Injected Cable Strain Relief for Stronger Connector Ends
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Solution Overview
Problem
Existing structural mechanisms for reinforcing electrical cables are costly, complex to assemble, and prone to degradation, compromising the durability and reliability of high-stress areas.
Innovation Solution
Incorporating an internal strain relief element made of a cured injectable fluidic substance, such as epoxy, within the cable to provide structural reinforcement at high-stress points, ensuring durability and reliability while being cost-effective and simple to assemble.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If existing structural mechanisms are used to reinforce electrical cables, then the structural strength is improved, but the cost increases and assembly complexity increases
Solution Approach 1:
The patent combines the strain relief function with the cable insulation by integrating a liquid strain relief material directly into the cable assembly process. The liquid material is injected into the cable assembly and cured in place, merging the strain relief element with the cable structure itself, thereby eliminating separate assembly steps and reducing overall device complexity while maintaining structural strength
Solution Approach 2:
The patent utilizes the viscosity parameter of the liquid strain relief material to control its flow characteristics during injection. By selecting a material with appropriate viscosity, the material flows to fill the cable interior uniformly and then maintains its position after curing, achieving effective strain relief without requiring complex injection equipment or multi-step assembly processes
2Strength
If existing structural mechanisms are used to reinforce electrical cables, then the structural strength is improved, but the manufacturing cost increases
Solution Approach 1:
The liquid strain relief material performs multiple functions simultaneously: it provides structural reinforcement, protects internal conductors, fills voids in the cable assembly, and cures in place to form a permanent bond. This self-service capability eliminates the need for separate components and assembly operations, reducing manufacturing cost while maintaining structural strength
Solution Approach 2:
The patent employs a liquid injection process to deliver the strain relief material into the cable assembly. The liquid form allows the material to be pumped and injected through simple tubing into the cable interior, where it distributes itself uniformly. This hydraulic approach is simpler and more cost-effective than mechanical insertion of solid strain relief elements
3Strength
If existing structural mechanisms are used to reinforce electrical cables, then the structural strength is improved, but the reliability decreases due to degradation
Solution Approach 1:
The patent uses a composite material system consisting of the liquid strain relief material and the cable insulation/jacket. The liquid material cures to form a bonded composite structure that integrates the strain relief function with the cable's existing protective layers, creating a unified system that resists degradation more effectively than separate components
Solution Approach 2:
The patent exploits the phase change parameter of the liquid strain relief material, which transitions from liquid to solid upon curing. This phase change allows the material to be easily injected in liquid form, then permanently set in place as a solid, creating a reliable, degradation-resistant structure that maintains its properties over time without the wear associated with mechanical components
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 internal strain relief element enhances the structural integrity and longevity of electrical cables by providing targeted reinforcement without adding bulk or complexity, protecting the internal components from external wear and tear.
Implementation Method 1
an internal strain relief element is positioned within the hollow tube, wherein the internal strain relief element comprises a cured injectable fluidic substance
Data Source
AI summary
This application relates to a dispensed or injected structural reinforcement or hardening element, such as an injected internal strain relief, as incorporated into electrical cables. An electrical cable includes a cable portion comprising one or more electrical conductors that are positioned within an internal volume of the cable portion. Additionally, an electrical connector component is positioned at a terminating end of the cable portion. In addition, an internal strain relief element is positioned within the internal volume of the cable portion such that the internal strain relief element at least partially surrounds one or more of the electrical conductors, wherein the internal strain relief element comprises a cured injectable fluidic substance.