Welding Cable Plug Connectors with Flame-Retardant Polymer
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Solution Overview
Problem
Conventional electric cables used in welding devices, including those with control lights, fail to withstand the harsh conditions of welding due to exposure and lack of flame retardancy, necessitating frequent replacement.
Innovation Solution
An electric cable with a plug connector material comprising 98.0% to 99.8% polyurethane, styrene-butadiene block copolymers, or perfluorocarbons, and additives, incorporating an LED light source within the plug connectors to provide both high resistance and light transmission, along with a coating and wire insulation system for enhanced durability and flame resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional electric cables with control lights are used in welding devices, then control functionality is provided, but the cables fail quickly due to exposure and lack of flame retardancy
Solution Approach 1:
The plug connector uses a composite material system consisting of polymer A (98.0-99.8% by weight, selected from polyurethane, styrene-butadiene block copolymers, or perfluorocarbons) combined with polymer B (0.2-2.0% by weight, a flame retardant). This composite provides both the mechanical properties needed for cable flexibility and the flame retardancy required to withstand welding conditions, resolving the contradiction between durability and resistance to harmful welding factors.
Solution Approach 2:
The patent specifies precise compositional parameters for the plug connector material: polymer A content of 98.0-99.8% by weight and polymer B content of 0.2-2.0% by weight. These parameter ranges are optimized to achieve both flexibility and flame retardancy, allowing the cable to withstand welding conditions while maintaining control functionality.
2Object-affected harmful factors
If the plug connector material is made highly flame-retardant, then resistance to welding conditions improves, but light transmission capability deteriorates
Solution Approach 1:
The patent optimizes the concentration of flame retardant polymer B to 0.2-2.0% by weight, which is sufficient to provide flame retardancy while maintaining adequate light transmission for control functionality. This parameter optimization resolves the contradiction between flame retardancy and light transmission.
Solution Approach 2:
The composite material system of polymer A and polymer B creates a balanced formulation where the flame retardant is present in sufficient quantity for safety but in controlled amounts that do not completely block light transmission, enabling both protection and control signal visibility.
3Object-affected harmful factors
If the cable is designed for high heat tolerance, then resistance to welding conditions improves, but the complexity of material selection and manufacturing increases
Solution Approach 1:
The patent defines specific parameter ranges for the plug connector material composition (polymer A: 98.0-99.8%, polymer B: 0.2-2.0%) that ensure heat resistance while providing clear manufacturing guidelines. This parameter specification reduces material selection complexity by establishing definitive compositional boundaries.
Solution Approach 2:
The composite material system provides a standardized formulation approach where polymer A and polymer B are combined in defined ratios, creating a reproducible material system that achieves heat resistance through a established recipe rather than requiring complex material selection and optimization processes.
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 cable exhibits extraordinary resistance to welding conditions, allowing it to function as a control line for welding devices without frequent replacement, maintaining light emission and thermal stability through the use of heat-tolerant LEDs and halogen-free flame retardants.
Implementation Method 1
Each light source is configured in order to be supplied with electrical energy by means of at least one wire of the current line
Implementation Method 2
this material, however, is also sufficiently translucent in order to enable a light emission of the light source through the plug connector
Implementation Method 3
A sufficient flame resistance of the plug connector in order to withstand the conditions of a welding insert is already ensured by the inherent material properties of polymer A
Implementation Method 4
An LED is preferred as a light source, as this has a high heat tolerance and emits only little heat itself
Data Source
AI summary
An electric cable includes at least one current line having first and second ends, including several wires, a first plug connector and at least one second plug connector arranged on the first and second ends, respectively. At least one plug connector includes a material having A) 98.0% to 99.8% by weight of a polymer selected from the group consisting of polyurethane (PU), styrene-butadiene block copolymers (SBS), perfluorocarbons and mixtures thereof, and B) 0.2% to 2.0% by weight additives. The total of components A and B results in 100% by weight. A first connection nut and at least one second connection nut are arranged on the first and second plug connectors, respectively. At least one light source is arranged in a first plug connector and/or in a second plug connector and is configured in order to be supplied with electrical energy by at least one wire of the current line.