Molded cable (options) and the method of its manufacture

 

(57) Abstract:

Molded cable and a method of manufacturing a cable, preferably containing several wires and plastic material, interwoven with the wires in tissue-like structure to protect the wires and keeping them at a distance from each other. Tissue-like structure of plastic material is usually formed by injection molding. The cable contains wires including a first wire, the second wire and next to the last wire held at a certain distance relative to each other and having initial and terminal base. A narrow strip of plastic material forms around the wires starting base, then passes over the first wire, the second wire, the third wire, and continues such tissue-like structure to include the last wire. Then strip Opletal the last wire and twist the wire in the reverse order to the first wire, weaving them together at some distance from each other. Such tissue-like structure is repeated to the end position, in which form around the wire end basis. The invention allows to improve maintainability and reduce the tion, in particular the multiwire cable with braid made from molded plastic material, and method of manufacturing molded cable.

Electric cables are characterized by a great variety of forms, wire type, and number, type of insulation and configuration. Electrical cables can be very simple, with a single conductor and simple insulation around it, or very complex, with a large number of wires of different sizes and types, with different input devices and output along its length. At the ends of the cable can be of different output devices, or these ends may be exposed, depending on the target destination.

Electrical cables of different types are used in virtually all devices that use electronic devices or apparatuses. The cable required to connect electrical power from the electronic device or to transmit electronic signals to another electronic device, measuring instruments, meters, lights or other visual indicators, for communication between the devices and the coordination of their actions. Wherever required the transmission of electrical signals or electrical current from one device to another, usually IP is between devices in most modern devices and machines use a special electrical cable with several independent electric conductors. These specially made cables used in automobiles, trucks, airplanes, jet engines, missiles, and other military equipment, computers, TVs, some phones, stereos, and almost all other possible devices, where used any electronics.

There are several different configurations of electric cables and methods for their manufacture. Typically, sheath or braid contains several wires. The shell may be wound or cast in several different ways, known in the art. Injection molding method are cable with several wires enclosed within any molding material. It is possible to make a cable to one of several different configurations. The most common forms are flat ribbon cable or round cable. Wires in multi-conductor cable can be held parallel to each other, or can be connected to each other fraud in the form of a weave depending on the particular application and type of conductors.

In one of the known methods of electrical wires are twisted in such a way that the wire of the primary signal Keenum wires can take the current, or they may be grounded. Twisted wire then in most cases covered with insulating material.

In special cases the use of special cables often the wire is introduced into the cable and deduce from it in several different places, and each wire has some end device. These types of cables are often made in the Assembly fixture, specially designed for a particular application. The wires are secured in the device by one or the required groups. Each of the wires or groups of wires is inserted into the cable in a certain place and has a sufficient length from the cable to the terminal device that allows you to connect an end device with any electrical device. When all wires installed in its place, the cable is wrapped with an insulating material or use the process of casting the floor the pressure at which the cable is covered with an insulating material. In the latter case, the insulation material is often completely fills all voids between the wires and completely surrounds the wire forming the outer insulation of the cable.

In the author's certificate of the USSR 1479957, CL H 01 B 11/00, 7/08, 1989, describes a molded cable containing forming the verge intervals, as well as plastic material that holds the wire at a distance relative to each other and forming data wires tissue-like structure in which the first plastic material forms the initial basis around the wires, then Opletal the first wire at the top, a second bottom wire, the third wire on top, then continuing such tissue-like structure to the last wire, Opletal it and twist the wire in the reverse order to the first wire, weaving wire together.

Known cable has a number of disadvantages. After connecting the wires forming the cable is very difficult to fix a separate wire. Typically, the outer insulation of the cable must be removed at considerable length to the fault detection, or completely remove the replacement wire. If the wire is somehow intertwined, single wire usually cannot be removed or repaired, and because the wire is enclosed in a cast shell, you cannot delete or repair single wire without damaging the integrity of the cable.

Another drawback is the weight of the insulation material used in the manufacture of the cable. The weight of the insulation material may significantly exceed the weight Prov is operating, for example in automobiles, aircraft, space vehicles and other military or civilian applications.

In U.S. patent 4123304, CL H 01 B 13/00, 1978, describes a method of manufacturing the shielded cable, including the manufacture of plastic injection moulds, installing wires in it, including the first wire, the second wire and so on until the last wire, injection molded material, curing and removing the molding material together with the wires from moulds.

