Novel tensile flexible combined cable

Abstract

The utility model discloses a novel tensile flexible combination cable, which relates to the technical field of flexible combination cables, and comprises a functional cable core group, the outer side of the functional cable core group is wrapped with a tensile fiber bundle and a dynamic buffer strip, the tensile fiber bundle is spirally wrapped on the outer wall of the functional cable core group, and the dynamic buffer strip is wrapped on the outer wall of the functional cable core group. Spiral gaps of the tensile fiber bundles are filled with the dynamic buffer strips, the dynamic buffer strips are regular hexagon honeycomb-shaped frameworks, the outer sides of the tensile fiber bundles and the dynamic buffer strips are wrapped with stress transition layers, the tensile fiber bundles utilize double reverse angle fiber layers to counteract torsional stress through the arranged tensile fiber bundles and the dynamic buffer strips, and therefore the tensile strength of the tensile fiber bundles is improved. And the rough surface is utilized to improve the interface bonding force, the dynamic buffer strip can be instantly hardened under the impact load to protect the cable core, and meanwhile, through the special matching design of the stress transition layer and the outer sheath, the stress generated in the bending process of the cable is effectively dispersed, and the problem of cable core fracture caused by stress concentration is avoided.

Description

Technical Field

[0001] This utility model relates to the field of flexible composite cable technology, specifically to a novel tensile-resistant flexible composite cable. Background Technology

[0002] In today's technological field, flexible composite cables have become an indispensable component, especially with the widespread adoption of Type-C interfaces. These cables, combining data transmission and power supply, are widely used in consumer electronics, industrial equipment, and medical devices, among other fields. These cables must withstand high-intensity repeated bending while meeting stringent dynamic tensile strength requirements. Currently, most manufacturing technologies employ a layered, wrapped structure design. This design uses aramid fiber braided layers to cover multiple cores with different functions, and adds a spiral metal armor mesh on the outermost layer to enhance the overall strength and durability of the cable.

[0003] However, this design also has certain limitations. Due to the difference in stiffness between the metal armor mesh and the inner aramid fiber, this stiffness mismatch can lead to stress concentration when the cable needs to be bent during use. Stress concentration causes excessive pressure in certain areas inside the cable, accelerating core breakage. This breakage not only shortens the cable's lifespan but may also cause equipment failure at critical moments, inconveniencing users. Therefore, we propose a novel tensile-resistant flexible composite cable. Utility Model Content

[0004] The purpose of this invention is to address the issue of stress concentration caused by the stiffness difference between the metal armor mesh and the inner aramid fiber layer when the cable is bent during use. This stress concentration leads to excessive pressure on certain areas within the cable, accelerating core breakage. Such breakage not only shortens the cable's lifespan but can also cause equipment malfunctions at critical moments, inconveniencing users. This invention provides a novel tensile-resistant flexible composite cable.

[0005] To achieve the above objectives, this utility model specifically adopts the following technical solution:

[0006] A novel tensile-resistant flexible composite cable includes a functional core assembly. The functional core assembly is wrapped with tensile fiber bundles and a dynamic buffer strip on its outer side. The tensile fiber bundles are spirally wrapped around the outer wall of the functional core assembly, and the dynamic buffer strip is filled in the spiral gaps of the tensile fiber bundles. The dynamic buffer strip is a regular hexagonal honeycomb skeleton. The tensile fiber bundles and the dynamic buffer strip are wrapped with a stress transition layer on their outer side. The stress transition layer is a low-modulus thermoplastic elastomer layer, and the outer wall of the stress transition layer is wrapped with an outer sheath. The outer sheath is a braided reinforced polyurethane layer.

[0007] Furthermore, the tensile fiber bundle includes a tensile inner layer and a tensile outer layer, which are woven layers with opposite fiber directions. The tensile inner layer is a blend of aramid fiber and ultra-high molecular weight polyethylene fiber, and the tensile outer layer is woven from silicon carbide ceramic fiber.

[0008] Furthermore, the dynamic buffer strip includes a polymer skeleton and a shear-thickening fluid, wherein the polymer skeleton has a regular hexagonal structure and the shear-thickening fluid fills the center of the polymer skeleton.

