Composite Cable Outer Shape Consistency via Intermediary Sheath
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing composite cables used for routing from a vehicle body to a wheel experience changes in outer shape along the longitudinal direction due to differences in twist pitch and twist phase between twisted pair wires, leading to potential structural issues and processing challenges.
Innovation Solution
A composite cable design featuring a pair of first single core wires, a first multicore wire with a twisted pair of smaller cross-sectional area wires, and a second multicore wire with a twisted pair of even smaller wires, all covered with sheaths to maintain a consistent outer diameter and prevent shape changes, along with a binding tape and outer sheath for stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If different twist pitches or twist phases are used between first twisted pair wire and second twisted pair wire, then cable flexibility and signal transmission performance are improved, but outer shape consistency of the twisted assembly deteriorates
Solution Approach 1:
An outer sheath is introduced as an intermediary element that encloses the twisted assembly containing first and second twisted pair wires with different twist pitches or phases. The outer sheath masks the irregular outer shape caused by the different twist characteristics, providing a consistent external form while allowing the internal wires to maintain their optimized twist configurations for signal transmission.
Solution Approach 2:
The outer sheath acts as a flexible shell that conforms to the twisted assembly while providing a uniform outer surface. This flexible covering maintains outer shape consistency without restricting the internal wires from having different twist pitches or phases, thus preserving signal transmission performance while achieving external regularity.
2Object-affected harmful factors
If different twist pitches are used between twisted pair wires, then electromagnetic interference resistance is improved, but manufacturing precision and assembly consistency deteriorate
Solution Approach 1:
The outer sheath serves as a mediator that unifies the external appearance of the twisted assembly while allowing internal wires with different twist pitches to coexist. This enables manufacturers to optimize each twisted pair for electromagnetic interference resistance with different twist characteristics while maintaining consistent assembly dimensions for manufacturing precision.
Solution Approach 2:
The patent applies different twist pitch parameters to the first and second twisted pair wires to optimize electromagnetic interference resistance. The outer sheath then standardizes the external dimensional parameters, allowing the assembly to maintain manufacturing precision despite the varied internal twist parameters.
3Object-affected harmful factors
If twist phase differences are introduced between twisted pair wires, then signal shielding performance is improved, but outer shape regularity deteriorates
Solution Approach 1:
The outer sheath acts as an intermediary that encloses the twisted assembly with wires having different twist phases. This covering masks the irregular outer shape resulting from phase differences while preserving the internal configuration that provides signal shielding performance.
Solution Approach 2:
The outer sheath functions as a flexible shell that provides a regular outer surface while accommodating internal wires with different twist phases. This maintains signal shielding effectiveness through phase differences while achieving external shape regularity for consistent cable appearance and handling.
Data Source
AI summary
A composite cable includes a twisted assembly including a pair of first single core wires and first and second multicore wires that are each arranged in one or the other of regions facing each other across a center plane passing through the central axes of the pair of first single core wires, include an electric wire with a solid (non-hollowed) structure including a first or second twisted pair wire formed by twisting a pair of second or third single core wires with a smaller cross-sectional area than the first single core wire and a first or second inner sheath covering the first or second twisted pair wire so as to fill a space between the pair of second or third single core wires, and have an outer diameter that is not less than 70% and not more than 160% of the outer diameter of the first single core wire.