Stretchable Cable Assisting Wire Reduces Connector Load
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Solution Overview
Problem
Conventional electronic cables experience stress and load on connecting parts when the outer tube stretches due to bending or stretching, as the core wires do not stretch, leading to potential disconnection and damage.
Innovation Solution
Incorporating an assisting wire that is less stretchable than the outer tube, which is made of flexible and stretchable resin, to restrain the outer tube's movement and reduce the load on the connecting parts between core wires and terminals, using connectors to fasten the assisting wire to the outer tube.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the outer tube is made of flexible and stretchable resin to allow bending and stretching, then the cable's flexibility and adaptability are improved, but the connecting parts between core wires and terminals are subjected to excessive load and stress
Solution Approach 1:
An assisting wire is introduced as an intermediary element between the outer tube and the core wires. This assisting wire has stretchability lower than the outer tube but higher than the core wires, acting as a mediator that absorbs and distributes the stress generated when the cable is bent or stretched, thereby protecting the vulnerable connecting parts while maintaining cable flexibility
Solution Approach 2:
The cable employs a composite structure combining multiple materials with different mechanical properties: the outer tube uses flexible stretchable resin for adaptability, the assisting wire uses material with intermediate stretchability for stress absorption, and the core wires use conductive material for electrical function. This multi-material composite approach resolves the contradiction between flexibility and structural strength
2Ease of operation
If the outer tube stretches when the cable is bent or stretched, then the cable can accommodate movement and positioning, but the core wires experience excessive stress since they do not stretch
Solution Approach 1:
The assisting wire serves as a stress-distributing intermediary that is positioned between the stretchable outer tube and the non-stretchable core wires. When the cable undergoes bending or stretching, the assisting wire deforms to accommodate the movement while its intermediate stretchability prevents excessive stress from being transmitted directly to the core wires and their connecting parts
3Reliability
If the assisting wire is fastened to the outer tube to restrain its movement, then the outer tube's stretching is controlled, but the fastening structure must prevent slipping or snapping under load
Solution Approach 1:
The fastening structure is segmented into multiple independent fastening points distributed along the assisting wire and outer tube. This segmentation allows the fastening function to be achieved through multiple simple attachment points rather than a single complex mechanism, reducing overall structural complexity while maintaining reliable movement control of the outer tube
Solution Approach 2:
The assisting wire is pre-fastened to the outer tube at specific positions before the cable is put into service. This preliminary action ensures that the fastening structure is already in place to control outer tube movement from the beginning, preventing excessive stretching and eliminating the need for complex adjustment mechanisms during operation
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 design effectively reduces the load on the connecting parts between core wires and terminals, preventing damage and ensuring reliable electrical connection even when the cable is bent or stretched, while allowing for secure fastening and preventing slipping or snapping of the assisting wire.
Implementation Method 1
The outer tube is made of a flexible and stretchable resin. Therefore, the outer tube may stretch when the cable main is bent or stretched in the length direction thereof. However, since the core wires made of a conductor such as copper do not stretch, a load is applied to the connecting part between the core wires and the terminals when the outer tube stretches.
Data Source
AI summary
A cable main includes an outer tube, a core wire, and an assisting wire. The assisting wire is less stretchable than the outer tube. Connectors provided at ends of the cable main fasten ends of the assisting wire at ends of the outer tube so as to restrain the ends of the outer tube from moving in a stretch direction of the outer tube. According to this structure, even when the outer tube is stretched, a load applied to a connecting part between the core wire and a terminal of the connector can be reduced.