Wiring Member Yield via Segmented Base Material Folding
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Solution Overview
Problem
Existing methods for forming sheet materials with wire-like transmission members, such as electrical wires, into nonlinear shapes often result in reduced yield due to the direct punching of large-sized parent materials, which can lead to decreased efficiency and increased material waste.
Innovation Solution
A wiring member is created by folding or combining base materials to extend into different regions, allowing for the formation of a sheet material with a wire-like transmission member fixed on it, which increases yield and enables the formation of desired shapes with improved tensile strength and reduced material misalignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a large-sized parent material is punched out directly into a nonlinear shape, then the sheet material can be formed into the desired shape, but the yield is reduced
Solution Approach 1:
The patent divides the large-sized parent material into multiple smaller base materials that are processed separately into linear shapes with higher yield. These segmented base materials are then combined or folded to form the final nonlinear sheet material shape, avoiding the need to punch out the entire nonlinear shape from a single large parent material.
Solution Approach 2:
The patent transitions from a two-dimensional punching approach to a three-dimensional construction approach by folding or combining multiple base materials. This dimensional change allows the formation of nonlinear shapes through spatial arrangement rather than direct planar cutting, thereby improving yield.
2Ease of manufacture
If a sheet material is formed into a linear shape, then the manufacturing process is simpler, but the yield is still reduced depending on length
Solution Approach 1:
The patent segments the long linear sheet material into multiple shorter base materials that can be processed more efficiently. By dividing the long material into segments, the punching yield for each segment is improved, and the segments are then combined to achieve the required total length.
3Shape
If the sheet material is formed into a bent shape to accommodate wire-like transmission members, then the wiring member can follow complex routes, but the material waste increases
Solution Approach 1:
The patent segments the bent sheet material into multiple linear or lightly-bent base materials that are combined to form the final bent configuration. Each segment is optimized for minimal waste, and the combination of segments creates the required bent shape to accommodate wire-like transmission members along complex routes.
Data Source
AI summary
A wiring member includes a sheet material and a wire-like transmission member fixed on the sheet material. For example, the sheet material is considered to be made by combining a plurality of base materials to be processed to extend to regions different from each other.