Flexible Carrier Ring for Multi-Core Cable Component Integration
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Solution Overview
Problem
Existing multi-core electrical cables with integrated components face challenges in efficiently integrating electrical components for functions like signal filtering due to limitations in flexibility and space within the cable structure.
Innovation Solution
A flexible carrier ring-shaped in cross-section surrounds the cores, allowing partial elimination of insulation for electrical connection, with the electrical component and connection elements arranged on the carrier to facilitate contact with the cores, enabling flexible placement and secure bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If electrical components are integrated into multi-core electrical cables, then additional functions such as signal filtering can be performed directly on the cable, but the flexibility and space within the cable structure are limited
Solution Approach 1:
The cable is divided into distinct functional zones: core regions for signal transmission and a peripheral flexible carrier region for housing electrical components. This segmentation allows independent optimization of each zone, enabling component integration without compromising the core transmission function or overall cable flexibility.
Solution Approach 2:
The flexible carrier is positioned in the radial dimension (periphery) of the cable cross-section rather than occupying the central axial space. This dimensional relocation provides additional space for electrical components without interfering with the core arrangement or cable bending characteristics.
2Ease of operation
If insulation of cores is eliminated to allow electrical connection of the electrical component, then electrical contact can be established, but the insulation protection is compromised
Solution Approach 1:
Insulation is selectively removed only at specific locations where electrical connection elements contact the cores, while the remainder of the core insulation is preserved. This localized modification enables necessary electrical connections while maintaining insulation protection in all other areas, thus balancing connectivity needs with reliability requirements.
Solution Approach 2:
Electrical connection elements serve as intermediaries between the electrical component and the cores. These connection elements establish electrical contact with the cores without requiring extensive insulation removal, as they can be positioned to contact exposed conductor portions while the flexible carrier provides structural support and alignment.
3Ease of operation
If the flexible carrier is rolled up to enclose the cores, then the electrical component can be positioned between the cores and cable covering, but the electrical component may have less flexibility than the carrier
Solution Approach 1:
The flexible carrier is designed with dynamic flexibility to accommodate rolling during installation, while the electrical component mounted on it maintains sufficient flexibility for its operational function. The carrier's flexibility exceeds that of the component, allowing the assembly to be installed by rolling the carrier around the cores while the component remains functional within its operational flexibility requirements.
Data Source
Figure 1A~1B
Figure 1C
Figure 1D
AI summary
The invention relates to an electrical cable with at least two conductors (11-14) running side by side along a longitudinal direction (L); with insulation (21-24) by means of which the conductors (11-14) are electrically insulated from each other; and with an electrical component (4) that is in electrical contact with each of the conductors (11-14). The electrical component (3) is arranged on the inner side (I) of a flexible carrier (30) facing the conductors (11-14), the carrier being a ring-shaped cross-section surrounding the conductors (11-14).