Bowden Cable End Piece Connecting Structure
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Solution Overview
Problem
Conventional Bowden cables have a large diameter and high weight due to the limitations of metal shields, requiring multiple components and processing steps, which increases cost and degrades sliding properties.
Innovation Solution
A connecting structure for the end piece and outer cable using a hollow shield formed by twisting metal individual wires around a synthetic resin liner, with injection molding to integrate the mounting and bent pipe parts, reducing the number of components and processing steps, and enhancing the anchoring effect between the end piece and outer cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a metal band plate is used to form the shield in a conventional Bowden cable, then the shield can provide sufficient strength, but the minimum thickness of the metal band plate limits further reduction of the outer cable diameter and weight
Solution Approach 1:
The patent applies composite materials by combining synthetic resin (liner) with metal individual wires twisted around it to form the shield. This composite structure allows the shield to achieve sufficient strength while using thinner metal components, thereby reducing the overall diameter and weight of the outer cable compared to conventional solid metal band plate shields.
Solution Approach 2:
The shield is segmented into multiple individual metal wires (typically 7-19 wires) twisted around the synthetic resin liner, replacing the conventional solid metal band plate. This segmentation allows the metal material to be distributed more efficiently, maintaining strength while reducing total metal volume and enabling further diameter reduction.
2Ease of manufacture
If the mounting part and bent pipe part are produced separately using metal, then each component can be optimized for its specific function, but the number of components and processing steps increases, causing cost and weight increase
Solution Approach 1:
The patent merges the mounting part and bent pipe part into a single integrated end piece made of synthetic resin. This single-component design eliminates the need for separate metal components and their associated assembly steps (swaging, fitting), thereby reducing the number of components and processing steps while maintaining functional optimization through integrated design.
Solution Approach 2:
The end piece material changes from metal to synthetic resin, which enables integral molding of complex geometries that would be difficult or expensive to achieve with metal. This material parameter change allows the mounting part and bent pipe part to be formed as one piece through injection molding, reducing assembly complexity.
3Object-affected harmful factors
If a resin pipe inner is fitted into the metal bent pipe part to protect the inner wire, then the inner wire is protected, but the number of processing steps increases and a step occurs at the join area, degrading sliding properties
Solution Approach 1:
The protective function previously requiring a separate resin pipe inner fitted into a metal bent pipe part is merged into the single integral synthetic resin end piece. The end piece itself provides the protective function without requiring additional components, thereby eliminating the step at the join area and maintaining smooth sliding properties of the inner wire.
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 solution reduces the diameter and weight of the Bowden cable, improves its strength and flexibility, and maintains excellent sliding properties while simplifying the manufacturing process and reducing costs.
Implementation Method 1
the end piece is injection molded so as to envelop the first and second flare parts, the synthetic resin as a material of this end piece is made to enter between the metal individual wires
Data Source
AI summary
In a Bowden cable, a shield thereof is formed from a hollow strand that is formed by twisting a plurality of metal individual wires. An end part of this hollow strand is exposed by removing an outer skin and is increased in diameter, thereby forming a first flare part. An end part of a liner is also increased in diameter to form a second flare part. An end piece is injection molded so as to envelop these flare parts. A synthetic resin as a material of this end piece is made to enter between the metal individual wires. The end piece includes a mounting part and a bent pipe part for covering and surrounding an outer periphery of an outer cable in a state in which the outer cable is curved. The mounting part and the bent pipe part are formed as a unit by injection molding.