Twisted Copper-Alloy Cable Structure for Repeated Bending
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Solution Overview
Problem
Cables used in industrial environments require improved bending resistance to withstand repeated bending without conductor breakage and signal integrity maintenance.
Innovation Solution
A cable design featuring a core composed of twisted copper alloy conductors with a twist pitch less than or equal to 25 times the conductor diameter, surrounded by a polyvinyl chloride insulator with a tensile modulus of 150 MPa or more, and optionally including a shield layer and outer sheath made of polyvinyl chloride resin, which enhances bending resistance and signal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the twist pitch of the conductor is reduced to less than or equal to 25 times the outer diameter, then bending resistance is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by specifying a precise twist pitch range (less than or equal to 25 times the outer diameter of the conductor) to optimize bending resistance. This quantitative parameter control transforms the conductor structure to achieve improved reliability under bending conditions while maintaining manufacturability through defined specifications.
2Stability of the object's composition
If the tensile modulus of the insulator is increased to 150 MPa or more, then conductor position stability during bending is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent applies parameter changes by setting the tensile modulus of the insulator to 150 MPa or more, which stabilizes the conductor position during bending operations. This material property specification ensures that the insulator provides sufficient mechanical support to maintain conductor alignment while withstanding bending stresses.
Solution Approach 2:
The patent employs composite materials by formulating the insulator with specific polymer compositions that achieve the required tensile modulus of 150 MPa or more. This composite approach combines multiple material properties to simultaneously provide mechanical stability, electrical insulation, and bending resistance.
3Strength
If a copper alloy is used for the conductor instead of pure copper, then strength is improved, but electrical conductivity decreases
Solution Approach 1:
The patent applies parameter changes by selecting copper alloy compositions and processing parameters that optimize the balance between strength and electrical conductivity. Through controlled alloying and heat treatment, the conductor achieves sufficient mechanical strength to withstand bending while maintaining adequate electrical conductivity for signal transmission.
Data Source
AI summary
A cable includes a core including at least one covered electric wire, and an outer sheath disposed outside the core. The at least one covered electric wire includes a conductor made of a copper alloy and an insulator disposed outside the conductor. The conductor is a twisted wire formed by twisting a plurality of conductor element wires together, and a twist pitch of the conductor is less than or equal to 25 times an outer diameter of the conductor. The insulator contains a polyvinyl chloride resin and has a tensile modulus of 150 MPa or more.