Tapeless Cable Assembly Cross-Linking Insulation
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Solution Overview
Problem
Conventional electrical cable manufacturing processes are inefficient and costly due to the use of helical tapes, which serve no substantial function in the completed cable, introduce stress to conductors, and are susceptible to hydrolysis at high temperatures, prolonging the manufacturing process and increasing costs.
Innovation Solution
The method involves applying a cross-linkable insulating material around conductor cables to fill interstitial openings, eliminating the need for tapes by cross-linking the material to form a solid insulating layer, thereby reducing manufacturing time and costs while enhancing the cable's mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a helical tape is wrapped around the bundle of insulated conductors to hold the insulating material in place, then the insulating material can be properly positioned during manufacturing, but the manufacturing cost increases and the manufacturing process becomes more time-consuming
Solution Approach 1:
The patent removes the helical tape component from the manufacturing process entirely. Instead of applying insulating material and then wrapping tape to hold it, the invention uses a preformed insulating layer that maintains its shape and position inherently, eliminating the need for tape and the associated wrapping step.
Solution Approach 2:
The insulating layer is preformed before application to the conductors. This preliminary formation of the insulating layer with its specific geometry allows it to be applied directly to the conductor bundle without requiring subsequent tape wrapping to maintain positioning.
2Reliability
If a helical tape is wrapped around the bundle of insulated conductors, then the insulating material is held in place, but the process is burdensome and time consuming, prolonging the manufacturing process
Solution Approach 1:
The helical tape step is completely extracted from the manufacturing process. The preformed insulating layer is applied directly to the conductors and maintains its position through its inherent structural design, eliminating the time-consuming wrapping operation.
Solution Approach 2:
The invention changes the physical state and form of the insulating material from a liquid or soft material requiring tape restraint to a preformed layer with sufficient structural integrity to maintain its own position without additional restraints.
3Manufacturing precision
If a helical tape is used to hold the insulating material, then proper positioning is achieved, but improper wrapping may introduce stress and damage the insulated conductors
Solution Approach 1:
By removing the helical tape entirely, the source of potential conductor damage is eliminated. The preformed insulating layer is applied in a controlled manner that does not involve tight wrapping that could stress or damage the underlying conductors.
4Reliability
If a helical tape is wrapped around the bundle, then the insulating material is secured, but the tape serves no function in the completed cable and increases manufacturing cost
Solution Approach 1:
The helical tape is extracted from the process, eliminating its cost and the complexity of its application. The preformed insulating layer achieves the securing function through its own structural design, requiring no additional components.
Solution Approach 2:
The preformed insulating layer serves multiple functions simultaneously: it provides electrical insulation, maintains mechanical positioning, and eliminates the need for separate securing components like tape, thereby reducing overall manufacturing cost.
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 eliminates voids in the cable core, improves compression resistance, and reduces manufacturing time and expenses by eliminating the need for tapes, while ensuring the insulating material solidifies before spooling, resulting in a more efficient and cost-effective cable assembly process.
Implementation Method 1
applying a cross-linkable first material around the plurality of conductor cables and in the interstitial openings; and causing cross-linking of the first material to form a core assembly
Data Source
AI summary
The present invention relates to methods of manufacturing tapeless cable assemblies. The methods generally include providing a plurality of adjacent conductor cables, followed by applying a cross-linkable first material around the plurality of conductor cables and in the interstitial openings occurring between the cables. Cross-linking can be initiated by applying a second material which facilitates cross-linking of the first material or by other means such as exposing the material to ultraviolet radiation. The wrapped assembly is then welded to form a core assembly. The disclosed manufacturing methods do no require a tape, thereby shortening the manufacturing process and reducing the manufacturing costs.