TW202125538A - Method for manufacturing flexibleconductive wire with ceramic insulating layer - Google Patents

Abstract

Provided is a method for manufacturing a flexible conductive wire with a ceramic insulating layer. The flexible conductive wire includes a conductive wire and a ceramic insulating layer coating the conductive wire. The conductive wire includes an aluminum outer layer. The method for manufacturing the flexible conductive wire includes the following steps: applying a bending action to the conductive wire to flexibly shape the conductive wire; and applying an electrochemical oxidation reaction to the conductive wire to make the aluminum outer layer of the conductive wire form the ceramic insulating layer, wherein the ceramic insulating layer includes a dense underlayer and a porous structure layer, the dielectric strength which may be borne by the ceramic insulating layer is 600 V without breakdown, then the ceramic insulating layer may be crimped with the conductive wire, so that the usage restrictions of the ceramic insulating layer due to low ductility and malleability are solved, and the conductive wire has extremely high dielectric strength.

Description

Method for manufacturing flexible conductive wire with ceramic insulating layer

The present invention relates to a method for manufacturing a flexible conductive wire with a ceramic insulating layer, in particular to a method for manufacturing a flexible conductive wire with a ceramic insulating layer that is subjected to a bending action before forming a ceramic insulating layer.

An insulated wire or a cable is coated with a non-conductive material, such as resin, plastic, silicon rubber, etc., to form an insulating layer to prevent the wire from contacting the outside and causing leakage, short circuit, electric shock and other accidents. Therefore, the insulated wire or the cable is widely used in our daily and industrial electricity, and even wound into the winding of the motor.

However, the traditional insulation layer is easily affected by high temperature and accelerated aging and damage. It is easily damaged and burned when it exceeds 200°C. Currently, a technology has been developed. Please refer to Chinese Patent Publication No. CN101728011A "A copper wire with an insulation layer and its Manufacturing method", a copper wire is composed of a copper core, a pure aluminum layer and an aluminum oxide layer. The pure aluminum layer is compounded to the outer surface of the copper core by metal composite technology. The aluminum oxide layer is made by hard anodizing. . The aluminum oxide layer can withstand higher temperatures than ordinary plastic insulation layers, and can withstand temperatures below 400°C. However, the copper wire may need to be wound and bent during use. For example, when making a motor, it needs to be wound. The aluminum oxide layer is easily broken due to the operation of excessive deflection, and its use is limited. Therefore, the copper wire still has room for improvement.

In view of this, in order to solve the above-mentioned limitation that the copper wire with an aluminum oxide layer cannot be bent in use, the inventor proposes a method for manufacturing a flexible conductive wire with a ceramic insulating layer.

A method for manufacturing a flexible conductive wire with a ceramic insulating layer. The flexible conductive wire includes a wire and a ceramic insulating layer covering the wire. The wire includes an aluminum outer layer. The method for manufacturing the flexible conductive wire It comprises a flexural setting step and an electrochemical oxidation step. The flexural setting step is to apply a bending action to the wire to make the wire be flexurally shaped, and the electrochemical oxidation step is to apply an electrochemical treatment to the wire. Learn the oxidation reaction to make the aluminum outer layer of the wire form the ceramic insulating layer, wherein the ceramic insulating layer includes a uniform dense bottom layer and a porous structure layer, so that the ceramic insulating layer can withstand a dielectric strength of 600 volts per millimeter Voltage without breakdown.

Further, the thickness of the ceramic insulating layer is between 0.005 mm and 0.03 mm.

Further, the electrochemical oxidation reaction is an anode treatment, and the current density used is in the range of 50 A/dm ² to 1200 A/dm ² .

Further, an electrolytic solution used in the anode treatment is an acid solution, and the concentration of the acid solution is between 3% and 15%.

Further, the acidic solution contains oxalic acid.

Further, the inner bending radius of the wire bending is not less than 4 times the wire radius.

Furthermore, the angle at which the ceramic insulating layer formed by the wire is further flexed without breaking is less than 60 degrees.

Further, the angle at which the ceramic insulating layer formed by the wire is further flexed without breaking is less than 35 degrees.

