Rectangular Multi-Core Insulated Wire for Flexibility and Shape Stability
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Solution Overview
Problem
Conventional insulated wires used in coils for noncontact chargers, electric motors, and automobiles lack flexibility and shape stability due to hardening from extruded insulating layers and binding resins, and are prone to fraying without additional binding.
Innovation Solution
A rectangular cross-section multi-core insulated wire with a composite twisted structure of wires and an oppositely wound insulating fiber thread, providing flexibility and shape stability through a configuration that resists fraying and maintains shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If an extruded insulating layer and binding resin are used to maintain shape and prevent fraying, then shape stability and fraying resistance are improved, but flexibility deteriorates due to increased overall hardness
Solution Approach 1:
The patent replaces rigid extruded insulating layers and binding resins with a flexible insulating fiber thread that wraps around the wire assembly. This fiber thread provides the necessary insulation and shape maintenance while allowing the wire to bend and conform to desired shapes, thus resolving the contradiction between shape stability and flexibility.
2Reliability
If binding resin is used to prevent fraying of wire assembly, then fraying resistance is improved, but flexibility deteriorates due to increased hardness
Solution Approach 1:
The insulating fiber thread acts as a flexible binding element that prevents fraying of the wire assembly without the hardness and rigidity associated with binding resins. The fiber thread maintains reliability by securing the wire structure while preserving flexibility for bending and shaping operations.
3Reliability
If a large number of wires are assembled to achieve desired electrical properties, then electrical performance is improved, but shape maintenance deteriorates due to increased tendency to fray
Solution Approach 1:
The insulating fiber thread provides a flexible yet effective binding mechanism that maintains the shape of multi-wire assemblies with high insulation performance. The fiber thread wraps around the assembly to prevent individual wires from fraying while allowing the overall structure to maintain its rectangular cross-section and desired shape.
Data Source
AI summary
A rectangular cross-section multi-core insulated wire includes an assembly of wires in which insulating layers are formed on peripheries of conductors, and the assembly of the wires is a composite twisted structure, and includes first twisted wires formed by twisting the wires, second twisted wires formed by twisting the first twisted wires, and third twisted wires formed by twisting the second twisted wires. An insulating fiber thread is wound around a periphery, a cross-section is formed in a rectangular shape, and a winding direction of the fiber thread is a direction opposite to a twisting direction of outermost twisted wires in the assembly of the wires.