Insulated Cable Inner Sheath Elastic Modulus Control
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Solution Overview
Problem
Insulated electrical cables used in vehicle systems, such as EPB and WSS cables, face challenges in maintaining flex resistance at low temperatures, leading to potential breakage and deterioration due to repeated flexure, especially in environments ranging from -40°C to 120°C.
Innovation Solution
The insulated electrical cable design features a core wire with an insulating layer, an inner sheath layer with an elastic modulus of 10 MPa to 1000 MPa at -30°C, and an outer sheath layer, which enhances flex resistance at low temperatures without compromising routing flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the inner sheath layer is made of polyethylene resin to save cost, then manufacturing cost is reduced, but flex resistance at low temperatures deteriorates
Solution Approach 1:
The patent applies parameter changes by precisely controlling the elastic modulus of the inner sheath layer at -30°C to be within 10 MPa to 1000 MPa. This parameter control allows the use of cost-effective polyethylene resin while ensuring the material maintains appropriate flexibility at low temperatures, thereby improving flex resistance without significantly increasing manufacturing cost.
Solution Approach 2:
The patent employs composite materials by combining polyethylene resin for the inner sheath layer with polyurethane resin for the outer sheath layer. Each layer serves a specific function: the inner polyethylene layer provides cost efficiency and controlled flexibility when its elastic modulus is properly managed, while the outer polyurethane layer provides superior scratch resistance and environmental durability. This composite structure resolves the contradiction between cost and low-temperature flex resistance.
2Reliability
If the outer sheath layer is made of polyurethane resin, then resistance to scratch and flexibility are improved, but manufacturing cost increases
Solution Approach 1:
The patent applies local quality by assigning different material properties to different layers of the cable structure. The outer sheath layer uses polyurethane resin specifically where scratch resistance and flexibility are most needed (the outer surface exposed to environmental conditions), while the inner sheath layer uses the more cost-effective polyethylene resin. This localized material selection optimizes performance where required while controlling overall manufacturing cost.
3Ease of operation
If the inner sheath layer has low elastic modulus at low temperature, then routing flexibility is improved, but flex resistance deteriorates
Solution Approach 1:
The patent resolves this contradiction through precise parameter control by setting the elastic modulus of the inner sheath layer within the specific range of 10 MPa to 1000 MPa at -30°C. This controlled elastic modulus ensures the material remains flexible enough for routing while maintaining sufficient structural integrity to resist flex-induced breakage and deterioration, thereby simultaneously achieving both routing flexibility and flex resistance.
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 cable exhibits excellent flex resistance at temperatures from -40°C to 0°C, ensuring reliable performance in vehicle applications by maintaining structural integrity and flexibility.
Implementation Method 1
The inner sheath layer has an elastic modulus A at −30° C. in a range from 10 MPa to 1000 MPa
Data Source
AI summary
Provided is an insulated electrical cable including: a core wire made up of at least one insulated wire including a conductor and an insulating layer covering the conductor; an inner sheath layer covering the core wire; and an outer sheath layer covering the inner sheath layer. The inner sheath layer has an elastic modulus A at −30° C. in a range from 10 MPa to 1000 MPa.