Electric Wire with Optimized Insulation Hardness for Low-Temperature Bending
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Solution Overview
Problem
Thicker electric wires/cables are rigid and difficult to bend, leading to potential damage and performance deterioration, especially in narrow spaces and low-temperature environments, where they may crack or break when bent.
Innovation Solution
An electric wire with a conductor cross-sectional area between 225 mm² and 275 mm², featuring a conductor with strands of oxygen-free copper, a specific insulation and sheath configuration using chlorinated polyethylene and polyolefin resins, and a Shore A hardness of not more than 88, allowing for improved flexibility and low-temperature bending properties without cracking or breaking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the wire thickness is increased, then the strength and load-bearing capacity are improved, but the flexibility and ease of bending deteriorate
Solution Approach 1:
The patent applies parameter changes by precisely controlling the conductor cross-sectional area within 225-275 mm² and the Shore A hardness of the insulation and sheath at not more than 88. This optimization balances the strength provided by thicker construction with the flexibility needed for easy installation and bending without damage.
2Strength
If the wire thickness is increased, then the strength is improved, but the ease of installation in narrow spaces deteriorates
Solution Approach 1:
The patent optimizes the wire dimensions and material properties by controlling the cross-sectional area (225-275 mm²) and Shore A hardness (≤88), enabling the wire to maintain sufficient strength while achieving the flexibility required for installation in narrow spaces and around bends.
3Ease of operation
If the wire is bent extremely, then the routing flexibility is improved, but the reliability and performance deteriorate due to damage at bent portions
Solution Approach 1:
The patent controls the Shore A hardness of the insulation and sheath to not more than 88, which allows the wire to be bent to a diameter of three times its own diameter without causing cracks or breaks, thereby maintaining both routing flexibility and long-term reliability.
4Adaptability or versatility
If the temperature of use environment is lowered, then the operational range is expanded, but the flexibility and bending properties deteriorate
Solution Approach 1:
The patent specifies that the wire must maintain the ability to bend to a diameter of three times its diameter without cracks or breaks at -40°C. This is achieved by controlling the material properties, particularly the Shore A hardness of the insulation and sheath, to ensure flexibility is preserved across a wide temperature range from -40°C to +80°C.
Data Source
AI summary
An electric wire includes a conductor having a cross-sectional area of not less than 225 mm2 and not more than 275 mm2, an insulation provided so as to cover the outer periphery of the conductor, and a wire sheath provided so as to cover the outer periphery of the insulation. The amount of deflection is not less than 130 mm when, at 23° C., one end of the electric wire is fixed to a fixture table so that another end horizontally protrudes 400 mm from the fixture table and a weight of 2 kg is attached to the other end, and cracks and breaks do not occur when wound with a bending diameter of three times the diameter at −40° C.