Layered Insulated Wire Structure for Smaller Outer Diameter
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Solution Overview
Problem
Conventional insulated electric wires face challenges in reducing their diameter while maintaining insulation properties, flame retardancy, and oil resistance, as the thickness of the insulating and flame retardant layers must be increased to ensure reliability, making it difficult to achieve a smaller outer diameter.
Innovation Solution
The design incorporates a covering layer composed of multiple flame retardant layers and an insulating layer with a resin composition that includes a resin with a melting point of 125 degrees C or higher, which suppresses water penetration into the flame retardant layers, allowing for a thinner structure that maintains direct current stability and flame retardancy, and uses a non-halogen flame retardant resin composition with a specific ratio of resin to flame retardant for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the thickness of the insulating layer and flame retardant layer is increased to ensure reliability of insulation properties, flame retardancy and oil resistance, then the reliability is improved, but the outer diameter of the insulated electric wire increases
Solution Approach 1:
The patent changes the melting point parameter of the resin material to 125°C or higher, which fundamentally alters the thermal behavior of the insulating layer. This parameter change enables the material to resist oil penetration and maintain structural integrity at elevated temperatures, achieving reliable insulation and flame retardancy with reduced layer thickness.
Solution Approach 2:
The patent employs a composite resin composition in the insulating layer that combines high melting point resin (125°C or higher) with flame retardant additives. This composite material simultaneously provides oil resistance, thermal stability, and flame retardancy, allowing the insulating layer to be thinner while maintaining comprehensive performance.
2Length of stationary object
If the thickness of the insulating layer and flame retardant layer is reduced to decrease the outer diameter, then the outer diameter is reduced, but the reliability of insulation properties, flame retardancy and oil resistance deteriorates
Solution Approach 1:
By elevating the melting point parameter to 125°C or higher, the resin gains superior thermal resistance and oil impermeability. This allows the insulating layer to maintain its protective function at reduced thickness, preventing oil penetration and maintaining insulation properties even with a thinner structure.
Solution Approach 2:
The patent applies different material compositions to different layers: the insulating layer uses high melting point resin for thermal and oil resistance, while the flame retardant layer contains flame retardant additives for fire protection. This localized optimization allows each layer to be thinner while collectively maintaining comprehensive reliability.
3Ease of manufacture
If a resin with melting point below 125 degrees C is used in the insulating layer, then the ease of manufacture and flexibility are improved, but oil resistance and direct current stability deteriorate due to water penetration
Solution Approach 1:
The patent raises the melting point parameter to 125°C or higher, which fundamentally changes the resin's thermal and chemical resistance properties. This parameter change creates a more rigid structure that resists oil penetration and prevents water absorption, thereby maintaining direct current stability while still allowing manufacturing through extrusion processes.
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 enables a reduction in the outer diameter of the insulated electric wire while maintaining high levels of insulation, flame retardancy, and oil resistance, and contributes to weight reduction when used in wire harnesses, with improved mechanical properties and reduced risk of dielectric breakdown.
Implementation Method 1
the resin component includes 40% by mass or more of a resin having a melting point of 125 degrees C. or higher of 100% by mass of the resin component
Data Source
AI summary
An insulated electric wire is composed of a conductor, and a covering layer disposed around an outer circumference of the conductor. The covering layer has a plurality of flame retardant layers composed of a flame retardant resin composition, and an insulating layer interposed between the plurality of flame retardant layers. The insulating layer is made of a resin composition including a resin component, and the resin component includes 40% by mass or more of a resin having a melting point of 125 degrees C. or higher of 100% by mass of the resin component.