[0009] Furthermore, the outer wall of the stress transition layer is provided with multiple annular grooves at equal intervals, and the inner wall of the outer sheath is provided with a mating protrusion corresponding to the position of the annular groove, the mating protrusion engaging with the annular groove.

[0010] Furthermore, the mating protrusion is a frustoconical protrusion, and the mating protrusion is interference-fitted with the annular groove.

[0011] Furthermore, the braided reinforcement layer of the outer sheath adopts an interwoven structure of stainless steel microfilaments and nylon multifilaments.

[0012] The beneficial effects of this utility model are as follows:

[0013] 1. The functional core assembly of this utility model consists of at least two coaxial cables or twisted pairs arranged in parallel. Through the setting of tensile fiber bundles and dynamic buffer strips, the tensile fiber bundles use double reverse angle fiber layers to offset torsional stress and use rough surfaces to enhance interfacial bonding. The dynamic buffer strips can instantly harden and protect the core under impact loads. At the same time, through the special cooperation design between the stress transition layer and the outer sheath, the stress generated during the bending process of the cable is effectively dispersed, avoiding the problem of core breakage caused by stress concentration.

[0014] 2. This utility model features a tensile inner layer and a tensile outer layer. The tensile inner layer effectively withstands the tensile force on the cable and improves its flexibility and abrasion resistance through a blended structure of aramid fiber and ultra-high molecular weight polyethylene fiber. The tensile outer layer is woven from silicon carbide ceramic fiber, which has high strength, high hardness, and high abrasion resistance, further enhancing the tensile performance of the cable. At the same time, the micron-level rough structure formed on the surface of the silicon carbide ceramic fiber by plasma etching increases the friction between the fibers, making the tensile outer layer more tightly wrapped around the outside of the tensile inner layer, thus improving the overall strength and stability of the cable.

[0015] 3. This invention utilizes a polymer skeleton and a shear-thickening fluid. When the axial tensile force is excessive, the polymer skeleton undergoes axial compression deformation, releasing the shear-thickening fluid to fill the fiber gaps. The shear-thickening fluid absorbs and disperses impact energy, effectively resisting external impacts and protecting the internal functional core assembly from damage. When the cable is bent, the shear-thickening fluid in the dynamic buffer strip responds quickly, increasing fluid viscosity to effectively absorb the stress generated by bending, reducing stress concentration, and thus extending the cable's service life. Simultaneously, the hexagonal honeycomb skeleton design ensures that the dynamic buffer strip provides uniform cushioning in multiple directions, further enhancing the cable's durability. Attached Figure Description

[0016] Figure 1 This is a cross-sectional structural diagram of the present invention;

[0017] Figure 2 This is a cross-sectional structural diagram of the dynamic buffer strip in this utility model;

[0018] Figure 3 This is a cross-sectional structural diagram of the tensile fiber bundle in this utility model;

[0019] Figure 4 This is a partial cross-sectional view of the mating position of the stress transition layer and the outer sheath in this utility model.

[0020] Reference numerals: 1. Functional core assembly; 2. Tensile fiber bundle; 3. Dynamic buffer strip; 4. Stress transition layer; 5. Outer sheath; 6. Polymer skeleton; 7. Shear thickening fluid; 8. Tensile inner layer; 9. Tensile outer layer; 10. Annular groove; 11. Matching protrusion. Detailed Implementation

[0021] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings.

[0022] Please see Figures 1-4This utility model proposes a novel tensile-resistant flexible composite cable, comprising a functional core assembly 1. The outer side of the functional core assembly 1 is wrapped with tensile fiber bundles 2 and dynamic buffer strips 3. The tensile fiber bundles 2 are spirally wrapped around the outer wall of the functional core assembly 1, and the dynamic buffer strips 3 are filled in the spiral gaps of the tensile fiber bundles 2. The dynamic buffer strips 3 are hexagonal honeycomb skeletons. The outer side of the tensile fiber bundles 2 and the dynamic buffer strips 3 is wrapped with a stress transition layer 4. The stress transition layer 4 is a low-modulus thermoplastic elastomer layer, and the outer wall of the stress transition layer 4 is wrapped with an outer sheath 5. The outer sheath 5 is a braided reinforced polyurethane layer.

