Molded Electrical Wire with Level Difference Insulation Lock
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Solution Overview
Problem
Existing molded portion-equipped electrical wires require a step to remove the insulating covering of the insulated electrical wire during manufacturing, which is inefficient and can lead to misalignment and reduced insulation reliability.
Innovation Solution
A molded portion-equipped electrical wire design where a thermal contraction tube forms an insulating covering that catches on a level difference forming surface, eliminating the need for removing the insulating covering and ensuring reliable insulation without misalignment, with optional adhesion for enhanced waterproofing and a ring-shaped level difference forming member for improved flexibility and component reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the insulating covering is removed during manufacturing, then the terminal can be connected to the conductor, but the manufacturing process becomes more complex and time-consuming
Solution Approach 1:
The insulating covering is pre-formed with an integrated catching structure (level difference portion) that automatically secures the covering end in place during the molding process, eliminating the need for subsequent removal and reinstallation steps
Solution Approach 2:
The catching structure is integrated directly into the insulating covering itself rather than being a separate component, combining the insulation function with the securing function into a single element
2Ease of operation
If the insulating covering is removed and reinstalled, then the terminal connection can be made, but misalignment may occur reducing insulation reliability
Solution Approach 1:
The level difference portion acts as an intermediary securing mechanism between the insulating covering and the molded portion, providing a positive mechanical lock that prevents misalignment during the terminal connection process
Solution Approach 2:
The catching structure is pre-formed on the insulating covering to automatically engage with the molded portion, ensuring proper alignment is established before terminal connection occurs
3Reliability
If a traditional insulating covering is used, then the conductor is insulated, but the covering may shift or misalign during assembly
Solution Approach 1:
The level difference portion serves as a mechanical intermediary that locks the insulating covering in a fixed position relative to the molded portion, preventing shift or misalignment during assembly and ensuring consistent insulation reliability
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 design eliminates the need for removing the insulating covering, ensures reliable insulation and positional accuracy, and provides enhanced waterproofing and flexibility by allowing the conductor to bend, while reducing the number of components and simplifying the manufacturing process.
Implementation Method 1
an insulating covering that covers a periphery of the mold and the conductor and is obtained due to a thermal contraction tube contracting
Data Source
AI summary
A molded portion-equipped electrical wire that includes a conductor; a terminal connected to an end of the conductor; a mold covering a portion at which the conductor and the terminal are connected such that the terminal protrudes from one end side of the mold and the conductor protrudes from another end side of the mold; an insulating covering that covers a periphery of the mold and the conductor and is obtained due to a thermal contraction tube contracting; and a body that is provided on an outer circumferential surface of the mold and includes a level difference forming surface facing the one end side, wherein an end of the covering is caught on a level difference portion formed by the level difference forming surface, and the body is made of an elastic material.