Multi-Material Welding Cable Jacket for Wear and Flexibility

Solution Overview

Problem

Conventional welding cables suffer from wear and tear in harsh environments, leading to reduced lifespan and increased operational costs due to excessive weight or insufficient durability in their outer jackets.

Innovation Solution

A welding cable design featuring a multi-material outer jacket, with a flexible and lightweight section near the operator and a durable section farther from the operator, constructed from materials like synthetic polymers and leather, respectively, to enhance durability and reduce operator fatigue.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a conventional outer jacket is used to protect the welding cable, then the cable gains protection against wear and tear, but the cable becomes excessively heavy and less flexible

Engineering Contradiction:

Improvecable protectionVSAvoidcable weight

Core Design Contradiction:

ReliabilityVSWeight of moving object

Solution Approach 1:

The outer jacket is divided into two distinct sections: a first section made of lightweight, flexible material (such as synthetic polymer) and a second section made of durable material (such as leather). This segmentation allows each section to perform its specific function optimally without compromising the entire cable's weight and flexibility characteristics.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the cable are assigned different material properties based on their specific functional requirements. The section closer to the operator uses lightweight material for ease of handling, while the section farther from the operator uses durable material for enhanced protection against abrasion and wear.

Inventive Principle:

Principle #3Local quality

2Duration of action of stationary object

If a durable outer jacket material is used to increase cable lifespan, then the cable becomes more resistant to abrasion, but the cable becomes stiffer and harder to manipulate

Engineering Contradiction:

Improvecable lifespanVSAvoidcable flexibility

Core Design Contradiction:

Duration of action of stationary objectVSEase of operation

Solution Approach 1:

The outer jacket is divided into two distinct sections: a first section made of lightweight, flexible material (such as synthetic polymer) and a second section made of durable material (such as leather). This segmentation allows each section to perform its specific function optimally without compromising the entire cable's weight and flexibility characteristics.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the cable are assigned different material properties based on their specific functional requirements. The section closer to the operator uses lightweight material for ease of handling, while the section farther from the operator uses durable material for enhanced protection against abrasion and wear.

Inventive Principle:

Principle #3Local quality

3Ease of operation

If a lightweight outer jacket is used to improve cable flexibility, then the cable becomes easier to handle, but the cable becomes insufficiently durable and suffers premature failure

Engineering Contradiction:

Improvecable flexibilityVSAvoidcable durability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The outer jacket is divided into two distinct sections: a first section made of lightweight, flexible material (such as synthetic polymer) and a second section made of durable material (such as leather). This segmentation allows each section to perform its specific function optimally without compromising the entire cable's weight and flexibility characteristics.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the cable are assigned different material properties based on their specific functional requirements. The section closer to the operator uses lightweight material for ease of handling, while the section farther from the operator uses durable material for enhanced protection against abrasion and wear.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS20250214169A1Welding-type cables and welding-type torches having welding-type cables

Publication Date: 2025.07.03 ILLINOIS TOOL WORKS INC

AI summary

Disclosed example welding-type cables include: a conductor configured to conduct welding-type current; and an outer jacket around the conductor, wherein a first length of the outer jacket is constructed from a first material, and a second length of the outer jacket is constructed from a second material different than the first material, the second length covering a different portion of the conductor than the first length.