Explosion-Protected Data Cable Filler Viscosity
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Solution Overview
Problem
Data cables with 'free areas' in their cross-section allow air and gas to flow through, which is undesirable in explosion-protected zones and when laying cables between such zones, as existing methods to fill these areas deform the foamed dielectric insulation and impair transmission properties.
Innovation Solution
A data cable design with at least one pair of wires and a cable sheath, where cavities between the wires and sheath are filled with a filler having a specific viscosity that adheres and remains in place under pressure differences, minimizing gas exchange and preventing deformation of the dielectric insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If filling mixture is extruded under significant pressure to fill free areas, then gas flow through the cable is reduced, but the foamed dielectric insulation and electric shields are deformed irreparably
Solution Approach 1:
The patent changes the viscosity parameter of the filler material to a specific range (100-10,000 cP) that allows the material to flow into cavities under minimal pressure differential while maintaining enough body to avoid deforming the dielectric insulation. This parameter optimization resolves the contradiction between filling effectiveness and structural preservation.
Solution Approach 2:
The patent uses a fluid filler material that can be introduced into the cable cavities through pressure differential (pneumatic principle) without requiring mechanical extrusion. The fluid nature of the filler allows it to flow into and fill the free areas and cavities between wire pairs and cable sheath, reducing gas flow paths without applying damaging mechanical pressure to the dielectric insulation.
2Volume of stationary object
If filling mixture is extruded under raised pressure, then free areas are filled, but transmission properties of data cable are impaired or lost
Solution Approach 1:
The patent optimizes the viscosity parameter of the filler to a specific range (100-10,000 cP) that enables the material to fill cavities effectively while maintaining cable transmission properties. This viscosity parameter allows the filler to flow into cavities without applying excessive pressure that would deform the dielectric insulation and impair transmission characteristics.
Solution Approach 2:
The patent introduces the filler material into the cable during or immediately after the cable manufacturing process, before the cable is put into service. This preliminary action ensures that all cavities and free areas are filled before the cable undergoes normal operational stress, preventing gas flow and maintaining transmission properties throughout the cable's service life.
3Ease of manufacture
If filler has low viscosity for easy processing, then filler is easily introduced, but filler is pressed out of the cable under pressure difference
Solution Approach 1:
The patent defines a specific viscosity range (100-10,000 cP) that balances processability and retention. Within this range, the filler has sufficient fluidity to be introduced into the cable during manufacturing but maintains enough viscosity to remain in place under normal operational pressure differentials, preventing both extrusion difficulty and filler loss.
Solution Approach 2:
The patent uses the viscosity of the filler material as an intermediary property that mediates between the conflicting requirements of easy introduction and secure retention. The specific viscosity range acts as a compromise that allows the filler to flow during manufacturing while resisting flow during operation, effectively mediating between processing ease and compositional stability.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively reduces gas and liquid flow through the cable, maintaining transmission properties and ensuring safe use in both explosion-protected and non-protected zones by minimizing cavity volumes and preventing gas leakage.
Implementation Method 1
The filler has a viscosity such that it adheres in the data cable in such a way that it remains in the data cable at least nearly completely when there is a specified pressure difference between one end of the data cable and the other end of the data cable
Data Source
AI summary
The invention relates to a data cable. One embodiment of the data cable has at least one pair of wires and a cable sheath surrounding the at least one pair of wires. The at least one pair of wires has two wires twisted together in the longitudinal direction of the data cable. Cavities between the at least one pair of wires and the cable sheath are at least partially filled with a filler. The filler has a viscosity which is such that it adheres in the data cable in such a way as to remain in the data cable at least nearly completely when there is a specified pressure difference between one end of the data cable and the other end of the data cable.