Insulating Tape for Cable Conductor Isolation
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Solution Overview
Problem
Conventional cables require a minimum thickness of insulation material to maintain conductor concentricity, which is often too large for desired cosmetic properties, necessitating alternative insulators for electrically isolating conductors.
Innovation Solution
The use of insulating tape, such as polymeric tapes like Mylar™, which is substantially thinner than extruded insulation, to electrically isolate groups of conductors within the cable, allowing for various configurations including direct wrapping or helical paths around conductors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extruded insulation material is used to electrically isolate conductor groups, then electrical isolation is achieved, but the cable thickness becomes too large for desired cosmetic properties
Solution Approach 1:
The patent applies thin film insulation by wrapping insulating tape around conductor groups instead of using thick extruded insulation material. The tape provides electrical isolation while being substantially thinner than conventional extruded insulation, directly resolving the contradiction between achieving reliable electrical isolation and maintaining acceptable cable thickness for cosmetic properties.
2Manufacturing precision
If minimum thickness of extruded insulation material is used, then conductor concentricity is maintained, but cable cosmetic properties deteriorate
Solution Approach 1:
The insulating tape wraps conformally around conductor groups, maintaining conductor concentricity through its flexible wrapping nature while being thin enough to preserve cable cosmetic properties. This resolves the contradiction by providing sufficient insulation thickness for manufacturing precision without excessive cable thickness.
3Volume of moving object
If insulating tape is used instead of extruded insulation, then cable thickness is reduced, but electrical isolation effectiveness may be compromised
Solution Approach 1:
The patent employs composite material structures where insulating tape is wrapped around conductor groups and then encased in extruded insulation material. This composite approach allows the thin tape to provide initial electrical isolation and conductor support, while the outer extruded insulation provides additional electrical protection, together achieving both reduced cable thickness and maintained electrical isolation effectiveness.
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 insulating tape effectively isolates conductors while reducing the overall cable thickness, enhancing cosmetic properties and maintaining electrical integrity.
Implementation Method 1
a tape wrapped directly around the first group of conductors along the length of the cable... where the tape electrically isolates the first group of conductors from the second group of conductors
Data Source
AI summary
Cable structures with insulating tape and systems and methods for making the same are provided. In some embodiments, a cable may include a first group of conductors extending along a length of the cable, a tape wrapped directly around the first plurality of conductors along the length of the cable, and a second group of conductors extending along the length of the cable, where the tape electrically isolates the first group of conductors from the second group of conductors. The second group of conductors may extend around the tape or the tape may be wrapped directly around the second group of conductors. The tape may be a polymeric tape that may or may not include an adhesive.