Class 5 Insulated Conductor Polygonal Preforming
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Solution Overview
Problem
The existing method for manufacturing insulated electrical conductors with a polygonal cross-section requires an additional step to maintain the shape before applying the insulating sheath, making it complex and time-consuming.
Innovation Solution
A method that forms a subassembly of class 5 conductor wires, preforms it into a polygonal cross-section, and then surrounds it with an insulating sheath without the need for maintaining the shape, simplifying the process by eliminating the extra step.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If an additional step is added to maintain the polygonal shape before applying the insulating sheath, then the shape stability is improved, but the manufacturing complexity increases
Solution Approach 1:
The invention extracts and eliminates the unnecessary intermediate step of maintaining the polygonal shape before applying the insulating sheath. By removing this redundant process step, the manufacturing complexity is reduced while the final shape stability is preserved through the direct extrusion process that forms both the conductor and insulating sheath in one operation.
Solution Approach 2:
The invention merges the preforming operation and the insulating sheath application into a single integrated process step. The polygonal shape is formed directly during the extrusion of the insulating sheath, combining what were previously separate operations (shape maintenance and sheath application) into one unified process, thereby reducing manufacturing complexity.
2Manufacturing precision
If an additional step is added to maintain the polygonal shape, then the manufacturing precision is improved, but the production time increases
Solution Approach 1:
The invention performs the polygonal shape formation as a preliminary action integrated into the extrusion process itself. The insulating sheath is extruded while simultaneously forming the conductor into its final polygonal shape, eliminating the need for subsequent shape maintenance steps and thereby improving production speed without sacrificing precision.
Solution Approach 2:
The invention skips the intermediate shape maintenance step entirely by rushing through the process directly from conductor formation to insulating sheath application. The polygonal shape is established and maintained in a single continuous operation, bypassing the time-consuming intermediate step while preserving manufacturing precision through controlled extrusion parameters.
3Stability of the object's composition
If the polygonal shape is maintained using specific tools, then the shape retention is improved, but the device complexity increases
Solution Approach 1:
The invention enables the conductor assembly to self-maintain its polygonal shape through the inherent properties of the extrusion process itself. The insulating sheath is extruded in a way that automatically forms and maintains the polygonal geometry without requiring external shaping tools or devices, allowing the system to serve itself and eliminate complex tooling requirements.
Solution Approach 2:
The invention changes the process parameters of the extrusion operation to directly produce the polygonal shape. By adjusting extrusion speed, temperature, and die geometry, the process parameters are optimized to form the conductor into a stable polygonal shape during sheath application, eliminating the need for additional shaping tools while maintaining shape retention.
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 allows for a more efficient and less restrictive method to produce insulated electrical conductors with a stable polygonal section, ensuring proper shape retention after preforming without additional tools, and reduces the number of manufacturing steps.
Implementation Method 1
an insulating sheath is extruded around the preformed electrical conductor
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention relates to a method for manufacturing an insulated electrical conductor (32,33) comprising the following steps: i. preforming an assembly (12,13) of class 5 conductive wires comprising a plurality of sub-assemblies (10,11) of such conductive wires, each of said sub-assemblies (10,11) comprising a plurality of class 5 conductive wires, to obtain a preformed assembly (22,23) with a polygonal cross-section, then ii. surrounding with contact said preformed assembly (22,23) with an insulating sheath (15), without a prior step of holding the preformed assembly with polygonal cross-section, to obtain the insulated electrical conductor (32,33).