Insulated Wire Outer Diameter Reduction via Layered Coating
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Solution Overview
Problem
Existing insulated wires face challenges in reducing their outer diameter while maintaining high insulation and flame-retardant properties, as thick layers are required for both properties, leading to low direct-current stability due to moisture infiltration in the flame-retardant layer.
Innovation Solution
The insulated wire structure includes a conductor with a coating layer comprising multiple flame-retardant layers and an insulating layer in between, where the insulating layer suppresses water infiltration into the flame-retardant layer, allowing the flame-retardant layer to contribute to both flame-retardant and direct-current stability, and the thickness ratio of the insulating layer to the coating layer is optimized between 10% and 35% to achieve both properties effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the thickness of the flame-retardant layer is reduced to decrease the outer diameter, then the outer diameter is reduced, but the flame-retardant property deteriorates
Solution Approach 1:
The coating layer is divided into multiple flame-retardant layers and insulating layers stacked alternately. This segmentation allows the flame-retardant layers to provide flame resistance while the insulating layers prevent moisture infiltration, enabling thickness reduction without sacrificing flame-retardant property.
Solution Approach 2:
The patent uses a composite structure combining flame-retardant resin composition layers with insulating layers. This composite material approach allows both flame-retardant and insulation functions to be integrated in a thin-profile design, resolving the contradiction between reduced thickness and maintained flame-retardant performance.
2Length of stationary object
If the thickness of the insulating layer is reduced to decrease the outer diameter, then the outer diameter is reduced, but the insulation property deteriorates
Solution Approach 1:
The coating layer is segmented into alternating flame-retardant layers and insulating layers. This segmentation distributes the insulation function across multiple insulating layers positioned strategically within the coating structure, maintaining insulation property even when individual layer thicknesses are reduced.
Solution Approach 2:
The insulating layers act as intermediary barriers between the flame-retardant layers and the external environment. These intermediary insulating layers prevent moisture infiltration that would otherwise compromise both insulation and flame-retardant properties, enabling thinner overall design.
3Reliability
If multiple layers are stacked to achieve both insulation and flame-retardant properties, then both properties are maintained, but the outer diameter increases
Solution Approach 1:
The patent optimizes the thickness parameters of individual layers and the overall thickness ratio of the coating layer. By carefully controlling these parameters and using the formula for minimum coating layer thickness, the patent achieves both insulation and flame-retardant properties while minimizing the outer diameter through parameter optimization rather than simply reducing layer thicknesses.
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
This configuration reduces the outer diameter of the insulated wire while maintaining high insulation and flame-retardant properties, enhancing direct-current stability and mechanical strength, and preventing moisture infiltration, thus achieving a thinner profile without compromising performance.
Implementation Method 1
the insulating layer suppresses water infiltration into the flame-retardant layer
Data Source
AI summary
An insulated wire, having an electrical wire structure capable of reducing an outer diameter while maintaining an insulating property and a flame-retardant property, includes a conductor and a coating layer arranged on an outer periphery of the conductor. The coating layer includes a plurality of flame-retardant layers, each made of a flame-retardant resin composition, and an insulating layer interposed between the plurality of flame-retardant layers. A ratio of a thickness of the insulating layer to a thickness of the coating layer is equal to or larger than 10% and equal to or smaller than 35%.