Dual-Layer Insulated Wire With Modulus Gradient
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electric wires with single-layer insulations lack superior abrasion and flex resistance, making them inadequate for applications requiring high durability and ease of wiring in confined spaces.
Innovation Solution
A coated wire design featuring a dual-layer insulating system where the inner layer has a storage modulus of less than 700 MPa at 25°C and the outer layer has a storage modulus of not less than 700 MPa, made from specific polyethylene-based materials, and a multicore cable structure with twisted coated wires and a sheath for enhanced abrasion resistance and ease of wiring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single-layer insulating coating is used, then the device complexity is reduced, but the abrasion resistance and flex resistance are insufficient
Solution Approach 1:
The insulating layer is segmented into two distinct layers: an inner layer with storage modulus of 300-700 MPa providing flexibility and abrasion resistance, and an outer layer with storage modulus of 700-1500 MPa providing rigidity and protection. This segmentation allows each layer to perform its specific function optimally, resolving the contradiction between simplicity and performance.
Solution Approach 2:
The patent uses composite material structure with two layers of different resin materials having different storage moduli. The inner layer uses a softer material (300-700 MPa) while the outer layer uses a harder material (700-1500 MPa), creating a composite structure that combines both flexibility and rigidity, thereby achieving superior abrasion and flex resistance without excessive complexity.
2Reliability
If the insulating layer is made rigid to improve abrasion resistance, then the abrasion resistance improves, but the flexibility and ease of wiring in confined spaces deteriorates
Solution Approach 1:
Different regions of the insulating layer have different mechanical properties: the inner layer has lower storage modulus (300-700 MPa) for flexibility and abrasion resistance, while the outer layer has higher storage modulus (700-1500 MPa) for rigidity and abrasion resistance. This local differentiation of material properties allows the wire to be flexible where needed while maintaining abrasion resistance overall.
Solution Approach 2:
The patent changes the storage modulus parameter across different layers: the inner layer maintains storage modulus of 300-700 MPa for flexibility, while the outer layer has storage modulus of 700-1500 MPa for rigidity. This parameter gradient allows the insulating system to provide both flexibility for wiring in confined spaces and abrasion resistance for durability.
Data Source
AI summary
A coated wire according to the present disclosure includes a first conductor and a first insulating layer of resin covering the first conductor. The first insulating layer includes an inner layer and an outer layer. Further, a storage modulus of the inner layer at a temperature of 25° C. is less than 700 MPa, and a storage modulus of the outer layer at a temperature of 25° C. is not less than 700 MPa.