Fiber-Reinforced Polymer Cable for Dynamic Train Interconnections
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Solution Overview
Problem
Existing power cables lack sufficient rigidity and self-supporting capabilities, especially when used in dynamic applications like interconnecting train carriages that require flexibility and weight-bearing capacity, particularly for large conducting braids.
Innovation Solution
A power cable featuring a fiber-reinforced polymer substrate, such as fiberglass, coupled with a metal conductor and encased in heat shrink tubing, with a tapered thickness to provide varying levels of rigidity and support along its length, ensuring self-supporting functionality even under heavy loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a flat cable uses a metallic strip to prevent collapse in bends, then the cable maintains structural integrity in bends, but the cable lacks sufficient rigidity and self-supporting capability for heavy conducting braids
Solution Approach 1:
The patent uses a composite structure combining a fiberglass reinforcement element embedded in a flexible outer sheath. The fiberglass provides the necessary rigidity and tensile strength to support heavy conducting braids, while the flexible polymer sheath maintains flexibility and prevents collapse in bends. This composite approach resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The cable structure is segmented into distinct functional layers: a flexible outer sheath, an embedded fiberglass reinforcement element, and conducting braids. This segmentation allows each component to perform its specific function optimally - the sheath provides flexibility and protection, the fiberglass provides rigidity and support, and the conductors carry current.
2Strength
If a cable is made more rigid to support heavy conducting braids, then the cable gains self-supporting capability, but the cable loses flexibility needed for dynamic movements between train carriages
Solution Approach 1:
The fiberglass-reinforced flexible cable combines the rigidity of fiberglass with the flexibility of the polymer sheath. The fiberglass element provides tensile strength and support capability, while the flexible outer material allows the cable to bend and move dynamically. This composite structure enables the cable to simultaneously achieve self-supporting capability and flexibility for dynamic applications.
Solution Approach 2:
The fiberglass reinforcement is strategically positioned within the cable structure where it is most needed for support, while the flexible sheath covers the entire cable to maintain overall flexibility. This local placement of reinforcement provides support exactly where required without compromising the cable's ability to bend and move.
3Strength
If the cable uses a uniform thickness substrate, then the manufacturing is simpler, but the cable cannot provide varying levels of rigidity needed at different locations
Solution Approach 1:
The fiberglass reinforcement element has varying thickness along its length, providing greater rigidity where needed (such as near connection points or where heavy conductors are located) and lesser rigidity in other sections. This graduated thickness allows the cable to provide varying levels of support without requiring complex assembly of multiple components.
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 tapered fiber-reinforced polymer substrate effectively supports the weight of the cable and conducting braid, maintaining mechanical strength at high temperatures and accommodating dynamic movements, making it suitable for heavy-duty applications like train carriage interconnections.
Implementation Method 1
heat shrink tubing
Implementation Method 2
withstanding relatively high temperatures, e.g. 80°C, and maintaining most of its mechanical strength
Data Source
Figure 1~3
AI summary
A power cable (10), especially a jumper cable, comprising a self-supporting, fiber-reinforced polymer substrate (12) such as fiber glass coupled to a metal conductor (11).