[0023] In this embodiment, preferably, the tensile fiber bundle 2 includes a tensile inner layer 8 and a tensile outer layer 9. The tensile inner layer 8 and the tensile outer layer 9 are woven layers with opposite fiber directions. The tensile inner layer 8 is made of a blend of 70% aramid fiber and 30% ultra-high molecular weight polyethylene fiber with a weaving angle of +35°, and the tensile outer layer 9 is made of 100% silicon carbide ceramic fiber with a weaving angle of -35°. The surface of the silicon carbide ceramic fiber is formed by plasma etching to create a micron-level rough structure with a roughness Ra = 3.5-5 μm. Through the provision of the tensile inner layer 8 and the tensile outer layer 9, the tensile inner layer... Layer 8 can effectively withstand the tensile force on the cable, and the hybrid structure of aramid fiber and ultra-high molecular weight polyethylene fiber improves the flexibility and wear resistance of the cable. The tensile outer layer 9 is woven from silicon carbide ceramic fiber. Silicon carbide ceramic fiber has the characteristics of high strength, high hardness and high wear resistance, which can further enhance the tensile performance of the cable. At the same time, the micron-level rough structure formed by plasma etching on the surface of silicon carbide ceramic fiber increases the friction between fibers, making the tensile outer layer 9 more tightly wrapped around the outer side of the tensile inner layer 8, improving the overall strength and stability of the cable.

[0024] In this embodiment, preferably, the dynamic buffer strip 3 includes a polymer skeleton 6 and a shear-thickening fluid 7. The polymer skeleton 6 has a regular hexagonal structure with a unit wall thickness of 0.05 mm and a unit inner diameter of 0.8 mm. The shear-thickening fluid 7 fills the center of the polymer skeleton 6. The viscosity of the shear-thickening fluid 7 is 500-800 cP. Through the polymer skeleton 6 and the shear-thickening fluid 7, the polymer skeleton 6 undergoes 15% to 20% axial compression deformation when the axial tensile force is >30 N, releasing the shear-thickening fluid to fill the fiber gaps. The shear-thickening fluid 7 absorbs and disperses impact energy, effectively resisting external impacts and protecting the internal functional core assembly 1 from damage. When the cable is bent, the shear-thickening fluid 7 of the dynamic buffer strip 3 can respond quickly, increasing the fluid viscosity, effectively absorbing the stress generated by bending, reducing stress concentration, and thus extending the service life of the cable. At the same time, the regular hexagonal honeycomb skeleton design enables the dynamic buffer strip 3 to provide a uniform buffering effect in multiple directions, further enhancing the durability of the cable.

[0025] In this embodiment, preferably, the outer wall of the stress transition layer 4 is provided with multiple annular grooves 10 at equal intervals, the groove width to groove spacing ratio is 1:1.2, and the depth is 0.3mm. The inner wall of the outer sheath 5 is provided with mating protrusions 11 corresponding to the positions of the annular grooves 10. The mating protrusions 11 engage with the annular grooves 10. When the cable bending radius is less than 8D (D is the cable diameter), the annular grooves 10 induce local folding deformation in the stress transition layer 4, reducing the bending curvature of the functional core assembly 1, thereby reducing stress concentration caused by bending and further improving the cable's durability and service life. The interference fit design of the mating protrusions 11 and the annular grooves 10 ensures a tight connection between the stress transition layer 4 and the outer sheath 5, effectively preventing the cable from loosening or falling off during use, further improving the overall stability and reliability of the cable.

[0026] In this embodiment, preferably, the mating ridge 11 is a frustoconical protrusion, and the mating ridge 11 is interference-fitted with the annular groove 10. Through this interference-fit structure, when the cable is subjected to external tension or pressure, the frustoconical protrusion 11 can better embed into the annular groove 10, thereby enhancing the connection strength between the stress transition layer 4 and the outer sheath 5, effectively preventing delamination or breakage of the cable under extreme conditions. This design not only improves the tensile strength and durability of the cable but also ensures its stability and reliability in various complex environments, providing users with a safer and more reliable user experience.

