Composite Cable Shield Layer Deformation Prevention
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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 higher density first line filler between the stranded electric wire and the shield layer, and a lower density second line filler between the assembly and the sheath, both fillers being intertwined in the same direction as the electric wires, to maintain the circular shape and reduce pressure on the shield layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a filler is formed between the electric wire assembly and the sheath layer to maintain a circular cross-sectional shape, then the cross-sectional shape of the composite cable is maintained, but the shield layer is compressed and deforms, leading to potential breakage
Solution Approach 1:
The filler is divided into two distinct types: a first filler positioned between the stranded electric wire and the shield layer, and a second filler positioned between the electric wire assembly and the sheath layer. This segmentation allows each filler type to serve specific functions - the first filler provides gentle support to the shield layer while the second filler maintains the overall circular shape of the composite cable, thereby preventing shield layer compression and deformation.
Solution Approach 2:
Different filler materials with different properties are used in different locations. The first filler near the shield layer has properties that provide gentle support and minimize compression, while the second filler near the sheath layer has properties optimized for maintaining the overall circular cross-sectional shape. This local differentiation of filler quality resolves the contradiction between shape maintenance and shield layer protection.
2Shape
If the shield layer cross-sectional shape deforms due to filler compression, then the composite cable can be manufactured with a circular outer shape, but repeated bending causes high possibility of shield layer breakage
Solution Approach 1:
By segmenting the filler into two types positioned at different locations, the first filler protects the shield layer from compression during manufacturing while the second filler maintains the circular shape. This segmentation ensures the shield layer maintains its circular cross-sectional shape even during repeated bending, thereby extending the cable's service life and preventing breakage.
Solution Approach 2:
The first filler acts as a cushioning layer positioned beforehand between the stranded electric wire and the shield layer. This pre-positioned cushioning prevents direct compression of the shield layer during cable assembly and manufacturing processes, and provides ongoing protection during repeated bending operations, thereby enhancing durability and preventing breakage.
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. The first electric wires and the shield electric wire are intertwined in a first direction, and the second electric wires are also intertwined in the first direction.