Bend Resistant Cable With Alternating Stranding Directions
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Solution Overview
Problem
Existing bend resistant cables for vehicles, such as EMB cables, fail to provide sufficient bend resistance and tensile strength due to high contact pressure between child stranded conductors, leading to potential disconnection under severe conditions.
Innovation Solution
A stranded wire is formed by alternately arranging child stranded conductors with different stranding directions, allowing for parallel contact between strands, reducing contact pressure and stress concentration, and incorporating a central inclusion or hollow to enhance flexibility and abrasion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a reinforcing braided layer is added under the jacket to enhance bend resistance and tensile strength, then the cable's mechanical strength is improved, but the contact pressure between child stranded conductors increases causing abrasion
Solution Approach 1:
The patent applies different stranding directions to different child stranded conductors within the same cable structure. Specifically, odd-numbered child stranded conductors have strands stranded in one direction while even-numbered ones have strands stranded in the opposite direction. This local differentiation in stranding quality reduces contact pressure at interface portions between adjacent conductors during bending, while the overall reinforcing braided layer maintains mechanical strength.
2Ease of manufacture
If child stranded conductors are stranded in the same direction, then manufacturing is simplified, but stress concentration occurs at contact portions during bending leading to cable failure
Solution Approach 1:
The patent introduces asymmetry in the stranding direction of child stranded conductors. Instead of all conductors being stranded uniformly in the same direction (symmetric configuration), alternating conductors are stranded in opposite directions (odd-numbered conductors in one direction, even-numbered in the other). This asymmetric arrangement prevents stress concentration at contact portions during bending, significantly improving bend resistance while maintaining manufacturing feasibility.
Data Source
AI summary
A bend resistant cable includes a stranded wire including a plurality of child stranded conductors each having a plurality of strands, the plurality of child stranded conductors being circumferentially disposed and stranded. A stranding direction of the plurality of strands of the child stranded conductors circumferentially adjacent to each other is different from each other.