Welded Protective Sheath for Electric Cables
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Solution Overview
Problem
Conventional protective sheaths for electrical cables face issues with seam-based fastening methods that can damage metal wires during manufacturing and use, leading to corrosion and degradation of protective properties, especially in harsh environments, and require removal of protective films for electrical continuity, which can further damage the sheath.
Innovation Solution
A protective sheath with a non-conductive core wire and electrically conductive wires, where the protective film is integrated by welding onto the assembly of wires, eliminating seams and potential damage, and allowing for easy removal without compromising the sheath's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the protective film is fastened by sewing to the wire assembly, then the film is secured to protect cables, but the sewing process damages metal wires through cutting or scratching, leading to corrosion and degradation of protective properties
Solution Approach 1:
The patent replaces the mechanical sewing process with a welding process to attach the protective film to the wire assembly. This substitution eliminates the mechanical cutting and scratching actions that damage metal wires, while still achieving secure attachment of the film through welding of the wires without compromising their integrity
Solution Approach 2:
The patent introduces a welding process as an intermediary method between the protective film and wire assembly. This welding intermediary allows the film to be secured without direct mechanical contact that would cause damage, using thermal energy instead to create a bond that protects rather than harms the wire structure
2Ease of manufacture
If sewing threads are used to secure the protective film, then the film is attached to the sheath, but the threads can be damaged during use when the film needs to be removed, compromising the sheath's integrity
Solution Approach 1:
The patent replaces the mechanical sewing thread attachment system with a welding-based attachment system. This eliminates the vulnerable sewing threads that could be damaged during film removal, while maintaining ease of manufacture through the welding process and improving reliability by eliminating the thread integrity issue
Solution Approach 2:
The patent extracts and removes the sewing thread element from the attachment system. By eliminating the threads entirely and using welding directly on the wires, the patent removes the source of potential damage during film removal while maintaining the attachment functionality
3Adaptability or versatility
If the protective film is removed for electrical continuity, then electrical connection can be established, but the removal process risks damaging the sheath structure
Solution Approach 1:
The patent replaces the mechanical sewing attachment with welding, which creates a stronger bond that allows the protective film to be removed cleanly without damaging the underlying sheath structure. The welding attachment method enables film removal for electrical continuity while preserving the integrity of the wire assembly and sheath
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
The solution provides durable protection against abrasion, mechanical damage, and electromagnetic interference while maintaining electrical continuity, ensuring the sheath's performance in hostile environments without degrading over time.
Implementation Method 1
the protective film is associated with the assembly of wires by welding
Data Source
AI summary
The present invention relates to a protective sheath (1) comprising an assembly of at least one electrically non-conductive wire (4), referred to as a core wire and contributing to the final shape imparted to the sheath, and electrically conductive wires (5), as well as at least one protective film (3) combined with the entirety or a portion of one of the surfaces of the sheath, and characterised in that the protective film (3) is combined with said surface by welding. Carrying out said assembly of the film by welding instead of by sewing ensures that the sheath is not damaged during the production thereof.