Composite Cable Layout for Combined Power and Data Isolation
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Solution Overview
Problem
The segregation of data and power cables in electrical installations poses challenges, particularly in applications like electric vehicle charging, where both are required but must be run separately due to electrical interference and safety standards, such as British Standard BS7671, which prohibits their proximity.
Innovation Solution
A composite cable design that insulates both data and power cores to the same nominal voltage, optionally includes a dummy core to alleviate pressure on the data cable during twisting, and uses advanced shielding and bedding materials like polyvinylchloride with specific additives for enhanced protection and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If data and power cables are segregated according to British Standard BS7671, then electrical safety and interference protection are improved, but cable installation complexity and space requirements increase
Solution Approach 1:
The patent combines data cable and power cable into a single composite cable assembly, integrating previously separate cables into one unified structure. This merging maintains the required electrical segregation through internal positioning while eliminating the need for separate routing, thereby reducing installation complexity without compromising safety
Solution Approach 2:
The patent introduces an intermediary structure (the composite cable assembly with specific positioning elements) that mediates between the conflicting requirements of electrical segregation and installation simplicity. This intermediary maintains proper spacing and orientation between data and power conductors while providing a single integrated installation unit
2Object-affected harmful factors
If data and power cables are run separately, then electrical interference is reduced, but installation time and labor costs increase
Solution Approach 1:
By combining data and power cables into a single composite assembly with pre-established proper spacing and shielding, the patent eliminates the time-consuming process of installing and aligning separate cables while maintaining interference protection through the integrated structure
3Shape
If data cable is twisted with power cable in composite cable, then cable flexibility and compactness are improved, but data cable integrity and signal quality deteriorate
Solution Approach 1:
The patent applies different structural characteristics to different parts of the composite cable: the data cable maintains its original non-twisted structure to preserve signal integrity, while the power cable and outer assembly provide the necessary compactness. This local differentiation allows the whole cable to be compact without compromising data transmission
Solution Approach 2:
The patent introduces positioning elements and spacing structures as intermediaries between the data and power cables within the composite assembly. These intermediaries maintain proper separation and prevent harmful interactions during the cable formation process while allowing the overall assembly to achieve compact dimensions
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
Enables the safe and efficient co-existence of data and power cables within a single composite cable, maintaining the integrity of the data cable and supporting higher current capacities, while adhering to safety standards and accommodating various electrical phases.
Implementation Method 1
Each core may be provided with separate polymeric insulation material with dielectric strength to withstand high voltage testing at 2500V
Implementation Method 2
The at least one data cable is preferably super screened to minimise or avoid electronic interference. A super screen may include one or more braided screens and one or more metal foil screens.
Implementation Method 3
The cores may be protected by a polymeric bedding material. The polymeric bedding material may be provided about an outer side of the respective cores and sandwich the cores relative to one another.
Data Source
AI summary
A composite cable comprising at least one data cable and at least one electric power core, with the at least one data cable and at least one electric power core insulated to the same nominal voltage rating.