Composite Cable Lubricant-Free Design
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Solution Overview
Problem
The existing composite cables used in vehicles for connecting wheel-side and vehicle-body components face issues with lubricant scattering during termination, leading to a deteriorated working environment and reduced flexibility.
Innovation Solution
A composite cable design featuring a first and second twisted-pair wire, with a larger third electric wire arranged circumferentially, and a tape member spirally wound around the assembled article, all twisted in the same direction, eliminates the need for lubricants like talc powder by reducing friction between wires and the sheath.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a lubricant such as talc powder is interposed between electric wires and a sheath to reduce friction and improve flex resistance, then the flex resistance is improved, but the lubricant may be scattered in the workplace during cable termination, leading to deterioration of the working environment
Solution Approach 1:
The patent extracts and removes the lubricant (talc powder) from the cable structure entirely, replacing it with a lubricant-free design that achieves flex resistance through structural means rather than material coating, thereby eliminating the harmful scattering effect during termination
Solution Approach 2:
The patent applies different structural characteristics to different parts of the cable - specifically using a twisted-pair configuration for signal wires and a specific arrangement with a pair of third electric wires having larger outer diameters, creating local structural qualities that reduce friction and improve flex resistance without requiring lubricant material
2Object-generated harmful factors
If a tape member is spirally wound around the assembled article with all components twisted in the same direction, then the working environment is protected and friction is reduced, but the device complexity increases
Solution Approach 1:
The patent merges the functions of multiple components into a unified twisted structure where the first twisted-pair wire, second twisted-pair wire, and pair of third electric wires are all twisted together in the same direction, creating a harmonized assembly that reduces internal friction and eliminates the need for separate lubricant application
Solution Approach 2:
The patent segments the cable into distinct functional units - twisted-pair wires for signal transmission and a pair of third electric wires with larger diameters for power or ground functions - allowing each segment to be optimized for its specific function while contributing to the overall friction-reduction through the unified twist direction
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
This design prevents environmental deterioration during cable termination while maintaining flexibility and improving workability and distortion resistance.
Implementation Method 1
a tape member spirally wound around an assembled article that is formed by twisting the first twisted-pair wire, the second twisted-pair wire and the pair of third electric wires together
Data Source
AI summary
A composite cable includes a first twisted-pair wire formed by twisting a pair of first electric wires which each include a first center conductor and a first insulation, a second twisted-pair wire formed by twisting a pair of second electric wires which each include a second center conductor and a second insulation, a pair of third electric wires arranged between the first and second twisted-pair wires, the third electric wires each having a larger outer diameter than the first and second electric wires and including a third center conductor with a larger cross-sectional area than the first and second center conductors and a third insulation, and a tape member spirally wound around an assembled article formed by twisting the first and second twisted-pair wires and the pair of third electric wires together. The twisted-pair wires, the assembled article and the tape member are twisted or wound in a same direction.