Communication Cable Intermediate Layer for Stable Signals and Easy Peeling
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Solution Overview
Problem
Existing communication cables face issues with unstable communication characteristics and poor peeling properties when mounted in vehicles due to structural changes in twisted-pair wires, such as collapse in twist pitch and distance between wires, and difficulty in peeling off the sheath.
Innovation Solution
A communication cable design featuring an electric wire bundle with insulated electric wires, a sheath layer in close contact with an intermediate layer, and a solid structure, where the intermediate layer has a lower melting point than the sheath and covering layers, composed of polyethylene resin or copolymer, while the sheath and covering layers are made of polypropylene resins.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the sheath and insulation sheath are in close contact through solid structure, then communication stability is improved, but peeling properties deteriorate due to fusion during extrusion molding
Solution Approach 1:
The cable structure is divided into three distinct layers: the insulation sheath (first resin layer), the intermediate layer (second resin layer), and the outer sheath (third resin layer). This segmentation allows each layer to have different material properties, enabling the intermediate layer to prevent fusion between the insulation sheath and outer sheath while maintaining structural integrity for stable communication.
Solution Approach 2:
The intermediate layer acts as a mediator between the insulation sheath and the outer sheath. It prevents direct contact and fusion between these two layers during extrusion molding, while still providing mechanical support to maintain the twisted-pair structure. The intermediate layer's material properties (higher melting point) allow it to resist fusion while the outer sheath can be easily peeled.
2Ease of operation
If air gaps are present between sheath and insulated electric wires, then peeling properties are improved, but structural stability deteriorates causing twist pitch collapse and wire distance change
Solution Approach 1:
The cable structure is divided into three distinct layers: the insulation sheath (first resin layer), the intermediate layer (second resin layer), and the outer sheath (third resin layer). This segmentation allows each layer to have different material properties, enabling the intermediate layer to prevent fusion between the insulation sheath and outer sheath while maintaining structural integrity for stable communication.
Solution Approach 2:
The intermediate layer acts as a mediator between the insulation sheath and the outer sheath. It prevents direct contact and fusion between these two layers during extrusion molding, while still providing mechanical support to maintain the twisted-pair structure. The intermediate layer's material properties (higher melting point) allow it to resist fusion while the outer sheath can be easily peeled.
3Ease of manufacture
If the sheath material has high melt flow rate (0.25 g/10 min or more), then ease of extrusion molding is improved, but peeling properties worsen due to fusion with insulation sheath
Solution Approach 1:
The cable structure is divided into three distinct layers: the insulation sheath (first resin layer), the intermediate layer (second resin layer), and the outer sheath (third resin layer). This segmentation allows each layer to have different material properties, enabling the intermediate layer to prevent fusion between the insulation sheath and outer sheath while maintaining structural integrity for stable communication.
Solution Approach 2:
The patent changes the material parameter (melting point) of the intermediate layer to be higher than both the insulation sheath and the outer sheath. This parameter change ensures that during extrusion molding, the intermediate layer remains solid and prevents fusion, while allowing the outer sheath to have good melt flow properties for easy molding. The specific requirement is that the intermediate layer's melting point is higher than the outer sheath's melting point by 20°C or more.
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 design stabilizes communication characteristics and enhances peeling properties, allowing easy detachment of the sheath layer without structural changes, even when mounted in vehicles.
Implementation Method 1
A melting point of a base resin constituting the intermediate layer is 20° C. or more lower than a melting point of base resins constituting the covering layer and the sheath layer
Data Source
AI summary
A communication cable includes: an electric wire bundle including a plurality of insulated electric wires, each having an electric conductor and a covering layer covering the electric conductor; a sheath layer covering an outer periphery of the electric wire bundle; and an intermediate layer that is interposed between the electric wire bundle and the sheath layer, and covers the outer periphery of the electric wire bundle. The intermediate layer is in close contact with a covering layer of each insulated electric wire, and the sheath layer has a solid structure in which the sheath layer is arranged so as to be in close contact with the intermediate layer. A melting point of a base resin constituting the intermediate layer is 20° C. or more lower than a melting point of base resins constituting the covering layer and the sheath layer.