Lightweight Impact-Resistant Power Cable Design
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Solution Overview
Problem
Existing multipolar power cables face challenges in achieving impact resistance without a containment layer, which increases complexity, expense, and dimensions, while also requiring uniform expansion of polymeric fillers to maintain cable concentricity and prevent surface irregularities.
Innovation Solution
A multipolar power cable design featuring a plurality of cores with interstitial zones filled by an expanded polymeric filler and an impact-resistant layer radially external to the filler, using thermally expandable microspheres as a foaming agent to ensure uniform expansion and circularity, with distinct polymeric compositions for the filler and impact-resistant layer to balance flexibility and mechanical resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal armour or shield is used to provide impact resistance, then impact resistance is improved, but weight increases considerably
Solution Approach 1:
The patent changes the physical state and density parameters of the protective material by using expanded polymeric materials with air pockets, transforming solid metal armour into lightweight cellular polymer structures that provide equivalent impact resistance with significantly reduced weight
Solution Approach 2:
The patent employs composite polymeric materials combining expanded polymers with interstitial fillers to create a multi-phase composite structure that delivers metal-like impact protection while maintaining lightweight characteristics, replacing homogeneous metal armour with heterogeneous polymer composites
2Weight of moving object
If expanded polymeric material is used to replace metal armour, then weight is reduced, but flexibility is improved while impact resistance may be compromised
Solution Approach 1:
The patent utilizes porous expanded polymeric materials with controlled cell structures that provide impact absorption through cellular deformation mechanisms, achieving lightweight construction while maintaining protective capabilities through optimized porosity and cell morphology
Solution Approach 2:
The expanded polymeric material provides beforehand cushioning by absorbing impact energy through its cellular structure deformation, preventing direct transmission of impact forces to the cable cores and insulating layers, thus protecting the cable before damage can occur
3Weight of moving object
If polymeric filler is expanded during extrusion, then weight is reduced and flexibility is improved, but uniform expansion is difficult to achieve without special containment
Solution Approach 1:
The patent applies local quality by using interstitial filler material with different expansion characteristics than the outer sheath polymer, allowing the filler to expand uniformly within the confined spaces between cores while the outer sheath provides structural containment and maintains overall cable geometry
Solution Approach 2:
The patent implements preliminary action by pre-positioning the expandable polymeric filler in the interstitial zones before final expansion during or after extrusion, ensuring uniform distribution and controlled expansion that maintains cable concentricity and prevents surface irregularities
4Manufacturing precision
If containment layer is added to ensure uniform expansion, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent applies universality by designing the outer polymeric sheath to serve multiple functions: providing mechanical protection, containing the expandable filler during and after extrusion, maintaining cable geometry, and enabling uniform expansion of the interstitial filler, thus eliminating the need for separate containment layers
Solution Approach 2:
The patent merges the containment function with the outer protective sheath, combining what would traditionally be separate layers (containment and protection) into a single multi-functional polymeric structure that simplifies the overall cable construction while achieving the desired expansion uniformity
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 provides a lightweight, flexible, and impact-resistant cable with improved circularity and reduced weight, maintaining performance under mechanical stress and passing impact, flame, and crush tests, while avoiding the need for a containment layer.
Implementation Method 1
using thermally expandable microspheres as a foaming agent to ensure uniform expansion and circularity
Data Source
AI summary
The present disclosure relates to an impact resistant, multipolar power cable (10) comprising, a plurality of cores (1), each core (1) comprising at least one conductive element (3) and an electrical insulating layer (5) in a position radially external to the at least one conductive element (3). The cores (1) are stranded together so as to form an assembled element providing a plurality of interstitial zones (2). An expanded polymeric filler (6) fills the interstitial zones (2) between the plurality of cores (1). An expanded impact resistant layer (7) is in a position radially external to the expanded polymeric filler (6) and comprises a polymer that differs from the expanded polymeric filler (6).