Water-Blocking Insulated Wire With Vacuum-Filled Strand Gaps
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Solution Overview
Problem
The existing methods for applying water-stopping treatment to insulated electric wires face challenges in achieving consistent water-stopping performance due to the spatial distribution of the water-stopping agent, with air entrainment affecting the distribution and leading to inadequate sealing.
Innovation Solution
An insulated electric wire design featuring a conductor with twisted elemental wires, an exposed portion for applying a water-stopping agent, and a covered portion, where the agent fills gaps between wires, ensuring contact with the agent or another wire without air layers, and a method involving partial exposure, density modification, filling, and curing steps to achieve uniform distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If air is fed into the compression chamber to force water-stopping material to permeate gaps, then permeation capability is improved, but air becomes entrained in the water-stopping agent layer affecting spatial distribution
Solution Approach 1:
The patent extracts and removes air from the compression chamber using a vacuum pump before introducing the water-stopping agent. This prevents air entrapment in the water-stopping agent layer and ensures uniform spatial distribution without harmful air pockets that would compromise water-stopping performance.
Solution Approach 2:
The patent performs preliminary vacuum treatment of the compression chamber before introducing the water-stopping agent. This preliminary action removes air from the chamber and prevents air entrapment during the subsequent water-stopping agent application, ensuring proper spatial distribution from the outset.
2Reliability
If water-stopping agent is applied to ensure complete gap filling, then water-stopping performance is improved, but uniform spatial distribution becomes difficult to achieve
Solution Approach 1:
The patent changes the physical parameters of the compression chamber environment by applying vacuum to reduce air pressure and remove entrained air. This parameter change allows the water-stopping agent to flow uniformly and fill gaps completely without air entrapment, achieving both high water-stopping performance and uniform spatial distribution.
Solution Approach 2:
The patent creates an inert environment by removing air from the compression chamber using vacuum treatment. This inert atmosphere prevents air entrapment and allows the water-stopping agent to distribute uniformly while ensuring complete gap filling, thereby achieving both reliability and manufacturing precision.
3Reliability
If water-stopping treatment is applied to exposed conductor, then water-stopping performance is improved, but complexity of production process increases
Solution Approach 1:
The patent uses a vacuum pump that serves multiple functions: it removes air from the compression chamber, prevents air entrapment during water-stopping agent application, and ensures uniform spatial distribution. This multi-functional approach improves water-stopping performance while minimizing the addition of separate process steps.
Solution Approach 2:
The vacuum treatment process automatically removes air entrapment issues without requiring manual intervention or additional complex equipment. The system self-regulates the compression chamber environment, allowing the water-stopping agent to distribute uniformly and fill gaps completely through the vacuum-assisted application process.
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 ensures superior water-stopping performance by ensuring the water-stopping agent adheres uniformly to the wires, preventing water entry and maintaining effectiveness even with bubbles, thus enhancing the wire's waterproof characteristics.
Implementation Method 1
gaps between the elemental wires in the exposed portion are filled with a water-stopping agent
Data Source
AI summary
An insulated electric wire includes a conductor in which elemental wires made of a metal material are twisted together; and an insulation covering that covers an outer circumference of the conductor. The insulated electric wire includes: an exposed portion in which the insulation covering is removed from the outer circumference of the conductor; a covered portion in which the insulation covering covers the outer circumference of the conductor, the exposed portion and the covered portion being provided adjacent to each other in a longitudinal axis direction; and a water-stopping portion in which gaps between the elemental wires in the exposed portion are filled with a water-stopping agent. In an area enclosed by the surface of the water-stopping agent, the surface of the elemental wires is in contact with only the water-stopping agent or another elemental wire.