Strippable Cable Insulation with Knit Line Weakness
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing electrical wires and cables require tools for stripping, leading to time-consuming and potentially injurious processes, especially in complex installations like ductless mini-split AC systems and thermostats, with existing specialty cables often causing damage to fine wires and increasing manufacturing complexity.
Innovation Solution
A readily-strippable cable design featuring a continuous electrically insulating layer with a uniformly weak portion that allows for tool-free exposure of conductors by applying force perpendicular to the cable, utilizing knit lines or perforations created during extrusion to facilitate easy separation without compromising the cable's durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If traditional wire stripping tools are used, then the insulation can be removed, but the process is time-consuming and risks injury or damage to the conductor
Solution Approach 1:
The patent incorporates a pre-formed weak portion (such as a knit line or perforation) in the insulation layer during cable manufacturing. This preliminary structural feature enables the insulation to be easily torn or separated by hand without requiring stripping tools, thereby eliminating the time-consuming stripping operation and reducing the risk of injury or conductor damage.
2Ease of operation
If specialty cables with embedded strings are used to facilitate stripping, then the outer jacket can be torn, but the strings require additional space, materials, and manufacturing complexity
Solution Approach 1:
The patent removes the unnecessary embedded string component from the cable design. Instead, it relies solely on the pre-formed weak portion (knit line or perforation) in the insulation layer to facilitate easy tearing and separation. This extraction of the string element simplifies the manufacturing process, reduces material requirements, and eliminates the space occupied by the string while still achieving the desired ease of jacket removal.
3Strength
If the insulation layer is made uniformly strong, then the cable is durable, but it cannot be easily stripped without tools
Solution Approach 1:
The patent applies local quality by creating a weak portion (knit line or perforation) at a specific location in the insulation layer while maintaining the overall strength and integrity of the insulation. This localized weakness allows the insulation to be easily torn or separated by hand in the weak portion area, while the rest of the insulation remains sufficiently strong to provide electrical insulation and mechanical protection during installation and service.
Data Source
AI summary
A cable having conductors that may be easily exposed in preparation for electrical connection, without requiring the use of tools, is provided. The cable has an insulating layer having at least one relatively weak portion that extends along the length of the cable, which allows the insulating layer to split as the wires are pulled apart, thereby exposing the wires without the use of tools. The wires themselves may, similarly, have a weakened portion thus allowing the conductors themselves to be exposed in preparation for electrical connection, without requiring the use of tools.