Shield Layer-Cut Electric Wire Process

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Solution Overview

Problem

Existing methods for cutting shield layers in electric wires often damage the insulating and core layers due to complex processes and the need for precise laser control, which can lead to unintended damage if not executed accurately.

Innovation Solution

A process and apparatus that involves making a notch in the outer coating layer, swelling the shield layer radially, pushing it down towards the coating layer, and cutting it on the outer face as a base, thereby protecting the insulating and core layers from damage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If laser light is applied to cut the shield layer, then the shield layer can be cut without damaging the insulating layer, but the laser light must be precisely controlled to prevent damage to the insulating layer and the process becomes complex

Engineering Contradiction:

Improvecutting precisionVSAvoidlaser control complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent replaces the laser cutting system with a mechanical cutting system. A cutting blade is introduced to mechanically cut the shield layer after it has been exposed and swollen, eliminating the need for precise laser control while achieving the same cutting objective without damaging the insulating layer.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces a cutting blade as an intermediary tool between the swollen shield layer and the final cut product. This intermediary mechanical tool allows for controlled cutting of the shield layer without requiring precise laser positioning, thereby simplifying the control system while maintaining cutting precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If a thin plate-like insertion member is inserted between the shield layer and insulating layer to displace the shield layer, then the shield layer can be cut without damaging the insulating layer, but the process becomes complex and troublesome

Engineering Contradiction:

Improveinsulating layer protectionVSAvoidinsertion member process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the shield layer from its original position by swelling it radially outward, separating it from the insulating layer without requiring an insertion member. This extraction method eliminates the complex insertion step while achieving the same protective effect of isolating the shield layer during cutting.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent changes the physical state and position of the shield layer by applying radial swelling force, causing it to expand outward and separate from the insulating layer. This parameter change (position and shape) achieves layer separation without requiring the insertion of additional components, thereby simplifying the process.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If the shield layer is swollen radially to create space for cutting, then the cutting process is simplified, but force must be applied in the axial direction which adds process steps

Engineering Contradiction:

Improvecutting process simplicityVSAvoidswelling mechanism complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The patent combines the swelling mechanism with the existing cutting apparatus by integrating radial expansion capability into the cutting tool. This merging of functions allows the same device to perform both swelling and cutting operations, eliminating the need for separate swelling equipment and reducing overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The patent employs a dynamic swelling mechanism that can adjust the radial expansion force as needed during the cutting process. This dynamic capability allows the system to adapt to different shield layer thicknesses and material properties, simplifying the overall process by providing flexible control rather than requiring fixed, complex pre-swelling equipment.

Inventive Principle:

Principle #15Dynamics

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 method simplifies the cutting process, prevents damage to the insulating and core layers, and allows for easy and precise removal of the shield layer without complex steps or precise laser control.

Implementation Method 1

causing the coating layers on both sides of the exposed shield layer to relatively approach each other, thereby applying force in the axial direction of the shield layer so that the shield layer is swollen (e.g., displaced) in the radial direction

Methodology Applied

Scientific EffectRadial swelling:

Implementation Method 2

pushing down the swollen shield layer toward the outer face of the coating layer

Methodology Applied

Scientific EffectAxial pushing force: Mechanical Force

Implementation Method 3

cutting the pushed-down shield layer on the outer face of the coating layer as a base

Methodology Applied

Scientific EffectMechanical cutting:

Data Source

PatentUS9620919B2Process for producing shield layer-cut electric wire

Publication Date: 2017.04.11 ASAHI SEIKO CO LTD

AI summary

A simplified process for producing a shield layer-cut electric wire that does not damage an insulating layer and a core wire and when cutting a shield layer.