Flat Routing Material Edgewise Bending via Inner Folds
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Solution Overview
Problem
Existing methods for bending flat conductive materials with insulating coatings into an edgewise direction often result in coating deterioration, uneven thickness, and increased electrical resistance due to heat application, leading to decreased current application performance.
Innovation Solution
A routing material with a flat conductive material and insulating coating featuring folds on the inner peripheral side, formed through a multi-step mold pressing process that allows edgewise bending at predetermined angles without heating, maintaining uniform thickness and preventing coating deterioration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If heating is applied to the conductive material to improve workability and prevent cracks, then bending to an edgewise direction becomes feasible, but the insulating coating deteriorates or tears
Solution Approach 1:
The patent changes the temperature parameter from heated state (100-250°C) to normal temperature, eliminating thermal damage to the insulating coating while achieving edgewise bending through a different mechanism (folds on inner peripheral side) that doesn't require heat activation
2Reliability
If edgewise bending is performed without heating, then the insulating coating is protected from deterioration, but the outer peripheral side thickness becomes smaller than the inner peripheral side thickness
Solution Approach 1:
The patent changes the bending mechanism from direct edgewise bending (causing thickness variation) to bending with folds on the inner peripheral side, which redistributes the deformation and maintains more uniform thickness across the conductive material cross-section
Solution Approach 2:
The patent applies local folds specifically on the inner peripheral side of the bent portion, concentrating the deformation in a localized region to protect the outer peripheral side thickness and maintain overall uniformity
3Ease of operation
If the conductive material thickness becomes uneven due to edgewise bending, then the outer peripheral side thickness decreases, but electrical resistance increases and current application performance decreases
Solution Approach 1:
The patent changes the bending approach from direct edgewise bending to bending with folds on the inner peripheral side, which maintains more uniform thickness distribution and prevents the thinning-induced resistance increase on the outer peripheral side
Solution Approach 2:
The patent introduces localized folds on the inner peripheral side to manage deformation locally, preventing the propagation of thickness reduction to the outer peripheral side and maintaining electrical performance
Data Source
AI summary
A flat routing material includes a flat conductive material and an insulating coating covering the conductive material. The routing material includes a bent portion as a part bending in an edgewise direction at a predetermined angle or more, and one or more folds extending toward the outer peripheral side of the bent portion are provided on at least the inner peripheral side of the bent portion. The folds are manufactured by press working.