Polymer Cable Insulation Cooling for Twisted Pair Spacing

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Solution Overview

Problem

Existing methods for manufacturing wire and cable products face challenges in controlling deformation of insulation layers due to compressive forces during manufacturing processes, leading to increased capacitance, reduced signal integrity, and higher costs due to the need for additional insulation to maintain conductor spacing and impedance.

Innovation Solution

The method involves temporarily altering the hardness of polymer insulation layers by controlling temperature through convective thermal transfer, using cryogenic fluids or chilled air to increase the Young's modulus, thereby reducing deformation and maintaining conductor spacing without adding extra insulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If additional insulation material is added to compensate for compression deformation, then conductor spacing and impedance are maintained, but cable size and cost increase

Engineering Contradiction:

Improveconductor spacingVSAvoidcable size

Core Design Contradiction:

Manufacturing precisionVSVolume of moving object

Solution Approach 1:

The patent changes the temperature parameter of the polymer insulation layer during manufacturing processes. By cooling the insulation layer, its hardness and resistance to compressive deformation are increased, allowing the layer to maintain conductor spacing without requiring additional material thickness.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent applies cooling to the polymer insulation layer before compressive forces are applied during manufacturing operations such as braiding, twisting, or jacketing. This preliminary hardening prevents deformation before it occurs, eliminating the need for compensatory additional insulation material.

Inventive Principle:

Principle #10Preliminary action

2Manufacturing precision

If manufacturing line speed is reduced to alleviate compression forces, then deformation is reduced, but productivity decreases

Engineering Contradiction:

Improveinsulation deformationVSAvoidline speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent changes the temperature parameter of the polymer insulation layer to increase its resistance to compressive forces. This allows manufacturing to proceed at high speeds without suffering from the deformation issues that would normally require slower processing.

Inventive Principle:

Principle #35Parameter changes

3Strength

If thicker and stiffer jacketing layers are used to compensate for compression, then cable integrity is maintained, but size and cost increase

Engineering Contradiction:

Improvecable integrityVSAvoidcable size

Core Design Contradiction:

StrengthVSVolume of moving object

Solution Approach 1:

The patent changes the temperature parameter of the polymer materials during manufacturing to optimize their mechanical properties temporarily, allowing thinner jacketing layers to provide the same protective function without requiring excessive thickness.

Inventive Principle:

Principle #35Parameter changes

4Manufacturing precision

If polymer insulation hardness is increased to resist compression, then deformation is reduced, but processing difficulty increases

Engineering Contradiction:

Improveinsulation deformationVSAvoidprocessing difficulty

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent dynamically adjusts the hardness of the polymer insulation layer during the manufacturing process by controlling temperature. The insulation layer is softer during initial processing operations for ease of handling, then temporarily hardened during compression operations, then allowed to return to its original state for subsequent processing.

Inventive Principle:

Principle #15Dynamics

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 reduces deformation, maintains desired impedance and electrical properties, and decreases material usage, resulting in cost-effective cables with improved signal transmission and mechanical properties.

Implementation Method 1

controlling temperature through convective thermal transfer, using cryogenic fluids or chilled air to increase the Young's modulus

Methodology Applied

Scientific EffectConvective thermal transfer: Convection

Implementation Method 2

using cryogenic fluids or chilled air to increase the Young's modulus

Methodology Applied

Scientific EffectCryogenic cooling: Cryogenics

Data Source

PatentUS20250210234A1System and method for forming wire and cable

Publication Date: 2025.06.26 DAIKIN AMERICA INC

AI summary

A system and method for manufacturing wire and cable products with a polymer cable component is provided. The systems and methods include increasing the hardness of a polymer cable component in order to reduce compression and deformation of the cable components during manufacturing. In some instances, the hardness is temporarily increased prior to or during the process of creating twisted pair or during the cabling process. In a specific application, the Young's modulus of an insulated conducting wire is increased during the twinning process by controlling convective thermal transfer.