Polymer Cable Insulation Cooling to Prevent Twisting Deformation
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Solution Overview
Problem
Existing methods for manufacturing wire and cable products face challenges in reducing deformation and compression forces during manufacturing processes, leading to increased capacitance, reduced signal integrity, and higher costs due to the need for additional insulation to compensate for deformations.
Innovation Solution
The method involves temporarily altering the hardness of polymer insulation layers by exposing them to chilled fluids, such as cryogenic liquids, to increase the Young's modulus and reduce deformation during manufacturing processes like twisting and braiding, thereby maintaining conductor spacing and improving electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the manufacturing line speed is reduced to alleviate compression forces, then deformation of polymer components is reduced, but productivity decreases
Solution Approach 1:
The patent changes the temperature parameter of the polymer insulation layer to alter its hardness. By cooling the polymer below its glass transition temperature, the material becomes harder and more resistant to compression forces during manufacturing, allowing high-speed production without deformation
Solution Approach 2:
The patent applies preliminary cooling to the polymer insulation layer before the compression forces are applied during manufacturing processes. This preliminary hardening prevents deformation before it can occur, rather than attempting to correct it afterward
2Manufacturing precision
If additional insulation material is added to compensate for compression deformation, then conductor spacing is maintained, but cable size and cost increase
Solution Approach 1:
The patent changes the temperature parameter of the polymer insulation layer to alter its hardness. By cooling the polymer below its glass transition temperature, the material becomes harder and more resistant to compression forces during manufacturing, allowing high-speed production without deformation
Solution Approach 2:
The patent applies preliminary cooling to the polymer insulation layer before the compression forces are applied during manufacturing processes. This preliminary hardening prevents deformation before it can occur, rather than attempting to correct it afterward
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
This approach reduces deformation, maintains conductor spacing, and allows for faster manufacturing speeds while minimizing the need for additional insulation, thus improving electrical performance and reducing production costs.
Implementation Method 1
temporarily altering the hardness of polymer insulation layers by exposing them to chilled fluids, such as cryogenic liquids
Implementation Method 2
exposing them to chilled fluids, such as cryogenic liquids, to increase the Young's modulus and reduce deformation
Data Source
AI summary
A system and method for manufacturing wire and cable products with a polymer cable component is provided. The systems and methods include increasing the hardness of a polymer cable component in order to reduce compression and deformation of the cable components during manufacturing. In some instances, the hardness is temporarily increased prior to or during the process of creating twisted pair or during the cabling process.