Tape-Like Cable Cross-Web for Longer Spools and Less Space
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Solution Overview
Problem
Existing cross-webs for cable manufacturing are labor-intensive and expensive, with high spatial requirements that lead to increased storage, handling, and shipping costs, as well as frequent interruptions in cable manufacturing due to depleted spool sizes.
Innovation Solution
Development of a cross-web with a pliable dielectric polymeric material having an elongated 'H' or flattened 'X' cross-section and a tape-like appearance, featuring a high aspect ratio, which can be produced through extrusion or polymer fusion, allowing for minimal spatial requirements and efficient cable production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional cross-web designs with low aspect ratios are used, then ease of manufacture is improved, but spatial requirements increase leading to higher storage and handling costs
Solution Approach 1:
The patent applies parameter changes by fundamentally altering the aspect ratio parameter of the cross-web from traditional low values to at least 5:1, and preferably at least 10:1. This parameter transformation maintains manufacturability through extrusion processes while dramatically reducing the spatial volume occupied by the cross-web, thereby resolving the contradiction between ease of manufacture and spatial requirements
Solution Approach 2:
The invention employs dimensionality change by transitioning from conventional cross-web geometries to an elongated tape-like structure with high aspect ratio. This dimensional reconfiguration compresses the cross-web profile along its length, reducing the dimensions perpendicular to the longitudinal axis while maintaining functional integrity, thus achieving reduced spatial requirements without sacrificing manufacturability
2Ease of operation
If traditional spool sizes are used, then handling is simplified, but manufacturing interruptions increase due to frequent spool changes
Solution Approach 1:
The patent implements continuity of useful action by enabling significantly longer spool lengths through the reduced spatial requirements of high aspect ratio cross-webs. This allows the extrusion process to continue for extended periods without interruption, eliminating frequent spool changes and maintaining continuous manufacturing operation, thereby resolving the contradiction between ease of handling and manufacturing productivity
3Adaptability or versatility
If multi-step lamination processes are used, then cross-web construction versatility is improved, but manufacturing cost and time increase
Solution Approach 1:
The patent applies parameter changes by modifying the fundamental geometric parameters of the cross-web to achieve high aspect ratio tape-like structures through single-step extrusion. This parameter transformation provides construction versatility through geometric flexibility while eliminating the need for multi-step lamination processes, thereby reducing manufacturing cost and time
Solution Approach 2:
The invention extracts and eliminates the multi-step lamination process from the manufacturing sequence by achieving cross-web construction versatility through single-step extrusion of high aspect ratio structures. This extraction removes the complex, time-consuming, and costly lamination steps while retaining the ability to produce versatile cross-web configurations
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 new cross-web design reduces storage, handling, and transportation costs while minimizing interruptions in cable manufacturing by allowing for longer spool lengths and more efficient use of space, thus enhancing manufacturing efficiency and reducing material changeouts.
Implementation Method 1
The new cross-web design reduces storage, handling, and transportation costs while minimizing interruptions in cable manufacturing by allowing for longer spool lengths and more efficient use of space, thus enhancing manufacturing efficiency and reducing material changeouts.
Data Source
AI summary
Cross-web for use in cable manufacture having a tape-like appearance in their relaxed state and their method of manufacture.