Furthermore, the method for manufacturing a flexible conductive wire with a ceramic insulating layer further includes: performing a heat treatment on the ceramic insulating layer to remove a crystal salt and a crystal water in the ceramic insulating layer.

Furthermore, the temperature of the heat treatment is between 200 degrees and 450 degrees, and the temperature is maintained for at least one hour.

According to the above technical features, the following effects can be achieved:

1. By applying the bending action to the wire to shape the wire in the flexural shape, and then applying the electrochemical oxidation reaction to the wire to form the ceramic insulating layer on the aluminum outer layer, the ceramic insulating layer can Following the wire crimping, the low ductility of the ceramic insulating layer cannot be bent and the limitation in use is solved.

2. Through the electrochemical oxidation reaction, a uniform ceramic insulating layer must be formed on the surface of the entire wound aluminum outer layer, and the ceramic insulating layer can withstand a voltage of 600 volts per millimeter. No breakdown.

3. By performing the heating treatment to remove the crystal salt and the crystal water in the ceramic insulating layer, the ceramic insulating layer has a stable and good insulating effect, and produces an annealing effect on the wire, which can reduce its forming process Crystal defects reduce the resistance and improve the conductive effect.

4. Since air is a good insulating material, the porous structure layer of the ceramic layer is designed. The air layer can provide higher insulation and voltage withstanding effects than the ceramic layer, and control the high current density in the range of 50A/dm ² to 1200A/dm ² , the general electrochemical oxidation reaction is not more than 5A/dm ² , and the difference is more than 10 times. The higher the current density, the looser the ceramic layer obtained. Under this condition, in addition to being 2.5 times faster than the general electrochemical oxidation reaction In addition to thickening to achieve an appropriate resistance value, because the dielectric strength of the gas changes according to the shape and configuration of the electrode, the porous structure layer is designed to have a high dielectric strength effect due to the production parameters of this case. When the thickness is less than 0.02mm, it can resist 500V DC without breakdown.

Based on the above technical features, the main effects of the method for manufacturing a flexible conductive wire with a ceramic insulating layer of the present invention will be clearly presented in the following embodiments.

Referring to Figures 1 to 3, the method for manufacturing a flexible conductive wire (1) with a ceramic insulating layer of the present invention includes a flexure setting step (S01), an electrochemical oxidation step (S02), and a heat treatment step (S03). The manufactured flexible conductive wire (1) can be applied to, for example, the winding of a motor. The flexible conductive wire (1) includes a wire (11) and a ceramic insulating layer (12). The wire (11) includes a conductive wire body (111) and an aluminum outer layer (112). The ceramic insulating layer (12) is made of alumina and covers the wire (11).

In the flexural setting step (S01), a bending action is applied to the wire (11) to make the wire (11) a flexural shape, for example, the wire (11) is first wound to be wound by using a machine The shape on a stator or a rotor.

Referring to Figures 2 to 4, in the electrochemical oxidation step (S02), an electrochemical oxidation reaction is applied to the wire (11) to make the aluminum outer layer (112) form the ceramic insulation of the metal oxide The layer (12) enables the ceramic insulating layer (12) to withstand a voltage of 600 volts per millimeter without breakdown, wherein the ceramic insulating layer (12) includes a uniform dense bottom layer and a porous structure layer , Wherein the dense bottom layer is in contact with the wire (11), and the porous structure layer is formed on the outer surface of the ceramic insulating layer (12). The electrochemical oxidation reaction is an anode treatment. The detailed steps are to put the wire (11) in the flexural shape into an electrolytic solution (2) and connect it to an anode, and put a graphite sheet into the The electrolytic solution (2) is connected to a cathode, the wire (11) is completely immersed in the electrolytic solution (2), the electrolytic solution (2) is an acidic solution, and the concentration of the acidic solution is between 3% and 15%. Meanwhile, the electrolytic solution (2) contains an oxalic acid. In this example, the concentration of the oxalic acid is 5%, the anode and the cathode are applied with a voltage ranging from 30V to 40V, and the current density is in the range of 50A. /dm ² to 1200A/dm ² for 0.5 to 2 hours. Under this condition, the surface of the aluminum outer layer (112) can quickly form the ceramic insulating layer (12), and make the ceramic insulating layer (12) Thicken quickly to achieve an appropriate resistance value, wherein the ceramic insulating layer (12) is the outermost layer, and the aluminum outer layer (112) is between the conductive wire body (111) and the ceramic insulating layer (12), The thickness of the ceramic insulating layer (12) is between 0.005 mm and 0.03 mm. It should be noted that even if the wire (11) is wound into a high-density coil, as long as the aluminum outer layer (112) is completely immersed in the electrolytic solution (2), there will be electrolyte contact at many minute intervals. By applying the voltage to the wire (11), the entire wire (11) flows a uniform current, and the entire surface of the aluminum outer layer (112) that is wound must form a uniform ceramic insulating layer (12). ), during the electrochemical oxidation reaction, a crystalline salt and a crystalline water are also produced.

