the dipping method, for example, a rectangular conductor or the like is used as the object to be coated. By repeating a process in which the object is dipped in a coating material, pulled up, and then dried, an insulating film having an intended film thickness is formed. The electrodeposition method is a method, in which an insulating film is formed by applying direct current to: an object to be coated, which is dipped in an electrodeposition coating material (electrodeposition solution), and an electrode inserted into the electrodeposition coating material, to allow charged coating material particles to be precipitated on the side of the object to be coated.
Implementation Method 2
the water-dispersed electrodeposition solution for forming an insulating film, in which varieties of monomers can be used, and there is no need to perform an operation of thermal dissolution or the like in preparation of the electrodeposition solution. The water-dispersed electrodeposition solution can be easily produced at low cost. The insulation coating to be formed can be thickened easily. In addition, the water-dispersed electrodeposition solution has excellent storage stability.
Data Source
Figure 1
AI summary
A water-dispersed electrodeposition solution (11) for forming an insulating film includes: polymer particles; an organic solvent; a basic compound; and water. The polymer particles are made of: any one of; or both of polyamide-imide and polyester-imide, main chains thereof being free of an anionic group, a number-based median diameter D50 of the polymer particles is 0.05 µm to 0.5 µm, and polymer particles having a particle size within -30% to +30% of the number-based median diameter D50 are 50% or more of all of the polymer particles on a number basis.