Thermoplastic Sheath Conductor for Shaped Installation

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Solution Overview

Problem

Conventional conductor arrangements for electrical energy or data transmission are inflexible and difficult to install in tight spaces, often requiring pre-bent rigid conductors and excessive use of cable clips or guide tubes.

Innovation Solution

A conductor arrangement featuring a flexible internal conductor surrounded by a thermoplastic hard plastic sheath that can be heated to shape and retain form, eliminating the need for pre-bent conductors and additional installation aids, with the sheath providing protection and structural support.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If rigid solid conductors are used for fixed installation, then structural stability is improved, but flexibility and ease of installation in tight spaces deteriorates

Engineering Contradiction:
Improvestructural stabilityVSAvoidease of installation
Core Design Contradiction:
Stability of the object's compositionVSEase of operation

Solution Approach 1:

The patent applies parameter changes by utilizing the thermoplastic properties of the hard plastic sheath. When heated above its glass transition temperature (Tg), the sheath transitions from a rigid state to a softened, formable state, enabling the conductor to be bent and shaped. After cooling, it returns to its rigid state, maintaining the new shape. This temperature-dependent parameter change resolves the contradiction between structural stability and installation flexibility.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent employs phase transitions of the thermoplastic hard plastic sheath between solid (rigid) and softened (formable) states through heating and cooling cycles. During installation, heating causes the sheath to transition to a formable state allowing easy bending and shaping in tight spaces. After installation, cooling transitions it back to the rigid state, providing structural stability. This phase transition mechanism directly addresses both requirements.

Inventive Principle:
Principle #36Phase transitions

2Shape

If pre-bent rigid conductors are used, then shape retention is improved, but handling flexibility and adaptability deteriorates

Engineering Contradiction:
Improveshape retentionVSAvoidhandling flexibility
Core Design Contradiction:
ShapeVSAdaptability or versatility

Solution Approach 1:

The patent applies dynamics by making the conductor's mechanical properties changeable over time through temperature control. The hard plastic sheath transitions from rigid to formable and back, allowing the conductor to adapt its shape dynamically during installation while maintaining the final shape during operation. This dynamic property change enables both handling flexibility and shape retention.

Inventive Principle:
Principle #15Dynamics

Solution Approach 2:

The patent utilizes parameter changes in the thermoplastic sheath's mechanical properties through temperature variation. Above Tg, the sheath becomes soft and formable, providing handling flexibility. Below Tg, it becomes rigid, ensuring shape retention. This parameter change approach allows the same conductor to exhibit both desired properties at different stages.

Inventive Principle:
Principle #35Parameter changes

3Reliability

If cable clips or guide tubes are used for conductor installation, then fixation reliability is improved, but device complexity and installation time deteriorates

Engineering Contradiction:
Improvefixation reliabilityVSAvoiddevice complexity
Core Design Contradiction:
ReliabilityVSDevice complexity

Solution Approach 1:

The patent applies self-service by enabling the conductor to fix itself in the desired position through its own thermoplastic properties. The hard plastic sheath, when heated and shaped, maintains the conductor in the installed position through its rigidified structure, eliminating the need for external fixation devices like cable clips or guide tubes. The conductor serves its own fixation function.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent merges the functions of the conductor and the fixation mechanism into a single integrated component. The thermoplastic hard plastic sheath simultaneously provides insulation, structural support, and self-fixation capabilities, eliminating the need for separate fixation devices. This merging reduces device complexity while maintaining fixation reliability.

Inventive Principle:
Principle #5Merging (Combining)

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

Enables easy, flexible installation in confined areas, such as engine compartments, by allowing the conductor to be shaped and maintained in place without the need for additional hardware, enhancing handling and reducing installation complexity.

Implementation Method 1

the flexible internal conductor is surrounded by a thermoplastic hard plastic sheath which can be transformed into a formable state by heating to a threshold temperature Tg provided by a specific softening point, and hardens again after cooling

Methodology Applied
Scientific EffectThermal softening: Heating

Data Source

PatentUS11562832B2Conductor arrangement for an electrical energy and/or data transmission connection
Publication Date: 2023.01.24 DEERE & CO
  • US11562832B2 patent drawing
  • US11562832B2 patent drawing
  • US11562832B2 patent drawing

AI summary

A conductor arrangement for an electrical connection includes a flexible multi-core internal conductor, an electromagnetic shield surrounding the flexible multi-core internal conductor, a thermoplastic hard plastic sheath surrounding a first portion of the flexible multi-core internal conductor, and a flexible corrugated tube surrounding a second portion the flexible multi-core internal conductor. A first portion of the thermoplastic hard plastic sheath includes an elongated flattened shape. A second portion of the thermoplastic hard plastic sheath includes an essentially round shape. The second portion of the thermoplastic hard plastic sheath is adjacent the first portion of the thermoplastic hard plastic sheath.