Flat Cable Coextrusion with Binder for Layer Cohesion
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Solution Overview
Problem
Current methods for manufacturing flat electric cables require multiple sequential steps and rely on semi-finished products, making it difficult to achieve the stringent quality standards, particularly in the automotive industry, for mechanical resistance, dielectric strength, and other performance criteria.
Innovation Solution
A continuous manufacturing process involving coextrusion of synthetic materials with a binder to reinforce cohesive forces between layers, using materials like polyamides and polyolefins, and incorporating flame retardants, allowing for a solvent-free process and improved mechanical and dielectric performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple sequential manufacturing steps are used with semi-finished products, then manufacturing precision and quality can be maintained, but productivity is reduced and device complexity increases
Solution Approach 1:
The patent combines multiple sequential manufacturing steps (extrusion of conductors, application of insulating layers, lamination, and protective coating) into a single continuous extrusion process. The coextrusion die produces all layers simultaneously in one operation, eliminating the need for separate sequential steps and semi-finished products, thereby increasing productivity while maintaining manufacturing precision through integrated process control
Solution Approach 2:
The invention implements a continuous manufacturing process where conductors and insulating layers are produced without interruption. The continuous extrusion through a specially designed die creates all cable layers in one continuous operation, eliminating stopping and starting between steps, which improves productivity while ensuring consistent quality through uninterrupted process flow
2Manufacturing precision
If multiple sequential manufacturing steps are used, then manufacturing precision can be maintained, but device complexity increases
Solution Approach 1:
The patent merges multiple manufacturing functions into a single integrated extrusion system. The coextrusion die combines conductor formation, insulating layer application, and protective coating in one device, reducing the number of separate machines and process steps while maintaining manufacturing precision through unified process control
Solution Approach 2:
The continuous extrusion device performs multiple functions simultaneously: it forms conductors, applies insulating layers, creates protective coatings, and integrates lamination all in one operation. This multi-functional approach reduces device complexity compared to having separate specialized equipment for each manufacturing step while maintaining high manufacturing precision
3Ease of manufacture
If conventional extrusion and lamination methods are used, then ease of manufacture is maintained, but mechanical strength and dielectric performance are insufficient
Solution Approach 1:
The patent uses composite material structures with multiple layers having different properties: conductive layers for electrical function, insulating layers for dielectric performance, and protective layers for mechanical strength. The coextrusion process creates a bonded composite structure where layers are integrated at molecular level, providing superior mechanical strength and dielectric performance compared to conventional methods while maintaining ease of manufacture through a single continuous process
4Ease of manufacture
If conventional extrusion and lamination methods are used, then ease of manufacture is maintained, but dielectric strength is insufficient
Solution Approach 1:
The patent employs composite material structures with dedicated insulating layers positioned between conductors and protective layers. The coextrusion process ensures proper layer positioning and bonding, creating a composite structure with optimized dielectric strength while maintaining manufacturing simplicity through a single continuous operation
Solution Approach 2:
The invention applies different material properties to different regions of the cable cross-section: conductive materials where electrical conduction is needed, insulating materials between conductors for dielectric strength, and protective materials on the exterior for mechanical protection. This local optimization of material properties achieves superior dielectric strength while maintaining ease of manufacture through the integrated coextrusion process
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
Enables the production of high-quality flat cables with enhanced mechanical and dielectric properties, meeting stringent industry standards while eliminating the need for solvent-based processes and allowing for automation of the wiring process.
Implementation Method 1
a binder is interposed between said first and second layers during the coextrusion. This binder is chosen to reinforce the cohesive forces between these two layers
Implementation Method 2
the assembly is then subjected to a rolling operation
Data Source
Figure 1~3
Figure 4~6
AI summary
The method involves extruding a protector film having layer with synthetic material (20) e.g. polyamide, and another layer with a synthetic material (21) e.g. polyolefin, where materials are chosen for mechanical resistance and dielectric performance of respective layers. Two bands of a film are laminated against each other and parallel conductors (11) are arranged between the bands. A binder (22) is interposed between the layers during extrusion for cohesion of the layers.