Cable Jacket Composite Film and Braided Filament Bonding
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Solution Overview
Problem
Existing protective jackets for elongated assemblies, such as cable assemblies, face issues with mechanical failure due to localized stress and abrasion, leading to performance degradation and increased downtime, especially in confined spaces and harsh environments, and adding additional reinforcement increases weight.
Innovation Solution
A protective jacket system comprising a film layer and a braided, woven, or warp-knit layer of high-melt filament with a bonding region between the two, providing improved abrasion resistance and cut-through resistance without the need for additional protective sleeves, which reduces weight and enhances flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If additional protective materials are used to reinforce the jacket, then abrasion resistance and cut-through resistance are improved, but weight increases
Solution Approach 1:
The patent applies composite materials by combining a film layer with a braided, woven, or warp-knit layer of high-melt filament in a single integrated jacket structure. This composite construction provides enhanced abrasion and cut-through resistance through the synergistic combination of materials, eliminating the need for additional protective sleeves while maintaining improved strength-to-weight ratio
Solution Approach 2:
The patent merges the protective functions of multiple layers into a single integrated jacket system. The film layer and the high-melt filament layer are bonded together to form a unified structure that provides both flexibility and reinforcement, replacing the need for separate protective sleeves that would add weight
2Strength
If the jacket is made more rigid to improve abrasion resistance, then durability is improved, but flexibility deteriorates
Solution Approach 1:
The composite structure combines a flexible film layer with a reinforcement layer of high-melt filament, creating a jacket that maintains flexibility while gaining abrasion resistance. The film layer provides inherent flexibility, while the bonded filament layer adds protective strength without significantly compromising the overall flexibility of the assembly
Solution Approach 2:
The patent applies reinforcement locally through the braided, woven, or warp-knit layer of high-melt filament that is bonded to specific regions of the film layer. This localized reinforcement provides abrasion resistance where needed while maintaining the flexibility of the film layer in other areas, avoiding the need to make the entire jacket rigid
3Weight of moving object
If the jacket structure is simplified to reduce weight, then weight is reduced, but abrasion resistance and cut-through resistance deteriorate
Solution Approach 1:
The patent uses composite materials to achieve a lightweight yet strong jacket structure. The combination of film layer and high-melt filament layer creates an integrated protective system that provides enhanced abrasion and cut-through resistance without requiring additional protective sleeves, thereby maintaining weight reduction benefits
Solution Approach 2:
The high-melt filament layer serves multiple functions simultaneously: it provides abrasion resistance, cut-through resistance, and structural reinforcement, all within a single layer that is bonded to the film layer. This multi-functionality eliminates the need for separate protective components, reducing overall weight while maintaining strength
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 jacket system offers enhanced abrasion resistance by at least 15% and cut-through resistance by at least 10% compared to jackets without a bonding region, while maintaining flexibility and resistance to high temperatures, reducing the likelihood of mechanical failure and eliminating the need for additional protective sleeves.
Implementation Method 1
a bonding region between the braided, woven, or warp-knit layer and a second surface of the film layer, opposing to the first surface, to adhere at least a portion of the high-melt fibers
Data Source
AI summary
A jacket for an elongated assembly is disclosed. The jacket, which may be a tubular shape or sheet, comprises a film layer to surround a core member of the elongated assembly, wherein the film layer has a first surface to be arranged abutting the core member in a non-bonded relationship; a braided, woven, or warp-knit layer comprising high-melt filament having a titer from 30 to 800 denier; and a bonding region between the braided, woven, or warp-knit layer and a second surface of the film layer, opposing to the first surface, to adhere at least a portion of the high-melt fibers. The jacket may further comprise an inner film layer in a non-bonded relationship with the film layer.