Cable Insulation Segmentation for Grinding Oil Resistance
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Solution Overview
Problem
Electronic devices exposed to water-soluble grinding oil face challenges as existing materials, such as polyvinyl chloride resin outer coats, are not highly resistant, leading to potential liquid ingress and insulation resistance degradation.
Innovation Solution
The electronic device incorporates a fluorine-based resin insulating portion with a polyamide-based first sealing portion and a polybutylene terephthalate resin second sealing portion, providing enhanced resistance to water-soluble grinding oil and adherence, thereby preventing liquid ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a polyvinyl chloride resin outer coat is used, then cost is reduced, but resistance to water-soluble grinding oil deteriorates
Solution Approach 1:
The cable structure is divided into multiple layers with different functions: the outer coat (PVC resin) provides cost-effectiveness and basic protection, while the insulating portion (fluorine-based resin) provides oil resistance. This segmentation allows each material to optimize its specific function without requiring the entire cable to use expensive fluorine-based resin throughout.
Solution Approach 2:
The fluorine-based resin insulating portion is strategically positioned where oil resistance is most critical (around the lead wire), while the PVC outer coat covers areas where cost-effectiveness is prioritized. This local quality assignment ensures oil resistance at the critical interface while maintaining overall cost efficiency.
2Ease of manufacture
If a polyvinyl chloride resin outer coat is used, then cost is reduced, but liquid ingress prevention capability deteriorates
Solution Approach 1:
The protective structure is segmented into the outer coat for basic environmental protection and the insulating portion for specialized oil and liquid ingress prevention. This segmentation allows the fluorine-based resin to specifically address liquid ingress at the cable entry point while the PVC outer coat provides general protection.
Solution Approach 2:
The insulating portion acts as an intermediary barrier between the water-soluble grinding oil and the lead wire. Even if the outer coat is permeable to some extent, the fluorine-based resin insulating portion provides an additional protective layer that prevents liquid ingress to the critical electrical components.
3Device complexity
If adherence between lead wire and jacket is not considered, then manufacturing complexity is reduced, but insulation resistance deteriorates
Solution Approach 1:
The cable uses a composite structure with the fluorine-based resin insulating portion that inherently adheres to the lead wire. This composite design ensures good electrical insulation and mechanical adhesion without requiring complex additional coating processes, maintaining manufacturing simplicity while ensuring reliability.
Data Source
Figure 1A~1B
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AI summary
Provided is an electronic device that is highly resistant to a water-soluble grinding oil and a method for manufacturing the same. An electronic device includes a main body and a cable including a lead wire, an insulating portion, and an outer coat, a first sealing portion that covers the insulating portion, and a second sealing portion that seals the first sealing portion, the insulating portion is made of a material that is more resistant to a water-soluble grinding oil than the outer coat is, and the first sealing portion is made of a material that has higher adherence to the insulating portion than that of the second sealing portion does.