Impregnated Fiber Cable Structure for Harsh Environments
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Solution Overview
Problem
There is a need for electrical and optical cables that can withstand harsh environmental conditions and possess substantial mechanical strength, as existing cables may not adequately resist chemical attacks, fluid pressure, and axial loading in demanding environments.
Innovation Solution
The development of cables incorporating at least one plastic impregnated fiber layer, where the fibers can be glass, aramid, or carbon fibers impregnated with thermoset or thermoplastic resin, combined with conductors such as electrical or optical fibers, forming a structure that provides enhanced mechanical strength and resistance to fluid intrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional plastic insulation and flexible plastic materials are used for cable insulation and fluid exclusion, then the cable can be easily manufactured and maintained flexibility, but the cable lacks sufficient resistance to chemical attacks and fluid pressure in harsh environments
Solution Approach 1:
The patent applies composite materials by combining plastic impregnated fiber layers with traditional flexible plastic materials. The plastic impregnated fiber layer provides enhanced chemical resistance and fluid pressure resistance, while the flexible plastic material maintains ease of manufacture and flexibility. This composite structure resolves the contradiction by integrating materials with complementary properties.
Solution Approach 2:
The patent changes the material parameters by transitioning from pure flexible plastic to plastic impregnated fiber composite. This parameter change increases the cable's resistance to chemical attacks and fluid pressure while maintaining manufacturability through established impregnation processes.
2Strength
If round cable configuration with traditional strength members is used, then the cable has good mechanical strength and has been successfully used in harsh environments, but the cable lacks the enhanced mechanical strength and chemical resistance required for more demanding applications
Solution Approach 1:
The patent uses plastic impregnated fiber layers as composite strength members that provide both mechanical strength and chemical resistance. This composite approach enhances the performance of traditional round cable configurations without fundamentally changing the overall cable structure, thereby managing complexity while improving strength and resistance properties.
Solution Approach 2:
The plastic impregnated fiber layer serves multiple functions: it acts as a strength member providing mechanical strength, as a protective layer providing chemical resistance, and as a fluid barrier providing resistance to fluid pressure. This multi-functionality enhances cable performance without requiring separate components for each function, thus managing structural complexity.
3Reliability
If plastic impregnated fiber layers are used to enhance mechanical strength and chemical resistance, then the cable can withstand harsh environmental conditions, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies preliminary action by impregnating the fiber layers with plastic material during the manufacturing process before the cable is put into service. This pre-impregnation ensures that the fiber layers have the necessary chemical resistance and mechanical strength from the outset, rather than requiring post-manufacturing treatments or repairs.
Solution Approach 2:
The patent changes the material state by transforming loose fibers into impregnated fiber layers through the plastic impregnation process. This parameter change from dry fibers to resin-impregnated fibers enhances the cable's ability to withstand harsh environmental conditions while using established manufacturing techniques.
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 cables exhibit improved mechanical strength and resistance to chemical attacks and fluid pressure, making them suitable for harsh environments, while maintaining electrical conductivity and signal transmission capabilities.
Implementation Method 1
Plastic impregnated fiber perform is used to make articles such as fluid carrying tubes and liners for metal fluid carrying tubes
Implementation Method 2
The plastic or resin upon cure causes the fiber perform to make a structure that is resistant to chemical attack
Implementation Method 3
can withstand fluid under pressure, and typically has substantial mechanical strength, such as to resist fluid intrusion and carry axial loading
Implementation Method 4
An electrical cable may include a conductor that electrically conductive
Implementation Method 5
an optical cable may include a optical fiber that conducts an optical signal
Data Source
AI summary
A cable includes at least one plastic impregnated fiber layer and at least one conductor in contact with the at least one fiber layer. In some examples, the fiber may be glass fiber, aramid fiber or carbon fiber. In some examples, the plastic may be thermoset plastic, thermoplastic or chemically set resin. In some examples, the conductor may be an electrical conductor or an optical fiber.