Braided Synthetic Rope Thermal Stretching Conductor Protection
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Solution Overview
Problem
Braided cables exert compressive forces on electrical conductors during tensile loading, risking conductor damage due to stretching, and existing protective measures do not adequately address this issue.
Innovation Solution
A braided man-made fiber traction rope is thermally stretched together with the electrical conductor, creating a form-fitting connection that reduces compression forces and incorporates a compressible equalization layer to mitigate damage risks, along with additional protective features like insulating and protective films.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a protective tube is used to protect the conductor against pressure stresses, then the conductor is protected against compression forces, but the conductor remains at risk of tearing due to rope stretching
Solution Approach 1:
The patent combines the conductor and rope into a single integrated structure through co-extrusion, where both components are formed simultaneously in one manufacturing process. This merging eliminates the interface between separate protective tube and conductor, creating a unified structure where the conductor is inherently protected against both compression and tearing forces through the integrated design.
Solution Approach 2:
The patent uses composite material structure with the rope made from synthetic fibers (such as polyethylene, polypropylene, or aramid) and the conductor integrated within. This composite construction allows the rope matrix to provide both compression resistance and tensile protection to the conductor simultaneously, resolving the contradiction between protecting against compression while preventing tearing.
2Strength
If the conductor is made rigid to maintain structural integrity, then the conductor resists deformation, but the conductor is more susceptible to damage from compression forces during rope stretching
Solution Approach 1:
The patent employs a dynamically adaptable conductor design that can deform elastically under compression during rope stretching. The conductor is configured to accommodate temporary compression forces through controlled deformation, then recover its shape when the load is removed. This dynamic behavior allows the conductor to maintain structural integrity while resisting permanent damage from compression forces.
Solution Approach 2:
The patent changes the physical parameters of the conductor, such as its cross-sectional shape, material composition, and flexibility characteristics. By adjusting these parameters, the conductor can optimally balance structural integrity with compression resistance, allowing it to withstand the dynamic loads experienced during rope stretching without suffering permanent damage.
3Stability of the object's composition
If the rope is stretched to reduce compression forces on the conductor, then the form-fitting connection improves, but the conductor is at risk of tearing from the stretching process
Solution Approach 1:
The patent applies preliminary stretching to the rope and conductor assembly during the manufacturing process, before the conductor is fully installed or the rope is put into service. This preliminary action pre-establishes the form-fitting connection between the rope matrix and conductor, reducing compression forces during normal operation. The conductor is designed to withstand this preliminary stretching without tearing through careful selection of material properties and geometric configuration.
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
The solution significantly reduces the risk of conductor damage by absorbing compressive forces and providing protection against stretching, ensuring reliable data transmission and power supply.
Implementation Method 1
the man-made fiber traction cable is thermally stretched together with the conductor accommodated therein
Implementation Method 2
there is a permanent deformation of the rope and possibly also of the conductor, resulting in an intimate form-fitting connection
Implementation Method 3
The balancing layer can be flexible or elastically compressible, for example in the form of a foam layer
Implementation Method 4
the occurring inwardly directed compression forces is compressed
Data Source
Figure 1~2
Figure 3~7
AI summary
Braided chemical fiber cable in which at least one electrical conductor is included, characterized in that the cable together with the conductor included therein is thermally stretched.