Flex-Resistant Wire With Optimized Lay Lengths
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Solution Overview
Problem
Existing flex-resistant wires require additional elements like thin diameter inclusions or slurry layers to enhance flexibility, which increases complexity and cost, and may not adequately prevent conductor disconnection during bending.
Innovation Solution
A multiple-stranded wire design where bunched strands with conductors are twisted together, with specific lay lengths optimized to reduce strain and prevent untwisting, eliminating the need for additional elements by controlling the lay length of conductors and bunched strands relative to the strand and pitch diameters.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional elements like thin diameter inclusions or slurry layers are added to increase flexibility, then flex-resistance is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The invention extracts and eliminates the additional elements (thin diameter inclusions or slurry layers) from the wire structure. Instead of adding these separate components, the patent achieves flex-resistance through optimized geometric parameters of the conductor strands themselves, specifically by controlling the lay length to be 10-47.2 times the strand diameter, thereby simplifying the overall structure while maintaining or improving performance
Solution Approach 2:
The invention changes the geometric parameters of the existing conductor structure rather than adding new elements. By optimizing the lay length parameter to a specific range (10-47.2 times the strand diameter), the patent achieves improved flex-resistance through parameter optimization alone, avoiding the need for additional components and reducing manufacturing complexity
2Reliability
If additional elements like thin diameter inclusions or slurry layers are added to increase flexibility, then flex-resistance is improved, but manufacturing cost increases
Solution Approach 1:
The invention removes the need for additional materials such as thin diameter inclusions or slurry layers, using only the conductor strands with optimized geometric parameters. This extraction of unnecessary components directly reduces material costs and simplifies the manufacturing process
Solution Approach 2:
By optimizing the lay length parameter to 10-47.2 times the strand diameter, the invention achieves improved flex-resistance through parameter control rather than material addition. This approach reduces material costs and simplifies manufacturing processes while maintaining high performance
3Ease of manufacture
If conventional wire structures are used without optimized lay lengths, then manufacturing is simpler, but conductor disconnection occurs during repeated bending
Solution Approach 1:
The invention optimizes the lay length parameter to a specific range (10-47.2 times the strand diameter) to prevent conductor disconnection during bending. This parameter optimization maintains manufacturing simplicity while dramatically improving the reliability of conductor connections under flexing conditions
Solution Approach 2:
The optimized lay length creates a preliminary geometric configuration that resists the untwisting force generated during bending. By pre-setting the lay length within the optimal range, the structure inherently opposes the disconnection tendency before it occurs, preventing conductor separation during repeated flexing
Data Source
AI summary
A flex-resistant wire has a conductor portion configured as a multiple-stranded wire. The multiple-stranded wire has a plurality of bunched strands that are twisted together. Each of the bunched strands has a plurality of conductors that are twisted together. In each of the bunched strands, the lay length of the conductors that are twisted together is at least 10 times greater than a strand diameter of the bunched strand but not greater than 47.2 times the strand diameter. The lay length of the bunched strands that are twisted together is at least 5 times greater than a pitch diameter of the multiple-stranded wire but not greater than 30 times the pitch diameter. The lay length of the conductors is smaller than or equal to the lay length of the bunched strands. The flex-resistant wire may be provided as one of the wires forming a wire harness.