Asymmetric Wire Cross-Section for Stranded Cable Assembly

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Solution Overview

Problem

Existing wires with round cross-sections pose limitations in producing stranded wires with asymmetrical or irregular arrangements, leading to constricted assemblies and tapered cross-sections.

Innovation Solution

A wire with a cross-section featuring interconnected portions, including a central reduced section, allows for the production of stranded wires with a round or hexagonal cross-section, enabling asymmetrical or irregular structures and maintaining wire position during production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If wires with round cross-section are used in stranded wire production, then the wires are easy to manufacture and process, but the stranded wire assembly becomes constricted and tapered when asymmetrical or irregular arrangements are attempted

Engineering Contradiction:

Improveease of wire productionVSAvoidstranded wire cross-section uniformity

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The wire cross-section is designed with asymmetrical features, specifically a reduced cross-sectional area in a specific region while maintaining round portions in other areas. This asymmetrical design enables the wire to fit into asymmetrical or irregular arrangements within stranded wires without causing constriction or tapering, while still being manufacturable using conventional processes.

Inventive Principle:

Principle #4Asymmetry

2Ease of manufacture

If symmetrical or regular arrangement of wires is used, then the stranded wire production is simplified, but the design flexibility and adaptability are limited

Engineering Contradiction:

Improvestranded wire production simplicityVSAvoidarrangement configuration flexibility

Core Design Contradiction:

Ease of manufactureVSAdaptability or versatility

Solution Approach 1:

The wire cross-section incorporates different regional characteristics: round portions for uniform contact and support, and reduced cross-section portions for precise positioning and fit. This local differentiation allows the wire to adapt to various arrangement configurations (symmetrical, asymmetrical, regular, or irregular) while maintaining ease of manufacture through conventional processes.

Inventive Principle:

Principle #3Local quality

3Adaptability or versatility

If wires with reduced cross-section portions are used, then asymmetrical and irregular stranded wire arrangements become possible, but the wire structure becomes more complex

Engineering Contradiction:

Improvearrangement configuration flexibilityVSAvoidwire cross-section complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The wire cross-section is segmented into distinct regions: round portions and reduced cross-section portions. This segmentation allows each region to fulfill specific functions (support, positioning, fit) while the overall structure remains manufacturable using conventional drawing processes with appropriately designed dies.

Inventive Principle:

Principle #1Segmentation

Data Source

PatentUS11248340B2Wire, in particular for a stranded wire

Publication Date: 2022.02.15 LEONI KABEL GMBH

AI summary

A wire (10) is disclosed. Said wire (10), when viewed in cross-section, has at least one first portion (12) and at least one second portion (14) that are interconnected by a third portion (16) in which the wire (10) has a reduced cross-section.