Paracord-Wrapped Cable Stress Distribution
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Solution Overview
Problem
Electrical cables often break at the intersection of the plug head and cable due to concentrated forces, and standard wrapping methods like paracord do not provide adequate protection or functionality, as they cannot be used to carry a load without being unwrapped.
Innovation Solution
The electrical cable is wrapped with a constant length of material, such as paracord, that is connected to both plug heads and covered with additional wrapping material, allowing it to distribute forces and provide additional functionality like carrying a load, with features like loop ends and attachment members for connecting cables or loads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the cable is wrapped with paracord for protection, then the cable gains some protection, but the user cannot use the paracord to carry a load without first removing the wrap
Solution Approach 1:
The paracord is divided into two functional segments: an inner wrap that provides cable protection, and an outer wrap that provides load-carrying capability. This segmentation allows each layer to serve its specific function independently, resolving the contradiction between protection and versatility.
Solution Approach 2:
The outer paracord wrap is designed to serve multiple functions: it protects the inner wrap, provides a structural layer for carrying loads, and can be equipped with attachment members like carabiners. This multi-functionality resolves the contradiction by making the protective wrapping itself capable of load-bearing.
2Ease of operation
If users pull on the cable to remove the plug head, then it is easier to grasp, but the cable breaks over time due to concentrated forces
Solution Approach 1:
The paracord wrap acts as an intermediary element between the user's hand and the cable. It provides a larger surface area for grasping and distributes the pulling forces across the entire wrap structure, preventing force concentration at the vulnerable cable-plug intersection.
Solution Approach 2:
The paracord wrap changes the mechanical parameters of the cable assembly by increasing the effective grasping surface area and altering the force distribution pattern. This transforms the stress from a concentrated point load to a distributed line load, improving both ease of operation and cable durability.
3Ease of operation
If the plug head is made larger for easier grasping, then ease of operation improves, but the overall cable design becomes more complex
Solution Approach 1:
Instead of modifying the plug head structure, the paracord wrap serves as an external intermediary that provides the grasping function. This keeps the plug head design simple while achieving the same ease of operation benefit, resolving the contradiction between operational ease and design complexity.
Data Source
AI summary
A wrapped electrical cable, such as a charging cable, is disclosed which is more rugged than standard electrical cables. The electrical cable includes plug heads with a hole therethrough for receiving a cable, and a cable extending from the hole through one plug head to the hole through the opposing plug head. The cable and cord may be further wrapped in a sheath of cord, such as paracord. The cord may have connectors on either end, allowing a user to loop the cord for carrying and/or storage and/or hooking the cord to a load, or daisy chain multiple cords together to lengthen the cord. The plug heads and/or caps may be formed at least partly of transparent material and include one or more light sources/ The plug heads may also include two or more connector types in a single plug head.