Peelable Cable Jacket with Elastomeric Microcapillaries
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Solution Overview
Problem
Cables often require easy access to their internal components for connection and installation, but existing cable coatings are difficult to tear open due to their protective materials, leading to high installation and maintenance costs.
Innovation Solution
A coated conductor with a peelable polymeric coating comprising a polymeric matrix material and microcapillaries that extend in the direction of elongation, where the microcapillaries are filled with an elastomeric polymer having a lower flexural modulus than the matrix material, allowing for easier access without compromising mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tough protective materials are used for cable coating, then mechanical protection is improved, but ease of access to internal components deteriorates
Solution Approach 1:
The coating is segmented into multiple functional layers: a tough outer layer for mechanical protection and an inner peelable layer with microcapillaries for easy access. This segmentation allows each layer to perform its specific function optimally without compromising the other.
Solution Approach 2:
The peelable layer contains microcapillaries with elastomeric polymer that has different mechanical properties (lower flexural modulus) than the surrounding matrix material. This local variation in material properties creates zones of controlled flexibility that enable easy peeling while maintaining overall coating integrity.
2Productivity
If easy access to internal components is provided, then installation and maintenance costs are reduced, but mechanical properties of the coating deteriorate
Solution Approach 1:
The coating is divided into a protective outer layer and a separate peelable inner layer. The peelable layer contains microcapillaries that facilitate easy access to internal components during installation and maintenance, while the outer layer maintains mechanical strength and protection.
Solution Approach 2:
The peelable layer is formed as a composite material combining a polymeric matrix with elastomeric polymer-filled microcapillaries. This composite structure provides both the mechanical properties needed for protection and the flexibility required for easy peeling.
3Adaptability or versatility
If microcapillaries with elastomeric polymer are incorporated, then flexibility and ease of peeling are improved, but structural homogeneity deteriorates
Solution Approach 1:
The elastomeric polymer is selectively placed within microcapillaries rather than being uniformly distributed throughout the coating. This localized placement creates specific zones of flexibility and peeling capability while preserving the overall homogeneity and structural integrity of the coating matrix.
Solution Approach 2:
The peelable layer incorporates a porous structure with microcapillaries that contain elastomeric polymer. This porous architecture provides pathways for flexibility and peeling while the surrounding matrix material maintains structural continuity and homogeneity.
Data Source
Figure 1
Figure 2A~2E
Figure 2C~2D
AI summary
Coated conductors comprising a conductor and a peelable polymeric coating at least partially surrounding the conductor, where the peelable polymeric coating comprises from 1 to 8 microcapillaries which comprise an elastomeric polymer having a lower flexural modulus than the polymeric matrix material of the polymeric coating. Also disclosed are methods for making such coated conductors.