Post-fitting Shield Member Using Plated Fiber Bundle
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Solution Overview
Problem
The existing methods for manufacturing post-fitting shield members using twisted metal element wires face challenges such as difficulty in maintaining a uniform pitch distribution and ease of deformation, which complicates the attachment of these shield members to electric wires, leading to inefficient work processes and potential disconnections.
Innovation Solution
A post-fitting shield member is formed by winding a plated fiber bundle with high-strength fibers in a coil shape, which is then expanded to fit over an electric wire, utilizing metal plating to prevent plastic deformation and maintain a uniform pitch, and heat treatment to fix the shape, ensuring efficient attachment and enhanced shielding performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If metal element wires are used to form a shield layer by manual winding, then the shield member can be post-fitted to electric wires, but the work efficiency is low and pitch distribution is non-uniform
Solution Approach 1:
The patent changes the material parameter from metal to fiber with metal plating, which fundamentally alters the deformation characteristics. The fiber core provides elastic recovery capability while the metal plating maintains electrical conductivity, enabling both high work efficiency and uniform pitch distribution through superior elastic properties
Solution Approach 2:
The patent creates a composite structure by combining fiber members with metal plating layers. This composite material integrates the elastic flexibility of fiber with the conductivity and strength of metal, resolving the contradiction between ease of manipulation and pitch uniformity while maintaining shielding functionality
2Ease of operation
If metal element wires are expanded after coil winding, then the shield member can fit over electric wires, but plastic deformation occurs causing pitch deviation
Solution Approach 1:
The patent changes the material's elastic range parameter by using fiber members with metal plating instead of solid metal wires. This provides a wider elastic deformation range that prevents permanent plastic deformation during expansion, maintaining uniform pitch distribution while enabling easy post-fitting attachment
Solution Approach 2:
The patent uses a coil-shaped shield member that is pre-formed and then expanded in-place, replacing the need for precise manual winding. The expandable coil design allows for simple attachment operations while the material properties ensure permanent uniform pitch maintenance after expansion
3Strength
If external force acts on coiled twisted wires before expansion, then the wires may be deformed plastically, but this makes post-fitting difficult
Solution Approach 1:
The patent uses fiber members with metal plating where the fiber core provides high tensile strength and elastic recovery, while the metal plating layer provides conductivity and surface strength. This composite structure resists plastic deformation from external forces during handling and storage, yet remains flexible enough for easy expansion and post-fitting attachment
Solution Approach 2:
The patent designs the coil-shaped shield member with inherent elastic cushioning capability through the fiber material properties. This allows the structure to absorb and recover from external forces applied during handling and storage before expansion, preventing permanent deformation while maintaining ease of post-fitting operation
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 solution provides a post-fitting shield member that maintains a uniform pitch distribution and prevents deformation, ensuring efficient attachment to electric wires while enhancing shielding performance and work efficiency, with a shielding effect of at least 30 dB.
Implementation Method 1
The post-fitting shield member is formed by winding in a coil shape a plated fiber bundle with metal plating on a high-strength fiber member
Implementation Method 2
the high-strength fiber member in plating layers is not easily deformed plastically even if a plated fiber member is hooked on a certain member when the electric wire is inserted into the coil-shaped plated fiber bundle and the plated fiber bundle is expanded
Implementation Method 3
heat treatment to fix the shape, ensuring efficient attachment and enhanced shielding performance
Data Source
AI summary
A post-fitting shield member to be post-fitted with an electric wire is a plated fiber bundle wound in coil form and formed by performing metal plating on a high-strength fiber member. A manufacturing method of a shielded wire includes an insertion step of inserting an electric wire into the post-fitting shield member having a coil shape; a first fixing step of fixing one end portion of the post-fitting shield member into which the electric wire was inserted in the insertion step; an expansion step of expanding the post-fitting shield member that was fixed in the first fixing step toward the side of its other end portion; and a second fixing step of fixing the other end portion of the post-fitting shield member that was expanded in the expansion step.