Flat Cable with Embedded Load-Bearing Elements and Signaling
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Solution Overview
Problem
Existing cables for delimiting areas in industrial environments lack both load-bearing capacity and high visibility, especially in rugged and dynamic applications, and are often costly to maintain with round circumference designs that are not suitable for increased perceptibility or stability.
Innovation Solution
A flat cable with a polymeric carrier material and embedded load-bearing elements, such as metallic wire ropes or fibre ropes, that provide both tensile strength and visibility through integrated light-emitting or reflecting means, allowing for improved durability and visibility in a rectangular cross-section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If round cables with retroreflective beads are used, then visibility is improved, but load-bearing capacity and structural stability deteriorate
Solution Approach 1:
The patent applies composite materials by combining a polymeric carrier material with embedded metallic wire ropes or fibre ropes. This composite structure provides both the load-bearing capacity of the reinforcement elements and the visibility function through integrated light-emitting or retroreflective components, resolving the contradiction between strength and illumination.
Solution Approach 2:
The patent merges multiple functions into a single flat cable structure: the polymeric carrier material provides structural support, embedded wire ropes provide tensile strength, and integrated light-emitting or retroreflective elements provide visibility. This combination eliminates the need for separate lighting systems and structural supports, achieving both load-bearing capacity and high visibility in one component.
2Illumination intensity
If round cables with illuminating elements are used, then visibility is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the carrier material, load-bearing elements, and illuminating/retroreflective components into a single integrated flat cable structure. This merging eliminates the need for separate mounting brackets, wiring harnesses, and assembly steps required by traditional round cables with added illuminating elements, thereby reducing device complexity and manufacturing cost.
Solution Approach 2:
The patent uses a flat, flexible polymeric carrier material that inherently provides structural support and can be easily manufactured in continuous lengths. This flexible flat structure is simpler to produce than rigid round cables with embedded components, as it allows for continuous extrusion or lamination processes with integrated reinforcement and optical elements.
3Ease of operation
If round cables are used, then flexibility is maintained, but area delimitation effectiveness and perceptibility deteriorate
Solution Approach 1:
The patent transitions from a symmetric round cable cross-section to an asymmetric flat cable cross-section. This asymmetry increases the surface area available for light emission and retroreflection, improving perceptibility from all viewing angles. The flat geometry also provides a larger profile for area delimitation while maintaining flexibility through the polymeric carrier material and embedded reinforcement.
Solution Approach 2:
The patent changes the cable from a three-dimensional round structure to a two-dimensional flat structure. This dimensional change increases the surface area for optical signaling in the lateral dimension while maintaining flexibility through the flexible nature of the polymeric carrier material and embedded fibres or wires. The flat geometry provides better visibility and delimitation effectiveness without sacrificing operational flexibility.
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 flat cable design enhances stability and visibility while being cost-effective, suitable for both static and dynamic applications, and can be used for area delimitation and signaling purposes, offering improved safety and efficiency compared to traditional round cables.
Implementation Method 1
The cable consists of a metal wire, possibly a stranded rope, and one or more coating polymers, that covers said metal wires. In the coating layers, retroreflective beads are incorporated.
Implementation Method 2
The electrical cable is further equipped with illuminating leads or enwrapped in illuminating sheets. The document further proposes advanced materials, such as plastics that can be excited by applying tension as illuminants.
Data Source
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AI summary
Cable (1), in particular a flat cable (1), with a longitudinal dimension (I) and a lateral dimension (b). The cable (1) comprises a polymeric carrier material (2) which essentially defines the outer shape of said cable (1). At least one load bearing element (3) run in parallel to the longitudinal dimension (I) of the cable (1) and is embedded into the polymeric carrier material (2).The cable (1) further comprises at least one means for emitting (4.x) and/or for reflecting (4) light. The outer shape of the cable (1) is arranged such that the cable (1) features at least one planar surface (A).