Braided Cable Insulator Structure for Flexibility and Kink Resistance
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Solution Overview
Problem
Computer mouse cables lack sufficient flexibility and are prone to kink formation due to their inherent memory, which affects their performance and aesthetics.
Innovation Solution
The cables are designed with a braided cable insulator and multiple wires organized in a predetermined braiding pattern, including braided wire and cord insulators, to enhance flexibility, increase tensile strength, and reduce kink formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If stranded cables are used to improve flexibility, then flexibility is enhanced, but skin effect increases causing power loss
Solution Approach 1:
The patent changes the physical parameters of the cable construction by using a braided pattern with specific geometric characteristics. The braided structure modifies the effective surface area and current distribution characteristics, reducing skin effect while maintaining flexibility through the inherent geometry of the braid rather than relying on traditional stranded configurations.
Solution Approach 2:
The patent employs a composite structure combining multiple wire strands in a braided configuration with specific insulation materials. This composite approach allows optimization of both electrical properties (reducing skin effect) and mechanical properties (maintaining flexibility) through the synergistic combination of different materials and their spatial arrangement.
2Ease of manufacture
If traditional cable structures are used, then manufacturing is simpler, but kink formation increases
Solution Approach 1:
The patent divides the cable into multiple independent wire strands that are braided together. This segmentation allows each strand to move independently, reducing the propagation of bends and kinks through the entire cable. The modular stranded structure enables local deformation without affecting the whole cable, thereby reducing kink formation while maintaining manufacturability through standard braiding processes.
3Ease of manufacture
If solid cables are used to reduce manufacturing cost, then manufacturing cost decreases, but flexibility deteriorates
Solution Approach 1:
The patent divides the solid cable into multiple thinner wire strands that are braided together. This segmentation maintains flexibility by allowing individual strands to bend independently, while the overall cable structure remains cost-effective through the use of standard manufacturing processes and materials. The segmented approach achieves flexibility enhancement without proportionally increasing manufacturing complexity.
Data Source
AI summary
A cable including a number of cords of wires. The cords of wires are braided together in a predetermined braiding pattern. Each cord of wires includes a number of wires. The wires of each cord of wires are braided together in a predetermined braiding pattern. The cable further includes a cable insulator that collectively encapsulates the cords of wires. The cable further includes cord insulators. Each cord insulator collectively encapsulates the wires of each cord of wires. Each wire is encapsulated within a wire insulator. At least one of the cable insulator, the cord insulator, and the wire insulator is braided in a predetermined braiding pattern. The braiding of the cords of wires, the wires of each cord of wires, the cable insulator, the cord insulator, and the wire insulator, enhances at least one of flexibility and tensile strength of the cable. The braiding of the cords of wires, the wires of each cord of wires, the cable insulator, the cord insulator, and the wire insulator preferably decreases propensity of kink formation in the cable. A method for manufacturing cables is also provided by the present disclosure.