[0027] In this embodiment, preferably, the braided reinforcement layer of the outer sheath 5 adopts an interwoven structure of stainless steel microfilaments and nylon multifilaments. By adopting an interwoven structure of stainless steel microfilaments and nylon multifilaments in the outer sheath 5, not only is the tensile strength and abrasion resistance of the cable improved, but the cable is also made lighter and more flexible. Stainless steel microfilaments have high strength and corrosion resistance, effectively resisting external environmental erosion and mechanical damage; while nylon multifilaments have good flexibility and abrasion resistance, enhancing the bending performance and durability of the cable. This interwoven structure design enables the outer sheath 5 to provide excellent performance in multiple aspects, further improving the overall quality and reliability of the cable.

[0028] The working principle and usage of this utility model are as follows: In use, the functional core assembly 1 consists of at least two parallel coaxial cables or twisted pairs. Through the addition of tensile fiber bundles 2 and dynamic buffer strips 3, the tensile fiber bundles 2 utilize double-angle fiber layers to offset torsional stress and a rough surface to enhance interfacial bonding. The dynamic buffer strip 3 can instantly harden and protect the core under impact loads. Simultaneously, the special design of the stress transition layer 4 and the outer sheath 5 effectively disperses the stress generated during bending, preventing core breakage due to stress concentration. Furthermore, the outer sheath 5 uses a structure interwoven with stainless steel microfilaments and nylon multifilaments, which not only enhances the cable's tensile strength and abrasion resistance but also maintains its lightweight and flexibility, ensuring excellent performance in various complex environments.

[0029] The above description of the disclosed embodiments enables those skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the present invention. Therefore, the present invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. A novel tensile-resistant flexible composite cable, characterized in that: The device includes a functional core assembly (1), which is wrapped with tensile fiber bundles (2) and dynamic buffer strips (3) on the outside. The tensile fiber bundles (2) are spirally wrapped around the outer wall of the functional core assembly (1), and the dynamic buffer strips (3) are filled in the spiral gaps of the tensile fiber bundles (2). The dynamic buffer strips (3) are regular hexagonal honeycomb skeletons. The tensile fiber bundles (2) and the dynamic buffer strips (3) are wrapped with stress transition layers (4) on the outside. The stress transition layers (4) are low-modulus thermoplastic elastomer layers, and the outer wall of the stress transition layers (4) is wrapped with an outer sheath (5). The outer sheath (5) is a braided reinforced polyurethane layer.

2. The novel tensile-resistant flexible composite cable according to claim 1, characterized in that: The tensile fiber bundle (2) includes a tensile inner layer (8) and a tensile outer layer (9). The tensile inner layer (8) and the tensile outer layer (9) are woven layers with opposite fiber directions. The tensile inner layer (8) is a blend of aramid fiber and ultra-high molecular weight polyethylene fiber, and the tensile outer layer (9) is woven from silicon carbide ceramic fiber.

3. The novel tensile-resistant flexible composite cable according to claim 1, characterized in that: The dynamic buffer strip (3) includes a polymer skeleton (6) and a shear thickening fluid (7). The polymer skeleton (6) has a regular hexagonal structure, and the shear thickening fluid (7) fills the center of the polymer skeleton (6).

4. The novel tensile-resistant flexible composite cable according to claim 1, characterized in that: The outer wall of the stress transition layer (4) is provided with multiple annular grooves (10) at equal intervals, and the inner wall of the outer sheath (5) is provided with a mating protrusion (11) corresponding to the position of the annular groove (10), and the mating protrusion (11) engages with the annular groove (10).

5. The novel tensile-resistant flexible composite cable according to claim 4, characterized in that: The mating protrusion (11) is a frustoconical protrusion, and the mating protrusion (11) is interference-fitted with the annular groove (10).

6. The novel tensile-resistant flexible composite cable according to claim 1, characterized in that: The outer sheath (5) has a braided reinforcement layer with a structure of stainless steel microfilaments and nylon multifilaments interwoven.

Images