Stranded Insulated Cable Structure for Clean Core Wire Separation
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Solution Overview
Problem
The existing insulated electric cable configurations face issues with powder flying during the removal of the sheath and coating layers, which decreases workability and makes it difficult to separate the core wire, leading to poor adhesion between the core wire and the sheath.
Innovation Solution
The insulated electric cable design includes two first core wires with a larger cross-sectional area and two second core wires with a smaller cross-sectional area, stranded together to form a subunit, along with a tape member between the core member and the coating layers, ensuring easy separation and reduced powder attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If powder is applied to the outer peripheral surface of the core wire to decrease adhesion between the core wire and the sheath, then the adhesion is reduced, but the powder may fly to the periphery during cutting and removal of the sheath and coating layer, decreasing workability
Solution Approach 1:
The core member is segmented into multiple core wires (first core wires with larger cross-sectional area and second core wires with smaller cross-sectional area) that are stranded together. This segmentation allows the sheath and coating layers to be removed more easily without causing powder to fly, as the segmented structure reduces the overall adhesion force while maintaining individual wire integrity.
Solution Approach 2:
Different core wires have different cross-sectional areas, creating local quality variations within the core member. The first core wires have larger cross-sectional areas while the second core wires have smaller cross-sectional areas, allowing for optimized adhesion characteristics in different regions of the cable structure.
2Ease of operation
If the sheath and coating layer are removed to take out the core wire, then the core wire can be accessed, but powder applied to the core wire flies to the periphery, decreasing workability
Solution Approach 1:
By segmenting the core member into multiple stranded core wires, the structure allows for easier removal of the sheath and coating layers without generating harmful powder dispersion. The segmented configuration reduces the surface area from which powder can fly during the removal process.
3Reliability
If multiple core wires are stranded to form a core member, then the cable structure is enhanced, but the complexity of the cable structure increases
Solution Approach 1:
The core member is divided into multiple core wires that are stranded together, enhancing the cable's reliability and structural integrity. This segmentation provides flexibility and strength while maintaining a manageable structure through systematic stranding of the individual wires.
Solution Approach 2:
Multiple core wires are merged through stranding to form a unified core member. The first core wires and second core wires are combined in a stranded configuration, creating a cohesive structure that integrates the strengths of individual wires while maintaining overall cable simplicity.
Data Source
AI summary
An insulated electric cable including: two first core wires, each of the two first core wires including: a first conductor; and a first insulating layer covering the first conductor; and two second core wires, each of the two second core wires including: a second conductor having a cross-sectional area smaller than that of the first conductor; and a second insulating layer covering the second conductor; wherein the two second core wires are mutually stranded to form a subunit, and wherein one of the two first core wires, another of the two first core wires, and the subunit are mutually stranded and are in contact with each other to form a core member.