Using this method, make multi-core cables, in which the voids between the wires completely filled with insulating material on all sides surrounding the wire with the formation of the outer cable insulation. Obtained in this way the cable is heavy and low flexibility, and its repair is difficult because the removal or replacement of individual wires in the cable is impossible without violating the integrity of the latter.

The objective of this invention is to provide a molded cable, which has a significantly lower weight and greater flexibility compared with the known one in which the individual wire can be easily removed, repaired or replaced without disturbing the integrity of the entire cable and which can ispolzovaniya manufacturing molded cable, with the above advantages.

The solution of the problem of the invention is provided by creating a cast of the cable containing forming the cable wires including a first wire, the second wire and so on until the last wire and separated by certain intervals, as well as plastic material that holds the wire at a distance relative to each other and forming data wires tissue-like structure in which the first plastic material forms the initial basis around the wires, then Opletal the first wire at the top, a second bottom wire, the third wire on top, then continuing such tissue-like structure to the last wire, Opletal it and twist the wire in the reverse order to the first wire, weaving wires together while the plastic material is made in the form of narrow strips, and repeats tissue-like structure to the end position, where it forms around the wire end basis.

Thus, due to the fact that plastic material that holds the wires in the cable at a distance from each other, made in the form of narrow strips, the weight of the cable is much less in comparison with the known, the frequency between the wires is not filled, in the proposed cable single wire can be easily removed, repaired or replaced without disturbing the integrity of the entire cable. In addition, the wires can slide between the narrow strips within tissue-like structure, which makes the cable more flexible as compared with the known.

Plastic material molded cable may be a molding material is molded around the wires in the form of a tissue-like structure, and the wires can be inserted in molded cable in several places along the length of the cable, and around each of these wires formed the initial basis.

The wire can be withdrawn from the molded cable in several places, and around each of these wires formed leaf base.

In the proposed cast cable as a molding material can use silicone or polyurethane.

The solution of this problem is provided by creating a cast of the cable containing forming the cable wires including a first wire, the second wire and so on until the last wire and located at a distance relative to each other, as well as plastic material that holds the wire at some distance circle wire primary basis, then Opletal the first wire from the top, second from the bottom, third from the top, continuing this dovetailing to the last wire then passes around the last wire in the reverse order to the first wire, weaving wire together, with plastic material made in the form of narrow strips, and repeats such tissue-like structure to the end position, in which end forms the Foundation around the wires, and the wire is introduced into the cable in several places along the length of the cable with the formation of several primary reasons, and removed from the cable in several places along the length of the cable with the formation of multiple leaf bases.

Thus, due to the fact that plastic material that holds the wires in the cable at a distance from each other, made in the form of narrow strips, the weight of the cable is much less compared to what is known as plastic material covers only about half of the outer surface of the wires, and the voids between the wires is not filled, while in the proposed cable single wire can be easily removed, repaired or replaced without disturbing the integrity of the entire cable. In addition, the wires can slide between narrow potara to that wire is introduced into the cable in several places along the length of the cable with the formation of several primary reasons, and removed from the cable in several places along the length of the cable with the formation of multiple leaf bases, the cable can be used as a special cable, special purpose, with numerous inputs and outputs, and each end of the input or output has a dedicated terminal device.

Plastic material molded cable may be a molding material is molded around the wires in the form of a tissue-like structure, while the molding material may be a silicone or polyurethane.

The solution of this problem is provided by creating a way of getting the cable in a braid, including the manufacture of plastic injection moulds, installing wires in it, including the first wire, the second wire and so on until the last wire, injection molded material, curing and removing the molding material together with the wires from moulds, while the injection mold has a slit corresponding wires of a predetermined configuration and a tissue-like interlocking channels perpendicular to these cracks, and open the Rial spend so to direct the flow of molding material in tissue-like interlocking channels this moulds.

Due to the fact that in the proposed method for the manufacture of molded cable used casting mold, which has a slit corresponding wires of a given configuration, and tissue-like interlocking channels perpendicular to these cracks, and holes for injection of the molding material in such interlocking channels, cable manufactured by this method has a significantly lower weight compared to cable, made known method, and it can be made in the form of a cable with multiple inputs and outputs, and each end of the input or output has a special end device, with a separate wire in the cable produced by the proposed method, can be easily removed, repaired or replaced without disturbing the integrity of the entire cable. In addition, manufactured in this way the cable is more flexible than cable, manufactured in a known manner.

