Fiber-Reinforced Insulation Jacket for Electric Line Mechanical Load Transfer
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Solution Overview
Problem
Existing electrical signal lines, particularly in the motor vehicle industry, have oversized conductor cross-sections due to mechanical stability requirements, leading to inefficiencies in weight reduction and increased costs, despite only carrying low currents.
Innovation Solution
The use of a fiber-reinforced plastic insulation jacket with short fibers embedded in a plastic matrix surrounding a copper conductor, allowing for a reduced conductor cross-section while maintaining or improving mechanical load-bearing capacity, thereby transferring mechanical stress from the conductor to the insulation jacket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If the conductor cross-section is reduced to save weight and cost, then weight and material cost decrease, but mechanical stability and tensile strength deteriorate
Solution Approach 1:
The patent applies composite materials by embedding short fibers (glass, carbon, or organic fibers) into the plastic matrix of the insulating jacket, creating a fiber-reinforced composite structure. This composite insulation jacket provides enhanced tensile strength and mechanical stability, allowing the conductor cross-section to be reduced while maintaining overall line strength. The fibers carry a portion of the mechanical load, compensating for the reduced conductor size.
2Loss of substance
If the conductor cross-section is reduced, then material cost decreases, but mechanical load-bearing capacity deteriorates
Solution Approach 1:
The insulating jacket is formulated as a composite material containing short fibers dispersed in a plastic matrix. These fibers (such as glass fibers, carbon fibers, or organic fibers) significantly enhance the tensile strength and mechanical load-bearing capacity of the insulation layer. This allows the conductor cross-section to be minimized for electrical function only, while the composite insulation jacket assumes the mechanical load-bearing role.
3Weight of stationary object
If the insulation thickness is reduced in FLRY lines, then weight and diameter decrease, but mechanical stability deteriorates
Solution Approach 1:
The patent employs fiber-reinforced composite materials in the insulating jacket, where short fibers are embedded in a plastic matrix. This composite structure provides high tensile strength and mechanical stability even with reduced insulation thickness. The fibers distribute and bear mechanical stresses, maintaining the structural integrity and stability of the electrical line despite the reduced overall diameter and insulation thickness.
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 approach enables a significant reduction in conductor cross-section by up to a factor of 1.5 to 3, achieving improved mechanical stability and cost savings while maintaining electrical performance, with the fiber-reinforced insulation effectively absorbing tensile forces and ensuring the line can withstand specified tensile stresses without mechanical damage.
Implementation Method 1
the jacket consisting of a fiber-reinforced plastic and the plastic forming a matrix in which short fibers are embedded individually and distributed
Implementation Method 2
the fiber-reinforced insulation effectively absorbing tensile forces and ensuring the line can withstand specified tensile stresses without mechanical damage
Data Source
Figure 1~2
AI summary
The electric line (2) comprises an electrical conductor (4), and an insulation casing (8). The line is designed for a predetermined tensile stress, which is received partially on the insulation casing made of plastic. Milled fibers (10) are provided, which are aligned in the longitudinal direction of the line. An independent claim is also included for a method for laying an electric line.