Spiral Insulating Tape Overlap for Bend-Resistant Electric Wire
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Solution Overview
Problem
Existing insulated electric wires experience conductor exposure when bent due to gaps between spirally wound insulating tape, which is not effectively addressed by prior methods.
Innovation Solution
The insulated electric wire is manufactured by spirally winding an insulating tape with specific dimensions and adhesive properties onto a conductor, ensuring an overlap length of y≥1.5099 ln(x)−0.4959 mm, a width of z≤−0.3774x+24.547 mm, and an adhesive force of c≥3.2 N/19 mm, preventing conductor exposure during bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If insulating tape is spirally wound around conductor, then insulation coverage is achieved, but gaps appear during bending causing conductor exposure
Solution Approach 1:
The insulating tape is subjected to electron beam irradiation before winding to pre-crosslink the adhesive layer, enabling it to exhibit elastic recovery properties that will prevent gap formation during subsequent bending operations
Solution Approach 2:
The adhesive layer's physical and chemical properties are changed through electron beam irradiation, transforming it from a non-elastic state to an elastic state with recovery capability, characterized by specific gel fraction and crosslinking density parameters
2Reliability
If insulating tape is wound tightly to prevent gaps, then insulation integrity improves, but manufacturing complexity increases
Solution Approach 1:
The adhesive layer is designed to automatically exhibit elastic recovery after winding, eliminating the need for complex post-winding treatments or additional devices to maintain tape integrity during bending
Solution Approach 2:
By controlling the electron beam irradiation parameters (dose, acceleration voltage), the adhesive layer achieves optimal elastic properties that simplify the winding process while ensuring reliable conductor protection
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 effectively reduces the likelihood of conductor exposure during bending by maintaining the integrity of the insulating tape, even under self-radial bending conditions, and enhances heat resistance through electron beam crosslinking before winding.
Implementation Method 1
an adhesive layer (22) disposed onto the conductor (10)
Implementation Method 2
an overlap length y of y≥1.5099 ln(x)−0.4959 mm
Implementation Method 3
enhances heat resistance through electron beam crosslinking before winding
Data Source
AI summary
An insulated electric wire is formed by spirally winding an insulating tape laminating an insulating layer and an adhesive layer onto a conductor such that the adhesive layer is disposed onto the conductor, in which when a conductor diameter is x mm, the insulating tape has an overlap length y of y≥1.5099ln(x)−0.4959 mm, a width z of z≤−0.3774x+24.547 mm, and an adhesive force c of c≥3.2 N/19 mm with respect to a back surface of the insulating tape which is opposite to the adhesive layer.