Shield Tape Wrap Applicator with Edge Folder for Drain Wire
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Solution Overview
Problem
Conventional methods for applying shield tape around electronic wire and cable face issues such as loosening, kinking, and increased material and labor costs, particularly when using helically wound configurations, and create bulges or ridges when the drain wire is placed outside the shield tape, compromising cable integrity.
Innovation Solution
A device and method utilizing a series of folding dies to apply shield tape in a cigarette wrapped configuration with a Z-fold and J-fold design, allowing the drain wire to be placed inside without forming ridges, while minimizing material and labor costs, and ensuring efficient overlap for effective shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If helically wound shield tape is used to improve cable flexibility, then flexibility is improved, but the shield tape is prone to loosening and kinking at overlapping edges
Solution Approach 1:
The shield tape application process is divided into multiple folding stages using separate folding dies. The first folding die creates an initial fold, the second folding die creates a second fold, and the third folding die creates a third fold. This segmentation allows each fold to be controlled independently, preventing loosening and kinking while maintaining flexibility.
Solution Approach 2:
The first folding die performs a preliminary fold of the shield tape edge before the tape is fully wrapped around the conductor. This preliminary action pre-positions the tape edge and creates a controlled fold structure that prevents subsequent loosening and kinking during cable flexing.
2Object-affected harmful factors
If shield tape edges overlap by 25% to prevent radiation leakage, then shielding effectiveness is improved, but material consumption and manufacturing complexity increase
Solution Approach 1:
The folding dies are designed to dynamically adjust the shield tape folds during the wrapping process. The folds are created in sequence rather than simultaneously, allowing the tape to be progressively formed into the final configuration with the required overlap, simplifying the manufacturing process while ensuring proper shielding.
Solution Approach 2:
The folding dies apply localized folds at specific positions along the shield tape width. The first folding die folds one edge, the second folding die folds another edge, and the third folding die folds a central portion. This local quality approach ensures the required overlap for shielding effectiveness while minimizing unnecessary material consumption.
3Ease of manufacture
If drain wire is placed on the outside of shield tape, then electrical connection is simplified, but bulges or ridges are formed compromising cable integrity
Solution Approach 1:
The drain wire is nested within the folds of the shield tape rather than being placed on the outside. The first folding die creates a fold that forms a receiving area, the second folding die creates another fold, and the third folding die creates a final fold that encloses the drain wire within the shield tape structure. This nesting eliminates external ridges while maintaining electrical connection.
Solution Approach 2:
The folds of the shield tape act as an intermediary structure that contains the drain wire. Instead of directly placing the drain wire on the cable surface, the shield tape folds serve as a mediating layer that encloses the drain wire, eliminating surface bulges while maintaining the electrical connection path.
4Reliability
If additional barrier layer is applied between shield tape and conductors, then insulation reliability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The separate barrier layer is extracted and eliminated from the cable construction. Instead of applying an additional barrier layer between the shield tape and conductors, the invention uses the insulating film already present on the conductors in combination with the folded shield tape configuration to provide the necessary insulation, reducing manufacturing complexity and cost.
Solution Approach 2:
The insulating functions are merged into the existing components. The insulating film on the conductors and the folded shield tape structure work together to provide the necessary insulation and protection, eliminating the need for a separate barrier layer while maintaining insulation reliability.
Data Source
AI summary
A shielded electrical wire and device that includes a first folding die configured to fold a first edge of a shield tape a first direction from a central portion of the shield tape and to fold a second edge of the shield tape a second direction opposite to the first direction from the central portion of the shield tape, a second folding die configured to wrap the shield tape around at least two insulated conductors to apply a fold to the first edge of the shield tape so as to fold the first edge back over onto the central portion of the shield tape to form a receiving area, a third folding die configured to tighten the shield tape around the plurality of conductors while positioning the receiving area to receive a drain wire, a wire guide configured to install a drain wire in the receiving area, and a closing die configured to close the shield tape around the plurality of conductors and the drain wire to form an enclosure around the plurality of conductors with the second edge overlapping the receiving area at an outside surface of the enclosure.