Segmented Rod-like Conductor Manufacturing for Wiring Routes
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Solution Overview
Problem
The existing methods for manufacturing electrical wires, such as wire harnesses, require complex shaping and insertion processes, which are time-consuming and labor-intensive, especially when using long metal pipes to guide electrical wires in predetermined wiring routes.
Innovation Solution
A method involving rod-like conductors that are processed to correspond to sub-routes, connected using techniques like ultrasonic bonding, crimping, or pressure welding, and then covered with a second insulation sheath to create an electrical wire with rigidity and a shape that holds its form, allowing for easier manufacturing and improved workability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a long metal pipe is processed into a complicated shape corresponding to the wiring route, then the wires can be easily arranged into the wiring route, but the processing requires time and labor
Solution Approach 1:
The patent divides the wiring route into multiple sub routes and processes separate preliminary conductors for each sub route independently, then connects them together. This segmentation eliminates the need to process one long metal pipe into a complicated shape, reducing processing time while maintaining ease of wire arrangement.
2Ease of operation
If a long metal pipe is processed into a complicated shape corresponding to the wiring route, then the wires can be easily arranged into the wiring route, but the processing requires labor
Solution Approach 1:
The patent segments the wiring route into sub routes and processes separate preliminary conductors independently, reducing manufacturing complexity. Each preliminary conductor is processed to a simpler shape corresponding to its sub route, making the overall manufacturing process easier while still enabling easy wire arrangement.
Solution Approach 2:
Instead of processing one long metal pipe into a complicated shape and then inserting wires, the patent inverts the approach by processing separate preliminary conductors into simpler shapes and connecting them, eliminating the need for complicated pipe processing while achieving the same wire arrangement ease.
3Ease of operation
If multiple electrical wires are inserted through the hollow portions of the processed metal pipe, then the wiring route is established, but the insertion work requires time and labor
Solution Approach 1:
The patent inverts the traditional approach by not using a metal pipe for wire insertion at all. Instead, preliminary conductors are processed to shapes corresponding to sub routes and connected directly, eliminating the time-consuming insertion work while maintaining ease of wiring.
Solution Approach 2:
The patent merges the conductor formation and wire arrangement processes by processing preliminary conductors to shapes that directly correspond to sub routes and connecting them to form the final conductor. This combining eliminates the separate insertion step, improving productivity while maintaining ease of wiring.
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 approach simplifies the manufacturing process by reducing the complexity of shaping and insertion, enhancing wiring workability and facilitating the production of electrical wires that correspond to specific wiring routes with improved rigidity and integration, thus reducing time and labor costs.
Implementation Method 1
the plurality of preliminary conductors are connected by at least one of ultrasonic bonding, crimping, pressure welding, and joining using an attachment
Implementation Method 2
the plurality of preliminary conductors are connected by at least one of ultrasonic bonding, crimping, pressure welding, and joining using an attachment
Implementation Method 3
the plurality of preliminary conductors are connected by at least one of ultrasonic bonding, crimping, pressure welding, and joining using an attachment
Data Source
Figure 1
Figure 2A~2B
Figure 3A~3C
AI summary
There is provided a method for manufacturing an electrical wire. The electrical wire includes a rod-like conductor having a shape corresponding to a predetermined wiring route and also having rigidity to enable the rod-like conductor to hold the shape by itself, and an insulation sheath covering the rod-like conductor. The method includes: preparing a plurality of rod-like preliminary conductors having the rigidity so as to correspond to a plurality of sub routes into which the wiring route is divided; processing at least one of the plurality of preliminary conductors into a shape conforming to the corresponding sub routes; connecting the plurality of preliminary conductors to form the rod-like conductor; and forming the insulation sheath to cover the rod-like conductor.