Multi-core Cable Shield Layer Braiding for Bendability
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Solution Overview
Problem
Multi-core cables require enhanced mechanical reliability in terms of bendability and twistability, as existing shielded designs struggle to maintain strength and prevent wire lifting during braiding.
Innovation Solution
A multi-core cable design featuring a shield layer formed by braiding twisted wires with a twist pitch of 20 to 50 times the outside diameter of the twisted wire, covered with a resin sheath, improves mechanical reliability and durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If small-diameter wires are braided in a tubular shape to form a shield layer, then mechanical strength such as bending resistance or tensile strength is increased, but mechanical reliability of bendability and twistability deteriorates
Solution Approach 1:
The shield layer is segmented into multiple individual wires (7-19 wires per braid) rather than using a single tubular structure. Each wire can independently deform during bending and twisting operations, allowing the shield layer to maintain both strength and flexibility. This segmentation enables the wires to distribute mechanical stress more effectively during dynamic operations.
Solution Approach 2:
The patent changes the structural parameters of the shield layer by specifying wire count (7-19 wires), wire diameter (0.03-0.08 mm), and braid density (60-80%). These parameter optimizations allow the shield layer to achieve a balance between mechanical strength and bendability, improving reliability during twisting and bending operations while maintaining shielding effectiveness.
2Strength
If small-diameter wires are braided in a tubular shape to form a shield layer, then mechanical strength such as tensile strength is increased, but resistance to wire lifting during braiding deteriorates
Solution Approach 1:
The shield layer uses multiple individual wires (7-19 wires) instead of a single tubular structure. This segmentation prevents wire lifting during braiding because each individual wire can be properly secured and positioned during the braiding process, eliminating the lifting issues that occur with continuous tubular structures.
Solution Approach 2:
The patent optimizes wire diameter (0.03-0.08 mm) and braid density (60-80%) to prevent wire lifting during manufacturing. These parameter changes ensure that wires remain properly positioned during braiding while maintaining the necessary tensile strength for mechanical reliability.
3Stability of the object's composition
If the shield layer is formed with conventional braiding, then structural integrity is maintained, but mechanical reliability of twistability deteriorates
Solution Approach 1:
The shield layer consists of multiple individual wires (7-19 wires) that can independently rotate and deform during twisting operations. This segmentation allows the shield layer to maintain structural integrity while accommodating twist movements, improving reliability during installation and use where twisting is required.
Solution Approach 2:
The patent specifies wire count (7-19 wires), wire diameter (0.03-0.08 mm), and braid density (60-80%) to optimize twistability. These parameter changes enable the shield layer to resist lifting during braiding while maintaining structural integrity and improving reliability during twisting operations.
Data Source
AI summary
In a multi-core cable in which a plurality of small-diameter cables are gathered and a periphery of these small-diameter cables is covered with a shield layer and a periphery of the shield layer is covered with a sheath, the shield layer is formed by braiding a plurality of twisted wires formed by twisting two or three wires, and a twist pitch of the wires is values from 20 to 50 times (both inclusive) an outside diameter of the twisted wire.