Silicone Encased Cable with Snap Washer Integration
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Solution Overview
Problem
Existing communication and electrical systems, such as cables and optic fibers, often become tangled and damaged during installation, leading to complications and failures due to excessive abrasive movement and contamination, especially in demanding environments like aerospace and medical applications.
Innovation Solution
A method of processing multiple individual flexible systems into a single, custom-shaped silicone encasement using extrusion equipment, which creates a flexible and durable cable assembly that can be shaped to fit tight spaces, withstand extreme temperatures, and resist contamination, incorporating proprietary additives for enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple individual cables and flexible systems are installed separately, then each system can be independently installed and maintained, but the cables become tangled and damaged by excessive abrasive movement and contamination
Solution Approach 1:
The patent combines multiple individual cables, optic fibers, tubes, and electrical conductors into a single integrated cable assembly. These individual flexible systems are grouped together and encased in a common protective covering, eliminating the tangling and damage issues that occur during separate installation while maintaining the ability to convey multiple signals and fluids simultaneously
Solution Approach 2:
The patent employs a nested structure where multiple individual cables and flexible systems are placed inside a common protective encasement. The individual systems are arranged within the protective covering, creating a hierarchical structure that protects each component while allowing the entire assembly to be installed as a single unit
2Ease of operation
If initial installations and subsequent maintenance are performed on separate cables, then each cable can be individually handled, but the process becomes difficult to separately pull or extract these systems through the space available
Solution Approach 1:
The patent divides the cable assembly into separable segments where individual cables, optic fibers, and tubes can be independently accessed and removed from the common protective encasement. This segmentation allows maintenance personnel to service individual components without having to handle the entire assembly, simplifying both installation and maintenance operations
3Reliability
If a single encasement covers multiple cables and tubes, then the cable assembly becomes more durable and resistant to contamination, but the shape and routing flexibility is reduced
Solution Approach 1:
The patent uses a flexible protective encasement made from materials such as silicone rubber, thermoplastic elastomers, or other flexible polymers. This flexible covering protects the internal cables and tubes from contamination and damage while maintaining the ability of the entire assembly to bend, flex, and route through tight spaces and complex pathways
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 solution reduces installation time, prevents damage during installation, and ensures reliable performance and long life by providing a flexible, protective, and adaptable cable assembly that maintains its shape and functionality in harsh environments.
Implementation Method 1
A method of processing multiple individual flexible systems into a single, custom-shaped silicone encasement using extrusion equipment
Implementation Method 2
creates a flexible and durable cable assembly that can be shaped to fit tight spaces, withstand extreme temperatures, and resist contamination
Implementation Method 3
withstand extreme temperatures
Data Source
AI summary
The embodiments disclose a method for creating a silicone encased flexible cable using manufacturing machinery including arranging plural individual conduits, at least one assembly and at least one junction box assembly into a grouped arrangement including at least one of the conduits is a fluid communication conduit, wherein the silicone encased flexible cable is coupled between a controller and an electro-mechanical device, and wherein the fluid communication conduit is configured to transfer at least a liquid and pneumatic gas through the silicone encased flexible cable during operation of the electro-mechanical device; and integrating a snap washer within the singular encasement, wherein the manufacturing machinery is configured to cut a slit along the cable run of a silicone encased flexible cable, insert a snap washer base through the slit and position a snap washer into the snap washer and snapping the snap washer into a locked position.