Composite Cable Sheath Composition for Flexibility and Abrasion Resistance
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Solution Overview
Problem
Composite cables used in brake control systems, such as ABS and EPB, face challenges in maintaining flexibility and flex resistance while ensuring abrasion resistance and low-temperature properties, especially when multiple electric wires are incorporated, leading to a decline in these properties due to the use of polyurethane sheaths.
Innovation Solution
A composite cable design featuring a sheath composed of a resin composition containing ethylene rubber and styrene elastomer at 10 to 50 mass %, with cross-linked materials and organic mineral oil, and incorporating inorganic fillers like silica or magnesium hydroxide, which enhances abrasion resistance, flexibility, and flex resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If polyurethane is used as the sheath material to ensure abrasion resistance and low-temperature property, then abrasion resistance and low-temperature property are improved, but flexibility and flex resistance deteriorate
Solution Approach 1:
The patent uses a composite resin composition consisting of polyolefin resin (50-90 mass%) and polyurethane resin (10-50 mass%). This composite material combines the flexibility and processability of polyolefin with the abrasion resistance and low-temperature properties of polyurethane, resolving the contradiction between durability and flexibility.
Solution Approach 2:
The patent optimizes the compositional ratio between polyolefin resin and polyurethane resin, specifying that polyurethane resin should constitute 10-50 mass% of the total. This parameter optimization ensures that the sheath maintains adequate flexibility while achieving sufficient abrasion resistance and low-temperature performance.
2Device complexity
If multiple electric wires are incorporated into the sheath to achieve space saving, then cable integration is improved, but flexibility and flex resistance deteriorate
Solution Approach 1:
The composite resin composition enables the sheath to maintain flexibility even when accommodating multiple electric wires. The polyolefin base provides inherent flexibility that prevents the cable from becoming rigid despite increased wire count, while the polyurethane component ensures durability.
Solution Approach 2:
By controlling the polyurethane resin content within 10-50 mass%, the patent optimizes the balance between sheath rigidity and flexibility. This allows the cable to integrate multiple wires for space saving while maintaining adequate flex resistance for vehicle applications.
3Temperature
If polyurethane sheath is used to ensure low-temperature property, then low-temperature resistance is improved, but flex resistance deteriorates
Solution Approach 1:
The patent creates a composite resin system where polyolefin resin (50-90 mass%) provides the flex resistance and mechanical strength, while polyurethane resin (10-50 mass%) contributes low-temperature flexibility. This synergistic combination resolves the contradiction between cold-weather performance and bending durability.
Solution Approach 2:
The patent specifies that polyurethane resin should comprise 10-50 mass% of the total resin composition. This optimized ratio ensures that the sheath remains flexible at low temperatures (down to -40°C) while maintaining sufficient flex resistance to prevent conductor fracture during repeated bending cycles.
Data Source
AI summary
A composite cable includes a sheath surrounding an outer surface of a core at least including a plurality of thick electric wires each having a resin layer on an outer circumference of a conductor, and a plurality of thin electric wires each having a resin layer on an outer circumference of a conductor, in which the sheath includes a resin composition including base resin containing at least one type of ethylene rubber and styrene elastomer at 10 to 50 mass %.