Core Wire Set Layout for Heat-Shielded Drain Wire Welding

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Solution Overview

Problem

The manufacturing of miniaturized and highly integrated transmission connectors and cables is challenging due to the increased risk of damaging core wires during welding, particularly when using bare metal wires as drain wires, which can cause insulation layer damage and welding failures.

Innovation Solution

A core wire set design that includes a first and second core wire, a first and second covering layer, and a bare metal wire arranged in a triangular configuration within a wire placement space between the covering layers, preventing direct heat transfer to the core wires during welding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Volume of moving object

If the wire diameter is reduced for miniaturization, then the overall cable diameter and hardness are improved, but the manufacturing precision and welding reliability deteriorate due to increased risk of insulation layer damage

Engineering Contradiction:

Improvecable diameterVSAvoidwelding precision

Core Design Contradiction:

Volume of moving objectVSManufacturing precision

Solution Approach 1:

The patent introduces a heat-insulating covering layer as an intermediary between the core wires and the bare metal drain wire. This covering layer acts as a thermal barrier that prevents excessive heat from the drain wire during welding from damaging the insulation layer of the core wires, thereby enabling miniaturization while maintaining welding reliability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent applies heat-insulating covering layers to the core wires before the welding process. This pre-protection measure ensures that when welding occurs, the insulation layer is already shielded from potential heat damage, allowing for reduced wire diameters without compromising manufacturing precision.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Strength

If the welding temperature is increased to ensure proper welding, then the welding strength is improved, but the insulation layer of core wires is damaged or burned through by heat from the bare metal drain wire

Engineering Contradiction:

Improvewelding strengthVSAvoidheat damage to insulation layer

Core Design Contradiction:

StrengthVSObject-affected harmful factors

Solution Approach 1:

The heat-insulating covering layer serves as a protective intermediary that blocks harmful thermal energy from reaching the insulation layer during high-temperature welding, allowing adequate welding strength to be achieved without damaging the insulation.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent converts the potentially harmful heat generated during welding into a beneficial process by using heat-insulating materials that selectively block heat transfer to the insulation layer while allowing the welding process to proceed effectively at the connection points.

Inventive Principle:

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

3Reliability

If high-precision welding equipment is used to control welding parameters, then the welding reliability is improved, but the device complexity and manufacturing cost increase

Engineering Contradiction:

Improvewelding reliabilityVSAvoidwelding equipment complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The core wires equip themselves with heat-insulating covering layers that provide automatic protection during welding. This self-protecting mechanism eliminates the need for complex welding equipment with precise parameter control, as the covering layers inherently prevent heat damage regardless of welding temperature fluctuations.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The patent transforms the unavoidable heat generated during welding from a harmful factor into a manageable process by using simple heat-insulating covering layers, thereby achieving reliable welding with basic equipment rather than requiring complex high-precision welding systems.

Inventive Principle:

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

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 design reduces the risk of insulation layer damage and welding failures, allowing for the use of universal or low-level welding equipment even with reduced wire diameters, thereby simplifying the welding process and reducing equipment requirements.

Implementation Method 1

the first core wire and the second core wire are respectively covered with a first covering layer and a second covering layer, and the bare metal wire is arranged in a wire placement space between the first covering layer and the second covering layer

Methodology Applied

Scientific EffectThermal insulation: Thermal Insulation

Data Source

PatentUS20250079044A1Core wire set and transmission cable thereof

Publication Date: 2025.03.06 ELKA INT

AI summary

A core wire set comprising a first core wire, a second core wire arranged in parallel to the first core wire, a first covering layer covering the first core wire and the second core wire, a second covering layer, and a bare metal wire is provided. Wherein the second covering layer covers the first covering layer and a wire placement space is formed between the first covering layer and the second covering layer. Wherein the bare metal wire is arranged in the wire placement space.