Composite Cable Shield Layer Deformation Control
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Solution Overview
Problem
Existing composite cables experience deformation and potential breakage of the shield layer due to compression from fillers used to maintain a circular cross-sectional shape, especially when repeatedly bent.
Innovation Solution
A composite cable design featuring a shield electric wire with a stranded structure and opposing filler directions, where the first line filler has a higher filling rate and density within the shield layer, and the second line filler is more sparse between the assembly and sheath, maintaining the circular shape and reducing deformation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the shield layer is compressed by filler pressure, then the circular cross-sectional shape is maintained, but the shield layer becomes prone to breakage during repeated bending
Solution Approach 1:
By segmenting the filler into two types positioned at different locations, the compressive force on the shield layer is significantly reduced. The first filler provides minimal necessary support while the second filler carries the primary load of maintaining circular shape, thereby protecting the shield layer from excessive compression and reducing breakage risk during repeated bending.
Solution Approach 2:
The first filler acts as a cushioning layer positioned between the signal wires and the shield layer, providing beforehand protection against compressive forces. This cushioning effect prevents direct transmission of filler pressure to the shield layer, thereby maintaining reliability during repeated bending operations.
2Device complexity
If a single type of filler is used between the electric wire assembly and the sheath layer, then the structure is simple, but the shield layer cross-sectional shape deforms
Solution Approach 1:
The filler structure is segmented into two functional zones with different filler types, which increases structural complexity but is justified by the significant improvement in shield layer shape maintenance. The first filler zone specifically protects the shield layer while the second filler zone maintains overall cable geometry, achieving a balance between complexity and performance.
Solution Approach 2:
Different filler materials are selected for different local requirements: the first filler is chosen for its ability to minimize compression on the shield layer, while the second filler is chosen for its ability to maintain the circular shape of the entire cable assembly. This local quality differentiation resolves the shape deformation problem while keeping the overall structure manageable.
Data Source
AI summary
Both deformation of a cross-sectional shape of the entire composite cable and deformation of a cross-sectional shape of an electric wire included in the composite cable are suppressed. The composite cable includes: a plurality of first electric wires; a shield electric wire in which a shield layer 33 is formed around a twist pair wire 32 obtained by intertwining a plurality of second electric wires; a sheath formed around an electric wire assembly obtained by intertwining the first electric wires and the shield electric wire; a first line filler filled between the twist pair wire and the shield layer; and a second line filler filled between the electric wire assembly and the sheath. While the first electric wires and the shield electric wire are intertwined in a first direction, the second electric wires are intertwined in a second direction that is opposite to the first direction.