Composite Cable Rigidity Layout to Suppress Wire Buckling
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Solution Overview
Problem
Conventional composite cables experience reduced bending durability due to buckling of insulated wires, particularly those not coated by an inner sheath, which are thinner and more prone to stress concentration during repeated bending.
Innovation Solution
The composite cable design includes insulated wires with varying bending rigidity, where wires not covered by an inner sheath have higher rigidity through the use of harder metals, thicker insulators, or larger diameters, and are twisted as composite stranded wires to minimize buckling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If insulated wires not covered by inner sheath are made thinner to reduce cable diameter, then cable compactness is improved, but bending durability deteriorates due to buckling and stress concentration
Solution Approach 1:
The patent applies local quality by giving different bending rigidities to different insulated wires based on their specific conditions. Wires not covered by the inner sheath (which are more prone to buckling) are designed with higher bending rigidity through using harder metals, thicker insulators, or larger diameters, while wires covered by the inner sheath can maintain lower rigidity for flexibility. This localized differentiation resolves the contradiction by protecting vulnerable wires without unnecessarily increasing the overall cable diameter.
Solution Approach 2:
The patent employs parameter changes by adjusting the bending rigidity parameters of specific insulated wires. By changing material properties (harder metals), geometric parameters (thicker insulators or larger diameters), or structural configuration (composite stranded wires), the patent modifies the rigidity parameter of vulnerable wires to prevent buckling while maintaining cable compactness through optimized parameter selection.
2Reliability
If insulated wires not covered by inner sheath are made with higher bending rigidity to prevent buckling, then bending durability is improved, but wire flexibility deteriorates
Solution Approach 1:
The patent applies local quality by providing higher bending rigidity only to specific insulated wires that are not covered by the inner sheath and are therefore prone to buckling. Wires that are covered by the inner sheath maintain their original flexibility characteristics. This localized approach ensures that rigidity enhancement is applied only where necessary for durability, preserving overall cable flexibility where the inner sheath already provides protection.
Solution Approach 2:
The patent employs composite materials by using composite stranded wire structures for wires requiring higher rigidity. These composite structures combine multiple strands with different properties to achieve the desired balance between rigidity and flexibility, allowing the wire to resist buckling while maintaining adequate flexibility for installation and operation.
Data Source
AI summary
A composite cable is provided with a plurality of insulated wires, each including a conductor wire made of a conductive metal covered with an insulator made of a resin, an inner sheath covering some insulated wires of the plurality of insulated wires, and an outer sheath collectively covering the plurality of insulated wires and the inner sheath, wherein a bending rigidity of at least one insulated wire not covered by the inner sheath of the plurality of insulated wires is higher than a bending rigidity of the some insulated wires covered by the inner sheath.