Flat Combined Wire Structure for Repeated U-Bending
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Solution Overview
Problem
Existing flat combined wires are unable to meet the requirements of withstanding repeated U-bending and dynamic flexure necessary for modern automated manufacturing and AI machines, which demand higher flexure resistance and durability.
Innovation Solution
A flat combined wire structure comprising at least two side-by-side wires, each with three cores and an electrically insulating member, where the cores consist of twisted and woven yarns and conducting wires, providing enhanced structural strength and toughness, allowing for high flexure resistance and ability to withstand dynamic bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing flat combined wires are used, then the wiring of mechanical equipment can be achieved, but they cannot withstand repeated U-bending and dynamic flexure
Solution Approach 1:
The wire is divided into multiple independent cores (at least three cores per wire) that are twisted and woven together. Each core can independently withstand bending stress, and the segmented structure allows the wire to flex without breaking, enabling over ten million dynamic bending cycles
Solution Approach 2:
Each core is constructed as a composite structure with multiple yarns and multiple electrically conducting wires twisted and woven together. This composite material structure combines the flexibility of yarns with the conductivity and strength of metal wires, achieving both electrical function and mechanical durability
2Productivity
If single coaxial cables are used, then they can withstand repeated U-bending, but they cannot meet the control requirements of modern mechanical equipment with increased information transmission volume
Solution Approach 1:
The patent transitions from traditional round coaxial cables to a flat combined wire structure. This dimensional change allows multiple wires to be arranged side by side in a planar configuration, increasing information transmission capacity while the twisted and woven core structure maintains flexure resistance
3Reliability
If the wire structure is made more complex to improve flexure resistance, then the wire can withstand dynamic bending, but the manufacturing complexity increases
Solution Approach 1:
Multiple functions are merged into the core structure: electrical conductivity, mechanical strength, flexibility, and bend resistance are all achieved within the twisted and woven core design. This integration reduces the need for additional protective layers or complex supporting structures
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 flat combined wire achieves over ten million dynamic bending cycles with a radius of curvature of 0.5 mm to 30 mm, ensuring reliable operation in dynamic environments, such as modern production lines and automation equipment.
Implementation Method 1
Each of the cores includes multiple yarns and multiple electrically conducting wires twisted and woven with each other
Implementation Method 2
the electrically conducting wires are wrapped around the yarns
Implementation Method 3
The electrically insulating member covers the cores
Data Source
AI summary
A flat combined wire including at least two wires combined side by side with each other is provided. Each of the wires includes at least three cores and an electrically insulating member. Each of the cores includes multiple yarns and multiple electrically conducting wires twisted and woven with each other, and the electrically conducting wires are wrapped around the yarns. The electrically insulating member covers the cores.