Closed-Loop Cable Splice Geometry via Polymer Overmolding
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Solution Overview
Problem
The splicing of cables in cable transport installations creates geometric irregularities that generate vibrations, leading to environmental disturbance and accelerated wear of components, due to the inherent nature of traditional splicing methods which involve knots and core replacement.
Innovation Solution
A method of manufacturing closed-loop cables where the splice knots are formed using the ends of the strands, which are then inserted inside the cable and overmolded with a polymer to achieve high geometric regularity, reducing or eliminating vibrations and extending the cable's lifespan.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional splicing methods are used to join cable ends, then the cable can be closed-looped, but geometric irregularities are generated that cause vibrations and accelerate wear
Solution Approach 1:
A polymer compound is introduced as an intermediary material to fill the splice zone and surround the knotted strands. This polymer acts as a mediator that smooths out the geometric irregularities of the knots and tuck-in areas, creating a regular external cable surface while allowing the traditional splicing structure to remain intact internally.
Solution Approach 2:
The invention changes the physical state and properties of the splice zone by injecting a polymer compound that transitions from liquid/injected state to solidified state. This parameter change fills voids, smooths surfaces, and transforms the irregular splice zone into a geometrically regular section that matches the rest of the cable.
2Reliability
If traditional splicing with knots is used, then cable ends can be joined, but vibrations are generated that disturb the environment and accelerate component wear
Solution Approach 1:
The polymer compound serves as an intermediary damping material that surrounds the knotted strands and absorbs vibrational energy. This mediator reduces the transmission of vibrations to the environment and to other cable components, while still allowing the knot structure to provide the necessary mechanical connection.
Solution Approach 2:
The invention changes the mechanical properties of the splice zone by introducing a polymer material with damping characteristics. This parameter change transforms the splice zone from a vibration-generating irregularity into a vibration-damping section that reduces harmful oscillations.
3Device complexity
If the splice zone is left irregular as in traditional splicing, then the splicing process is simpler, but the cable lifespan is reduced due to accelerated wear
Solution Approach 1:
The polymer compound acts as a protective intermediary layer that surrounds and protects the knotted strands and tuck-in areas from mechanical wear and environmental degradation. This mediator shield extends the lifespan of the splice zone and the entire cable by preventing direct contact and wear between the irregular splice features and external elements.
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 method significantly reduces vibrations and prolongs the life of the cable by creating a highly regular splice zone, minimizing environmental disturbance and wear on components.
Implementation Method 1
a splice zone is understood to mean a zone comprising a splice node and the two cable portions immediately adjacent to this node, along which the two knotted strands have been tucked in place of the core
Implementation Method 2
The overmolding is carried out using a two-component thermosetting polymer
Data Source
Figure 1~2
Figure 3
AI summary
A method for manufacturing a closed-loop cable (1), said cable comprising a core (2) and metal strands (3) wound in a helix about the core (2), wherein the two ends of the cable are connected in splice areas in which splice knots are formed using the ends of each of the strands (3), which are then inserted into the cable after having locally removed the core (2) therefrom, each splice area then being overmoulded with a polymer. The invention also concerns a method for manufacturing a closed-loop cable (1) wherein the ends of the strands (2) are lined by overmoulding them with a polymer, prior to inserting same into the cable (1). It finally concerns a corresponding closed-loop cable (1) and the use thereof as a pure traction cable or as a hauling traction cable.