Melted Cable Ends for Vehicle Brake Assembly
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Solution Overview
Problem
Conventional cables used in vehicle brake and transmission systems have sharp distal ends that easily bifurcate and insert into outer tubes, making assembly difficult and potentially damaging the tubes, and existing solutions require additional components like metal sheaths that are costly and can further damage the cables.
Innovation Solution
A cable main body composed of unit filaments with melted distal ends forming a smooth, integral melted end to prevent insertion into outer tubes and enhance filament connection, which can also be sleeved with a sheath for additional restraint without damaging the cable.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the cable is cut into different lengths according to requirements, then the cable can be customized for various applications, but the distal end becomes sharp and bifurcates easily causing assembly difficulties and potential damage to outer tubes
Solution Approach 1:
The cable end is melted and formed into a rounded shape in advance during the cable manufacturing process, before the cable is installed. This preliminary action prevents the sharp end from bifurcating and inserting into the outer tube during assembly, thereby maintaining assembly ease while still allowing cable length customization.
2Reliability
If a metal sheath is pressed onto the cable distal end to restrain it, then the cable end is protected from damage, but the filaments may bifurcate and damage the cable during the pressing process, and additional cost and time are required
Solution Approach 1:
The melting process, which could be seen as a destructive thermal process, is converted into a beneficial forming process that rounds the cable end and prevents bifurcation. This eliminates the need for additional protective components like metal sheaths, reducing device complexity while maintaining cable end protection.
3Stability of the object's composition
If the distal end of the cable is pressed with a metal sheath, then the cable end is restrained, but the pressing action may cause filaments to bifurcate and damage the cable
Solution Approach 1:
The cable end geometry is changed by melting and rounding it, transforming the sharp parameters (sharp edge, prone to bifurcation) into benign parameters (rounded shape, resistant to bifurcation). This parameter change provides cable end restraint through the rounded geometry itself, eliminating the need for external pressing actions that could damage cable integrity.
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 melted end allows smooth passage through outer tubes and prevents filament separation, improving assembly efficiency and reducing the risk of cable damage, while the sheath provides restraint without additional assembly costs.
Implementation Method 1
distal ends of the unit filaments are melted to be integral to form a melted end
Data Source
AI summary
A cable-driving arrangement of a vehicle includes a cable main body. The cable main body is composed of a plurality of unit filaments, and distal ends of the unit filaments are melted to be integral to form a melted end. The cable main body is for being relatively positionably disposed on a vehicle with a portion near the melted end.