Wiring incorporated resin pipe and method of manufacturing the same
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Solution Overview
Problem
The existing methods for manufacturing wiring incorporated resin pipes, such as extrusion molding, result in increased thickness and weight due to the need for groove processing and winding of conductive wires, leading to decreased productivity and difficulty in electrical connections.
Innovation Solution
A method involving a tubular-shaped sheet with slits and a wiring unit where conductive wires are placed inside the slit, and a resin material is filled to seal the gap, eliminating the need for winding and reducing the thickness and weight of the pipe, allowing for faster and more efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If groove processing and wire winding are performed to incorporate wiring into the pipe, then wiring functionality is achieved, but the pipe thickness and weight increase
Solution Approach 1:
The patent combines the pipe body and wiring structure into a single integrated component. The wiring is embedded within recesses formed directly in the pipe wall during molding, eliminating the need for separate groove processing and wire winding steps. This merging of functions achieves wiring functionality while avoiding the weight increase associated with additive approaches.
Solution Approach 2:
The wiring structure is prepared in advance as part of the pipe molding process. Recesses for the wiring are formed during the initial pipe fabrication, and the wiring is positioned within these pre-prepared spaces before final sealing. This preliminary preparation eliminates subsequent wiring steps and prevents additional material accumulation that would increase weight.
2Adaptability or versatility
If groove processing and wire winding are performed to incorporate wiring into the pipe, then wiring functionality is achieved, but manufacturing time increases and productivity decreases
Solution Approach 1:
The patent merges multiple manufacturing steps into a single integrated molding process. The pipe body, wiring recesses, and wiring positioning are all accomplished during one molding operation, eliminating sequential groove machining and wire winding steps. This consolidation dramatically reduces manufacturing time and improves productivity while maintaining wiring functionality.
Solution Approach 2:
All wiring-related features are prepared in advance during the pipe molding process itself. The recesses are formed and wiring is positioned before the pipe is completed, eliminating the need for subsequent wiring operations. This preliminary integration of wiring functionality into the main manufacturing process eliminates time-consuming sequential steps.
3Adaptability or versatility
If the pipe is cut into arbitrary lengths, then customization is achieved, but the wiring inside the pipe is also cut, making electrical connections difficult
Solution Approach 1:
The wiring is prepared with extended leads that protrude from the pipe ends during the molding process. These pre-positioned wiring ends are positioned to extend beyond the pipe body, ensuring that even when the pipe is cut to various lengths, the wiring connections remain accessible and intact for electrical connections.
4Reliability
If outer tube is molded to cover the wiring, then wiring protection is achieved, but the final thickness and weight of the pipe are increased
Solution Approach 1:
The patent merges the protective function into the pipe wall structure itself. Recesses are formed in the pipe wall to house the wiring, and the surrounding pipe material provides protection. This integrated approach eliminates the need for a separate outer protective tube, maintaining thin-wall construction and low weight while ensuring wiring protection through the structural design of the pipe wall itself.
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 results in a lighter, more cost-effective resin pipe with reduced manufacturing time and increased productivity, enabling mass production of pipes with incorporated wiring.
Implementation Method 1
a resin material is filled in a gap formed by a matching surface of the slit of the tubular shaped sheet and the wiring unit
Data Source
AI summary
A wiring incorporated resin pipe includes a tubular shaped sheet formed in an approximately tubular shape at an interval so that a slit is formed between both ends in a transverse direction, a wiring unit arranged in the tubular shaped sheet along a longitudinal direction of the slit in an inner side of the slit and a resin material filled in a gap formed by matching surfaces of the slit of the tubular shaped sheet and the wiring unit to thereby seal the matching surfaces of the slit of the tubular shape sheet, in which conductive wires for wiring are laid inside the wiring unit in the longitudinal direction.