Peelable Cable Jacket With Microcapillaries
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Solution Overview
Problem
Cables often require easy access to their internal components for connection and installation, but existing cable jackets are designed for maximum protection, making it difficult to access internal components without damaging the coating, which can increase 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, allowing for easy peeling without compromising the mechanical properties of the jacket.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If cable jackets are designed for maximum protection using tough materials, then mechanical strength and durability are improved, but ease of accessing internal components deteriorates
Solution Approach 1:
The cable jacket is segmented into multiple layers with different functions: an inner peelable layer containing microcapillaries that allows easy access to internal components, and an outer layer providing mechanical protection. This segmentation enables the jacket to simultaneously offer both ease of access and mechanical strength.
Solution Approach 2:
Different regions of the cable jacket have different properties: the inner layer has controlled tear strength and contains microcapillaries for easy peeling, while the outer layer has high mechanical strength. This local differentiation allows the jacket to provide both ease of access at the access point and overall mechanical protection.
2Ease of operation
If cable jackets are made easy to peel, then ease of accessing internal components is improved, but mechanical properties of the jacket deteriorate
Solution Approach 1:
The jacket is divided into an inner peelable layer and an outer protective layer. The inner layer is specifically designed with microcapillaries and controlled tear strength to enable easy peeling, while the outer layer maintains the overall mechanical properties of the cable assembly.
Solution Approach 2:
The cable jacket uses a composite structure with an inner layer made from materials optimized for peeling (such as polyethylene or polypropylene with specific molecular weight and density) and an outer layer made from tougher materials. This composite approach allows the peeling property to be achieved without compromising the overall mechanical strength.
3Ease of operation
If microcapillaries are added to enable peeling, then ease of operation is improved, but manufacturing complexity increases
Solution Approach 1:
The microcapillaries are formed using extrusion technology where molten polymer is forced through a die with microcapillary structures. This hydraulic/extrusion process creates the microcapillary network in a continuous, automated manner during manufacturing, avoiding complex post-processing steps.
Solution Approach 2:
The microcapillary structure is created by controlling extrusion parameters such as temperature, pressure, and die geometry. By adjusting these parameters, the desired microcapillary configuration is achieved directly during the extrusion process, simplifying manufacturing.
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 a low-viscosity filler material. Also disclosed are methods for making such coated conductors.