It should be supplemented that, in the bending and shaping step (S01), the inner bend radius of the wire (11) is not less than 4 times the wire radius, then the ceramic insulating layer is uniformly formed in the electrochemical oxidation step (S02), Moreover, the ceramic insulating layer (12) formed in the electrochemical oxidation step (S02) has an angle of further deflection without cracking less than 60 degrees without cracking, and the preferred angle is less than 35 degrees.

Referring to the second figure, the third figure and the fifth figure, in the heating treatment step (S03), a heating treatment is applied to the ceramic insulating layer (12). The detailed steps are to place the flexible conductive wire (1) in a heat treatment furnace (3), heat it between 200°C and 450°C, and hold the temperature for at least one hour. Through the heat treatment, the aluminum The outer layer (112) can regenerate the ceramic insulating layer (12), which is actually a thermal oxidation reaction. More importantly, the heat treatment can remove the crystal salt and crystal water inside the ceramic insulating layer (12), The crystal salt and the crystal water will affect the resistance value of the ceramic insulating layer (12) and destroy the insulation of the ceramic insulating layer (12). Therefore, after the crystal salt and the crystal water are removed, the ceramic insulating layer ( 12) Maintain a stable and good insulation effect, and produce an annealing effect on the wire, which can reduce the crystal defects during the forming process, reduce the resistance, and improve the conductive effect.

In summary, by applying the bending action to the wire (11), the wire (11) is shaped in the flexural shape, and then the electrochemical oxidation reaction is applied to the wire (11) to make the aluminum outer layer (112) When the ceramic insulating layer (12) is formed, the ceramic insulating layer (12) can be curled with the wire (11), which solves the limitation in use caused by the low ductility of the ceramic insulating layer (12), wherein the wire (11) The bendable angle is between 10 degrees and 60 degrees, and through the electrochemical oxidation reaction, the entire wound aluminum outer layer (112) must form a uniform ceramic insulating layer ( 12), and the dielectric strength that the ceramic insulating layer (12) can withstand is a voltage of 600 volts per millimeter without breakdown, and then by performing the heating treatment to remove the crystals in the ceramic insulating layer (12) The salt and the crystal water make the ceramic insulating layer (12) have a stable and good insulating effect.

Table 1 The dielectric strength breakdown test of the ceramic insulating layer at a thickness of 0.01 mm at 250V/50MΩ MODEL 3301 250V/50MΩ 1 2 3 4 5 1 ∞ ∞ ∞ ∞ ∞ 2 ∞ ∞ ∞ ∞ ∞ 3 ∞ ∞ ∞ ∞ ∞ 4 ∞ ∞ ∞ ∞ ∞ 5 ∞ ∞ ∞ ∞ ∞ 6 ∞ ∞ ∞ ∞ ∞ 7 ∞ ∞ ∞ ∞ ∞ 8 ∞ ∞ ∞ ∞ ∞ 9 ∞ ∞ ∞ ∞ ∞ 10 ∞ ∞ ∞ ∞ ∞

From Table 1 1 to 10, ten test points are randomly selected when the thickness of the ceramic insulating layer (12) is 0.01 mm, and 1 to 5 are the number of tests, and the dielectric strength test is performed on the ceramic insulating layer (12) ( 250V/50MΩ), it can be observed that the parameters of any ten test points in five tests are ∞. ∞ means that the ceramic insulating layer (12) is not broken, and the dielectric strength of the ceramic insulating layer is 250V/0.01mm= 25000V/mm without breakdown. In theory, when the thickness of the ceramic insulating layer (12) is 0.03 mm, the dielectric strength can be 600V/50MΩ without breakdown.

