Composite Cable Separator Adhesive Layer Dust Control

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Solution Overview

Problem

Conventional composite cables face issues with dust from thin paper separators scattering during sheath peeling, leading to poor peeling workability and dust contamination.

Innovation Solution

A composite cable design featuring a polymer-based separator with an adhesive layer on one side, interposed between the wires and sheath, which adheres to the inclusion, facilitating uniform peeling and reducing dust fallout.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a thin paper separator is used to prevent adhesion between sheath and wires, then adhesion prevention is achieved, but separator dust scatters during peeling

Engineering Contradiction:

Improveadhesion preventionVSAvoidseparator dust scattering

Core Design Contradiction:

ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The separator is constructed as a composite material consisting of a base layer (polymer or paper) and an adhesive layer. This composite structure allows the separator to maintain its adhesion prevention function while the adhesive layer binds the separator to the inclusion during peeling, preventing dust scattering.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The adhesive layer acts as an intermediary between the separator and the inclusion. It creates a bonding interface that ensures the separator is removed together with the inclusion, preventing dust scattering while maintaining the separator's primary function of preventing adhesion between the sheath and wires.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Ease of operation

If a blade is used to peel off the sheath, then sheath removal is achieved, but peeling workability is poor due to dust scattering

Engineering Contradiction:

Improvesheath peelingVSAvoidpeeling workability

Core Design Contradiction:

Ease of operationVSProductivity

Solution Approach 1:

The adhesive layer serves as a mediator that bonds the separator to the inclusion. This ensures that during blade peeling, the separator is carried away with the inclusion rather than scattering as dust, thereby improving peeling workability and productivity.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The adhesive layer converts the potential harm of dust scattering into a benefit by ensuring the separator is firmly attached to the inclusion. This causes the separator to be removed as a unified structure with the inclusion, turning what would be scattered dust into a controlled removal process.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Adaptability or versatility

If the separator is made of thin paper, then flexibility is achieved, but dust fallout increases during peeling

Engineering Contradiction:

Improveseparator flexibilityVSAvoiddust fallout

Core Design Contradiction:

Adaptability or versatilityVSObject-generated harmful factors

Solution Approach 1:

The separator is designed as a composite material with a base layer (which can be thin paper for flexibility) and an adhesive layer. This composite structure maintains the flexibility needed for cable assembly while the adhesive layer prevents dust fallout by bonding the separator to the inclusion during peeling.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

Different layers of the separator have different properties: the base layer provides flexibility and adhesion prevention, while the adhesive layer provides dust prevention. This local differentiation of material properties allows the separator to simultaneously achieve flexibility and prevent dust fallout.

Inventive Principle:

Principle #3Local quality

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

The design enhances peeling workability, prevents separator dust from scattering, and allows for easier removal of the separator and sheath together, improving operational efficiency and reducing contamination.

Implementation Method 1

the adhesive layer adheres to the inclusion

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS11515063B2Composite cable

Publication Date: 2022.11.29 SUMITOMO WIRING SYSTEMS LTD

AI summary

A composite cable that enables to easily restrain falling-off of separator dust at the time of peeling off a sheath, in comparison with composite cables in the conventional art. The composite cable includes a plurality of wires, a separator that covers the outer circumference of the plurality of wires all together, a sheath that covers the outer circumference of the separator, and an inclusion that is interposed between the separator and the sheath. The separator has a base layer composed of a polymer and an adhesive layer formed on the surface of the base layer on the inclusion side. In the composite cable, the adhesive layer is adhered to the inclusion.