Heat-Shrink Conductive Cable Sheath for Flexible Fiber Protection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing data transmission cables, particularly optical fibers, are fragile and prone to breakage due to their small diameter and susceptibility to forces orthogonal to the fiber axis, leading to signal loss and installation difficulties, while copper-based cables face limitations in availability and energy-intensive reclamation, and conventional cable manufacturing methods use diluents that hinder electrical properties.
Innovation Solution
A method involving the introduction of a conductive material onto a heat-shrink material sheet, compressed to form a sheath with an interior volume, eliminating the need for copper and reducing the use of diluents, resulting in a cable with improved flexibility and electrical conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If heavy jacketing materials are placed about optical fibers to protect them during installation, then the cables are protected from physical damage, but the flexibility of the cables is restricted due to the stiffness of the jacket
Solution Approach 1:
The cable structure is divided into distinct segments: a flexible inner core containing the optical fiber, and a separate outer jacket. This segmentation allows the inner core to maintain flexibility for easy routing and handling, while the outer jacket provides protective strength when needed during installation.
Solution Approach 2:
Different parts of the cable have different properties optimized for their specific functions. The inner core is designed with high flexibility for ease of installation, while the outer jacket is designed with higher strength for protection. This local differentiation resolves the contradiction by providing both flexibility and strength in appropriate locations.
2Ease of operation
If the outer protective jacket is removed to allow more flexible handling of a terminal portion of the cable, then the flexibility is improved, but there is insufficient physical protection for this terminal portion
Solution Approach 1:
The cable design anticipates the need for both protection and flexibility at different locations. The terminal portions are pre-configured with appropriate protective elements that can be applied or removed as needed, allowing flexible handling where required while maintaining protection where necessary.
3Ease of manufacture
If conventional cable manufacturing methods use diluents to form the cable structure, then the cable formation process is simplified, but residual diluent in the cable hinders electrical properties
Solution Approach 1:
The harmful diluent is completely extracted or eliminated from the cable manufacturing process. The invention replaces diluent-based formation methods with alternative techniques that achieve cable structure formation without introducing substances that would hinder electrical properties, thereby maintaining both ease of manufacture and electrical reliability.
Solution Approach 2:
The manufacturing process uses temporary materials or methods that are completely removed after serving their structural formation purpose, rather than leaving permanent residues. This approach simplifies manufacturing while ensuring no harmful substances remain to affect electrical properties.
4Reliability
If copper-based cables are used for data transmission, then electrical conductivity is achieved, but there is a finite amount of copper available and substantial energy is needed to reclaim the copper from an expired cable
Solution Approach 1:
The invention changes the material parameter from copper to alternative conductive materials that offer comparable electrical conductivity but with improved sustainability characteristics. These alternative materials require significantly less energy for reclamation or are more readily available, thereby reducing energy loss while maintaining electrical performance.
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 method enables the production of lightweight, flexible cables with enhanced strength and conductivity, reducing porosity and bubbling, and eliminating the need for chemical modification of conductive carbon materials, while maintaining or improving electrical properties.
Implementation Method 1
a sheath including a heat-shrink material
Data Source
AI summary
The present disclosure relates to cables and methods of making cables. In at least one embodiment, a method for making a cable includes introducing a conductive material onto a sheet including a heat-shrink material. The method includes compressing a first portion of the sheet onto a second portion of the sheet to form a sheath having an interior volume, where the conductive material is disposed in the interior volume. In at least one embodiment, a cable includes a sheath including a heat-shrink material. The cable includes an interior volume including a conductive material including a conductive carbon material.