Automated Cable Sheathing with UV-Cured Acrylate Dispensing
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Solution Overview
Problem
Current methods for producing cable sheathings in automobiles face challenges such as manual wrapping complexity, strength issues due to low binder proportion in fiber braiding, and uneven coloring, which affect flexibility and identification requirements like high-voltage cable marking.
Innovation Solution
A device using a manipulator and nozzle for additive manufacturing with a grafted acrylate polymer-based liquid plastic material, which is crosslinked using UV radiation, allowing for homogeneous and flexible sheathing with easy color addition, ensuring more than 50% of the polymer is radiation-crosslinkable acrylate-based, with optional photoinitiators, fillers, and dyes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If adhesive tapes are wrapped manually around cables to produce cable bundles, then the sheathing can be applied to various cable configurations, but the production process is time-consuming and cannot be automated
Solution Approach 1:
The patent replaces the manual mechanical wrapping process with an automated dispensing system that applies liquid plastic material around cable bundles. The system uses a dispensing head controlled by a control unit to automatically apply material in spiral patterns, eliminating manual labor while maintaining adaptability to different cable configurations through programmable motion control.
Solution Approach 2:
The invention changes the state of the sheathing material from solid adhesive tape to liquid plastic material that can be dispensed and then cured. This parameter change enables automated application while allowing the material to conform to various cable bundle shapes and sizes, resolving the contradiction between automation and adaptability.
2Strength
If a suspension with fibers and binder is used to create textile-like fiber braid, then the sheathing provides mechanical protection, but the binder proportion must be kept low which results in strength problems
Solution Approach 1:
The patent uses composite materials consisting of reinforcing fibers embedded in a plastic matrix material. This composite structure provides both mechanical protection and structural integrity without requiring high binder proportions, as the plastic matrix itself provides the binding function while the fibers provide reinforcement.
Solution Approach 2:
The invention changes from a fiber braid structure with binder to a plastic matrix composite structure. This parameter change allows for better strength properties while simplifying the overall structure, as the plastic material provides both the binding and protective functions in a unified composite system.
3Reliability
If the sheathing is applied flush against the cables, then the coverage is complete, but problems arise in bending areas of the cable harness
Solution Approach 1:
The patent employs flexible plastic material that can be applied as a thin film or layer around the cable bundle. This flexible material maintains complete coverage while accommodating bends and flexing of the cable harness, resolving the contradiction between coverage and flexibility.
Solution Approach 2:
The invention creates a dynamic sheathing system where the plastic material can deform and flex with the cable bundle during installation and use. The material's flexibility allows it to maintain coverage completeness while adapting to bending areas, eliminating the rigid flush application problem.
4Ease of manufacture
If color pigments are added to the plastic material for cable identification, then high-voltage cables can be marked, but the suspension method leads to weakening or uneven distribution of pigments
Solution Approach 1:
The patent changes from using fiber-based suspension with pre-colored fibers to a liquid plastic material system where color pigments are directly mixed into the plastic compound. This parameter change enables uniform pigment distribution and consistent coloring, achieving both ease of manufacture and manufacturing precision in the coloring process.
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
Enables the production of flexible, machine-rollable cable harnesses with consistent layer thickness and color homogeneity, addressing strength and identification needs, and allowing for efficient, automated production without manual winding.
Implementation Method 1
a grafted acrylate polymer as its main component... which is crosslinked using UV radiation
Data Source
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AI summary
The invention relates to a device for manufacturing a sheath (1) for electrical cables (2), in particular a sheath (1) for cables (2) in automobiles, comprising at least one manipulator (9) and a nozzle (10) connected to the manipulator (9) for dispensing a curable liquid plastic material in the course of a generative manufacturing method. The plastic material comprises a radiation-crosslinkable, acrylate-based polymer as the main constituent.