Cable Conductor Stranding for Insulator Adhesion
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Solution Overview
Problem
In cable distal end processing, the outer and inner sheaths are pulled out axially, causing insulators to elongate and become unequal in length, leading to mismatched exposed dimensions of conductors, which can result in poor processing.
Innovation Solution
A cable design where a pair of insulated wires, each formed by covering a conductor with an insulator, are mutually stranded and coated with a sheath, with the conductor constructed by assembling and further stranding multiple wires, creating fine unevenness on the conductor's surface to increase adhesion between the conductor and insulator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the outer sheath and inner sheath are pulled out axially during distal end processing, then the sheath can be removed for conductor exposure, but the insulators are pulled and elongated causing unequal lengths and mismatched exposed dimensions
Solution Approach 1:
The conductor is pre-formed by assembling multiple stranded wires and further stranding them before the insulator is applied. This preliminary structuring of the conductor creates a rough surface that will later provide anchoring for the insulator, preventing elongation during sheath removal
Solution Approach 2:
The conductor surface is made locally rough through the stranding structure, creating fine unevenness at the interface with the insulator. This localized surface characteristic increases adhesion specifically at the conductor-insulator boundary, preventing insulator elongation when the sheath is pulled out
2Stability of the object's composition
If the insulators are in close contact with the inner sheath, then the cable structure is compact and protected, but the insulators may be pulled and elongated when the sheath is removed
Solution Approach 1:
The conductor is pre-formed by assembling multiple stranded wires and further stranding them before the insulator is applied. This preliminary structuring of the conductor creates a rough surface that will later provide anchoring for the insulator, preventing elongation during sheath removal
Solution Approach 2:
The conductor surface is made locally rough through the stranding structure, creating fine unevenness at the interface with the insulator. This localized surface characteristic increases adhesion specifically at the conductor-insulator boundary, preventing insulator elongation when the sheath is pulled out
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 increased adhesion between the conductor and insulator reduces elongation of the insulators during sheath removal, ensuring uniform lengths and matching exposed dimensions with predetermined dimensions for effective distal end processing.
Implementation Method 1
multiple fine unevenness are formed on an outer peripheral surface of the conductor by constructing the conductor by assembling the plurality of stranded wires, each of which is formed by wholly stranding the plurality of wires, and by further wholly stranding the stranded wires. Accordingly, the insulator extruded to the periphery of the conductor bites into the unevenness of the surface of the conductor. Also, an area of contact between the conductor and the insulator which coats the periphery of the conductor increases. This increases an adhesion between the conductor and the insulator.
Data Source
AI summary
An object of the invention is to provide a cable capable of matching exposed dimensions of conductors with a predetermined dimension to perform good processing at the time of distal end processing. In a cable (10) in which a pair of insulated wires (1) each of which is formed by covering a conductor (4) with an insulator (5) is mutually stranded and a periphery of these stranded insulated wires (1) is covered with a sheath (6) made of an inner sheath (2) and an outer sheath (3), the conductor (4) is formed by assembling a plurality of stranded wires (4a) each of which is formed by wholly stranding a plurality of wires (4b), and by further wholly stranding the stranded wires (4a).