Insulated Electric Wire With High-Density Exposed Conductor
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Solution Overview
Problem
Existing insulated electric wires face challenges in achieving reliable water-stopping performance due to the variability in sealant permeation between elemental wires, requiring low-viscosity sealants and complex processes, and the need for additional protective members to prevent sealant dripping or flowing.
Innovation Solution
An insulated electric wire design with a higher density of conductive material in exposed portions, where the insulation covering is removed, allows for larger gaps to be filled with a sealant, ensuring uniform permeation and eliminating the need for separate protective members by using a high-viscosity sealant that stays on the conductor's surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a low-viscosity sealant is used to ensure thorough permeation between elemental wires, then the sealant can fully permeate between elemental wires, but the sealant drips or flows on the outer surface of the conductor requiring additional protective members
Solution Approach 1:
The conductor structure is modified locally in the exposed portion by increasing the density of conductive material (elemental wires) compared to the covered portion. This local structural change creates larger gaps between wires in the exposed portion, enabling high-viscosity sealant to permeate thoroughly without requiring low-viscosity sealants that would drip on the outer surface.
Solution Approach 2:
The viscosity parameter of the sealant is changed from low-viscosity to high-viscosity. This parameter change is made possible by the structural modification of the conductor, which provides sufficient permeation paths even for high-viscosity materials, thereby eliminating the need for additional protective members against dripping.
2Object-generated harmful factors
If a high-viscosity sealant is used to prevent dripping on the conductor surface, then the sealant stays on the outer surface without flowing, but the sealant cannot thoroughly permeate between elemental wires
Solution Approach 1:
The conductor is designed with different structural qualities in different portions: the exposed portion has higher wire density creating larger gaps, while the covered portion maintains normal density. This local structural differentiation enables high-viscosity sealant to permeate the exposed portion thoroughly while maintaining its high viscosity to prevent dripping on the outer surface.
3Ease of manufacture
If the density of conductive material is increased in the exposed portion, then larger gaps are created between elemental wires allowing high-viscosity sealant permeation, but the conductor structure becomes non-uniform
Solution Approach 1:
The conductor structure is intentionally made non-uniform with different wire densities in different portions. The exposed portion has higher density to create permeation paths, while the covered portion maintains normal density. This local quality differentiation is a deliberate design choice to enable simplified water-stopping processes.
Data Source
AI summary
An insulated electric wire having a water-stopped portion that is simple in configuration and can be formed by simple processes, including a conductor containing a plurality of twisted elemental wires made of conductive material, and an insulation covering covering an outer surface of the conductor. The wire contains an exposed portion wherein the covering is removed from the outer surface of the conductor, and a covered portion wherein the covering covers the outer surface of the conductor, with the exposed and covered portions arranged adjacently along a longitudinal axis of the insulated electric wire, where a density of the conductive material per unit length is higher in the exposed portion than in a remote area of the covered portion that is an area excluding an area adjacent to the exposed portion, and a sealant made of an insulated material fills gaps between the elemental wires of the exposed portion.