Segmented Insulating Sheath for Flexible Electrical Cable
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Solution Overview
Problem
Existing electrical cables face challenges in maintaining reliable and permanent electrical contact under temperature fluctuations and mechanical stress, particularly when connecting battery cells or contact elements, due to limited flexibility and stress compensation.
Innovation Solution
The electrical cable design features a first and third section with integrally formed insulating sheaths, separated by gaps in the second section, which are configured in arcuate paths to allow for elastic expansion and reduce stress, enabling flexible connections and accommodating changes in length and position between contact elements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the insulating sheath is integrally formed throughout the cable, then the structural strength and continuity are improved, but the flexibility and stress compensation capability deteriorate
Solution Approach 1:
The insulating sheath is divided into multiple discrete insulating sections along the cable length, with gaps between them. This segmentation allows each section to move independently, providing flexibility and stress compensation while maintaining electrical insulation. The discrete sections can expand and contract separately in response to thermal and mechanical stresses.
Solution Approach 2:
The insulating sections are arranged in a longitudinal sequence along the cable, creating a one-dimensional array of insulated segments. This dimensional arrangement allows the cable to flex and expand along its length while maintaining insulation integrity across all sections.
2Reliability
If the cable structure is rigid to maintain electrical contact, then the reliability of electrical connection is improved, but the ability to accommodate temperature fluctuations and mechanical stress deteriorates
Solution Approach 1:
The cable is divided into multiple rigid insulating sections separated by flexible gaps. Each rigid section maintains reliable electrical contact at its connection points, while the gaps between sections provide flexibility to accommodate thermal expansion and mechanical stress, allowing the cable to adapt to temperature fluctuations without compromising connection reliability.
Solution Approach 2:
The cable structure allows for changes in the spacing and positioning of insulating sections in response to temperature and stress conditions. The gaps between sections can expand or contract, changing the cable's overall dimensions and flexibility characteristics to match environmental conditions while maintaining electrical connectivity.
3Reliability
If the insulating sheath is continuous without gaps, then the insulation integrity is improved, but the stress reduction and flexibility capability deteriorates
Solution Approach 1:
The insulating sheath is segmented into discrete sections with gaps between them. Each section maintains its insulation integrity independently, and the gaps provide stress relief and flexibility. This segmentation allows the cable to flex and expand without compromising the insulation properties of individual sections.
Solution Approach 2:
The gaps between insulating sections act as pre-configured stress absorption zones. These gaps are designed to accommodate expected thermal expansion and mechanical stress before the stress can damage the insulation or electrical connections, providing a cushioning effect that protects the cable system.
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
This design enhances the cable's flexibility and reduces stress on connection sites, ensuring reliable and permanent electrical contact even with temperature changes and mechanical displacement, allowing for efficient compensation of changes in spacing and length.
Implementation Method 1
configured in arcuate paths to allow for elastic expansion and reduce stress
Data Source
AI summary
An electrical cable includes a plurality of electrical lines extending from a first section to a third section through a second section. Each electrical line is enveloped by an insulating sheath. The electrical lines are arranged side-by-side in the first section in a first plane and in the third section in a third plane. The insulating sheath is integrally formed as a first insulating section in the first section and as a third insulating section in the third section. The insulating sheath is divided into a first further insulating section and a second further insulating section in the second section that are separated from each other by a gap. The first further insulating section is guided from the first insulating section to the third insulating section in a first arcuate path and the second further insulating section is guided from the first insulating section to the third insulating section in a second arcuate path.