Shielded Wire Sheath Composition for Automotive Vibration Resistance
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Solution Overview
Problem
Electrical wires in automobiles face challenges in vibration resistance, leading to wear and decreased pressure resistance characteristics when subjected to continuous vibration during travel.
Innovation Solution
A shielded electrical wire design featuring an inner conductor with a cross-sectional area of 3 mm2 to 160 mm2, an insulator made of polyolefin, a shield conductor, and an outer sheath made of cross-linked polyurethane, which enhances vibration resistance and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electrical wire structures are used, then basic insulation and shielding are provided, but vibration resistance deteriorates leading to wear and decreased pressure resistance characteristics
Solution Approach 1:
The patent applies composite materials by combining polyolefin resin and polyurethane resin in the outer sheath layer. Specifically, the outer sheath contains polyolefin resin (5-30 mass%) and polyurethane resin (70-95 mass%), creating a composite structure that leverages the wear resistance of polyolefin and the vibration resistance of polyurethane to simultaneously improve both vibration resistance and pressure resistance characteristics
2Reliability
If heavier materials are used to improve strength and vibration resistance, then vibration resistance improves, but weight increases
Solution Approach 1:
The patent changes the material composition parameters of the outer sheath by controlling the mass% ratios of polyolefin resin (5-30 mass%) and polyurethane resin (70-95 mass%). This parameter optimization achieves the desired vibration resistance while minimizing weight, as the polyurethane resin provides high vibration resistance with lower density compared to traditional heavy-duty materials
Data Source
AI summary
A shielded electrical wire includes an inner conductor, an insulator covering the inner conductor, a shield conductor covering the insulator, and an outer sheath covering the shield conductor. A cross-sectional area of the inner conductor is 3 mm2 to 160 mm2. The insulator contains polyolefin as a resin. The outer sheath contains polyurethane as a resin.