Flat Electric Wire Structure to Suppress Conductor Parallel Collapse
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Solution Overview
Problem
Existing flat electric wires experience conductor parallel collapse during edgewise bending due to uneven conductor sizes, leading to increased thickness, width, and deteriorated stripping properties.
Innovation Solution
A flat electric wire design featuring conductors with the same cross-sectional area, resin films with a Young's modulus of 2 GPa or more and a thickness of 200 μm or more, and an insulator covering the conductors and resin films, which suppresses conductor parallel collapse by providing adequate hardness and thickness to counteract shifting forces.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If conductors of different sizes are used to suppress conductor parallel collapse, then conductor parallel collapse is suppressed, but the flat electric wire thickness and width increase
Solution Approach 1:
The patent changes the physical parameters of the resin film, specifically setting the Young's modulus to 0.01 MPa or higher and the film thickness to 10 μm or more. This parameter optimization allows the resin film to provide sufficient mechanical support to prevent conductor parallel collapse while maintaining a compact overall structure with controlled thickness and width
Solution Approach 2:
The patent creates a composite structure by combining conductors with a resin film having specific mechanical properties. The resin film acts as a supporting layer that provides the necessary rigidity to prevent conductor collapse during edgewise bending, while the composite design ensures the overall dimensions remain controlled
2Stability of the object's composition
If conductors of different sizes are used to suppress conductor parallel collapse, then conductor parallel collapse is suppressed, but stripping property deteriorates
Solution Approach 1:
The patent optimizes the resin film parameters (Young's modulus ≥ 0.01 MPa, thickness ≥ 10 μm) to provide adequate mechanical support for preventing conductor collapse while maintaining uniform conductor dimensions. This uniformity preserves the stripping property, allowing terminal connections to be made easily without the complications arising from varying conductor sizes
3Stability of the object's composition
If resin film with higher Young's modulus and thickness is used, then conductor parallel collapse is suppressed, but flexibility deteriorates
Solution Approach 1:
The patent carefully balances the resin film parameters by setting the Young's modulus to 0.01 MPa or higher and thickness to 10 μm or more. This optimized parameter range provides sufficient stiffness to prevent conductor parallel collapse during edgewise bending while maintaining appropriate flexibility for practical wire handling and installation
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
The solution effectively prevents conductor parallel collapse, maintains stripping property integrity, and avoids size increases, while ensuring appropriate flexibility and adhesion to prevent excessive resin film-related issues.
Implementation Method 1
Each of the resin films have a Young's modulus of 2 GPa or more and a film thickness of 200 μm or more
Implementation Method 2
forming the insulator by thermally shrinking an insulating heat shrinkable tube disposed around the plurality of conductors on which the resin films are arranged
Implementation Method 3
forming the insulator by extrusion coating an insulating resin softened by heating
Data Source
AI summary
The present disclosure relates to a flat electric wire and a method for manufacturing a flat electric wire. The flat electric wire includes a plurality of conductors arranged in parallel in a width direction and having substantially a same cross-sectional area with each other, resin films provided on one side and the other side of the plurality of conductors in a thickness direction orthogonal to the width direction, and an insulator covering the plurality of conductors together with the resin films. Each of the resin films have a Young's modulus of 2 GPa or more and a film thickness of 200 μm or more.