Coaxial Wire Nested Tube Structure Simplifies Manufacturing
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Solution Overview
Problem
Conventional methods for manufacturing coaxial electric wires are complicated due to the need for managing molten resin temperature and extrusion speed, leading to complex and large-sized manufacturing apparatuses, especially when forming outer covers from various materials like braided wire or metal tape.
Innovation Solution
A coaxial electric wire design featuring an inner conductor, inner insulating layer, outer conductor, and outer insulating layer, where the insulating layers are made of cylindrical tubes and the outer conductor is a conductive tube, allowing for a simplified manufacturing process using a press-in apparatus without extrusion molding, and an optional flexible exterior member for increased flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If extrusion molding is used to form insulating layers and outer covers, then homogeneous and stable insulating layers can be formed, but the manufacturing apparatus becomes complicated and large-sized due to the need for managing molten resin temperature and extrusion speed
Solution Approach 1:
The invention changes the manufacturing parameters from extrusion molding (requiring temperature and speed control) to a press-in method using pre-formed tubular insulators. This parameter change eliminates the need for complex temperature and extrusion speed management while maintaining manufacturing precision through the use of pre-manufactured insulating tubes with controlled dimensions and properties.
Solution Approach 2:
The insulating layers are pre-formed as tubular insulators before the actual wire assembly process. This preliminary action allows the insulating layers to be manufactured separately with precise control over their properties, then simply inserted into the wire structure. This eliminates the need for complex real-time extrusion control during wire assembly, simplifying the manufacturing apparatus.
2Ease of manufacture
If conventional parallel arrangement of insulated core wires is used, then the electric wire can be manufactured with simple structure, but the electric wire becomes difficult to bend in directions perpendicular to the arranging direction, reducing wiring flexibility
Solution Approach 1:
The invention adopts a nested coaxial structure where the inner conductor is surrounded by an inner insulating layer, which is then surrounded by the outer conductor, and finally by the outer insulating layer. This nested arrangement allows the wire to bend freely in any direction while maintaining electrical insulation and structural integrity, significantly improving wiring flexibility compared to parallel wire arrangements.
3Weight of moving object
If two insulated core wires are arranged in parallel, then the electric wire can be light-weighted and environmentally friendly, but the diameter of the sheath becomes more than twice the diameter of the insulated core wire, generating useless space and requiring large wiring space
Solution Approach 1:
The coaxial nested structure allows the inner conductor and outer conductor to be arranged concentrically, utilizing the internal space efficiently. This eliminates the useless space between parallel wires and reduces the overall outer diameter of the cable to less than twice the diameter of a single core wire, thereby reducing wiring space requirements while maintaining the light-weight advantage.
Data Source
AI summary
A coaxial electric wire with an inner conductor, an inner insulating layer covering a periphery of the inner conductor, an outer conductor covering a periphery of the inner insulating layer, and an outer insulating layer covering a periphery of the outer conductor, where the inner insulating layer is made of a first insulating tube having an elongated cylindrical shape and an insulation performance, the outer insulating layer is made of a second insulating tube having an elongated cylindrical shape and an insulation performance, the outer conductor is made of a conductive tube having an elongated cylindrical shape and conductivity, the coaxial electric wire is manufactured by inserting the inner conductor into the first insulating tube, inserting the first insulating tube into the conductive tube, and inserting the conductive tube into the second insulating tube.