Based on the description of the above embodiments, when one can fully understand the operation and use of the present invention and the effects of the present invention, but the above embodiments are only the preferred embodiments of the present invention, and the implementation of the present invention cannot be limited by this. The scope, that is, simple equivalent changes and modifications made according to the scope of the patent application of the present invention and the content of the description of the invention, are all within the scope of the present invention.

(1): Flexing conductive wire (11): Wire (111): Conductive wire body (112): Aluminum outer layer (12): Ceramic insulation layer (2): Electrolytic solution (3): Heat treatment furnace (S01): Deflection setting step (S02): Electrochemical oxidation step (S03): Heat treatment step

[The first figure] is a perspective view illustrating a flexible conductive wire. [The second figure] is a perspective view illustrating the structure of the flexible conductive wire. [Third Figure] is a flowchart illustrating the flow of the method for manufacturing a flexible conductive wire with a ceramic insulating layer according to the present invention. [Fourth Figure] is a perspective view illustrating that the flexible conductive wire is put into an electroplating solution. [Fifth Figure] is a schematic diagram illustrating that the flexible conductive wire is placed in a heat treatment furnace.

(S01): Deflection setting step

(S02): Electrochemical oxidation step

(S03): Heat treatment step

Claims (10)

A method for manufacturing a flexible conductive wire with a ceramic insulating layer. The flexible conductive wire includes a wire and a ceramic insulating layer covering the wire. The wire includes an aluminum outer layer. The method for manufacturing the flexible conductive wire It includes the following steps: A bending action is applied to the wire so that the wire is shaped like a flex; and An electrochemical oxidation reaction is applied to the wire, so that the aluminum outer layer of the wire forms the ceramic insulating layer, wherein the ceramic insulating layer includes a uniformly dense bottom layer and a porous structure layer, so that the ceramic insulating layer can withstand the dielectric The electric strength is 600 volts per millimeter without breakdown. The method for manufacturing a flexible conductive wire with a ceramic insulating layer as described in item 1 of the scope of the patent application, wherein the thickness of the ceramic insulating layer is between 0.005 mm and 0.03 mm. As described in the first item of the scope of patent application, the method for manufacturing a flexible conductive wire with a ceramic insulating layer, wherein the electrochemical oxidation reaction is an anode treatment, and the current density ranges from 50A/dm ² to 1200A/dm ² . As described in item 3 of the scope of patent application, the method for manufacturing a flexible conductive wire with a ceramic insulating layer, wherein an electrolytic solution used in the anode treatment is an acid solution, and the concentration of the acid solution is between 3% and 15% between. The method for manufacturing a flexible conductive wire with a ceramic insulating layer as described in item 4 of the scope of patent application, wherein the acidic solution contains an oxalic acid. According to the method for manufacturing a flexible conductive wire with a ceramic insulating layer as described in item 1 of the scope of the patent application, the inner bending radius of the wire bending is not less than 4 times the wire radius. The method for manufacturing a flexible conductive wire with a ceramic insulating layer as described in the first item of the scope of the patent application, wherein the ceramic insulating layer formed by the wire is further deflected without breaking at an angle of less than 60 degrees. The method for manufacturing a flexible conductive wire with a ceramic insulating layer as described in item 7 of the scope of patent application, wherein the ceramic insulating layer formed by the wire is further deflected without breaking at an angle of less than 35 degrees. According to the method for manufacturing a flexible conductive wire with a ceramic insulating layer as described in item 1 of the scope of the patent application, a heating treatment is applied to the ceramic insulating layer to remove a crystalline salt and a ceramic insulating layer in the ceramic insulating layer. Crystal water. The method for manufacturing a flexible conductive wire with a ceramic insulating layer as described in item 9 of the scope of patent application, wherein the temperature of the heating treatment is between 200 degrees and 450 degrees, and the temperature is maintained for at least one hour.

Images