In the proposed method of manufacturing a molded cord tissue-like interlocking channels may form a flow path of the molding material forming a narrow initial oaou structure to include the last wire, then passing around it and back around these wires in reverse order to the first wire, weaving wire together and holding them at a distance when a predetermined configuration, repeating tissue-like structure to the end position, with the formation of an end of the base around the wires.

In the proposed cast cable molding material may be a silicone or polyurethane.

The above and other objectives and features of the invention can be better understood and appreciated from the following detailed description of the main variants of its implementation, selected for illustration and shown in the accompanying figures.

In Fig. 1 shows a top view of the molded cable with several wires withdrawn from the cable in different places.

In Fig. 2 is a bottom view of the initial section of the molded cable.

In Fig. 3 is a cross-section of the molded cable.

In Fig. 4 - cast form with molded cable.

In Fig. 5 - molding the form used for the manufacture of molded cable in accordance with this invention.

Below with reference to Fig. 1 - 3 describes one example of a preferred implementation of the invention, demons is accordance with this invention, as a rule, contains several wires 12 that are held at some distance twisted plastic material 28.

In the above description of the preferred embodiment of the molded cable and the best method of its manufacture in accordance with this invention. However, it is understood that the below described preferred embodiment is merely an illustration, and not limitation of the present invention. It is assumed that the scope of the invention includes all modifications, which are its main design features.

Cast braided cable sheath 10 may contain from three to almost an unlimited number of wires. Generally, the more wires, the more difficult it becomes woven structure, especially if you want to create more than one layer. Wire 12, as a rule, indicate the following way: the first wire 14, the second wire 16, and so on until the last wire 18. The wires 12 are held at a distance relative to each other plastic material 24, interwoven with the wires 12 in a tissue-like structure 30. In a preferred method of implementation of the plastic material 24 is molded material.

the 28 of plastic material 24. However, in a preferred execution of narrow strips 28 in fact formed the molten molding material injected into the mould with the formation of tissue-like structure 30 almost simultaneously throughout the length of the cable. First plastic material 24 forms the primary base 26 around the wires 12 about the initial section 20 cast braided cable 10. It holds all the ends 20 of the wire 12 at a certain distance. Then a narrow strip 28 entwine the first wire 14 from above, the second wire 16 from the bottom, the third wire on top, continuing this dovetailing to include the last wire 18. Then this narrow strip 28 entwine around the last wire 18 and continue to weave the wires in the opposite direction to the first wire 14, weaving wires together and holding them at a distance. Tissue-like structure is repeated up to the end position 32. A narrow strip 28 then forms the terminal base 34, covering all wires 12 and ending near the end position 32.

The initial base 26 and terminal base 34 hold all the wires together, preserving their relative position at the beginning and at the end of the cast of the cable 10. Without bases 26 and 34 of the wire 12 could svoego cable in these places.

There is a virtually unlimited number of different configurations that can be obtained using solid cable and method of its manufacture. The cable shown in Fig. 1 and 4, has one primary base 20 and three separate limit output 22. The exact configuration of the cable, the number and location of the initial and final conclusions and type of output devices is determined by its purpose. Description and illustrations do not limit the scope and application of the present invention. In any use case can have many inputs and outputs. In addition, the device may be a lot of cables of different configurations.

When using cast cable 10 in accordance with this invention are achieved significant benefits. The most obvious include greater flexibility, weight reduction, and the possibility of repair of the wires in the cable. Because the wires are not fixed and not fixed entirely within the solid shell of the cable, molded or wound, they have more freedom of movement. Wire 12 can slide between the narrow strips 28 within tissue-like structure 30. This makes the cable more flexible as compared with the known analogues.

Because plastifoam not filled, you want about half of the material or less, which leads to a considerable reduction of weight.

Due to the fact that the wires 12 in the cable 10 can slide inside a tissue-like structure, and visible about half the surface of the wire, it is possible to repair the wires 12 within the cast of the cable 10. Therefore questionable plot, you can easily view and organize access to it. One or more wires can be extracted from tissue-like structure 30 and return back without damaging the integrity of the cable. It is usually impossible for a known cable-analogues. In conventional cables need to remove or cut the shell to inspect the wire and get access to it. Therefore, in most cases, the cable is not repaired, and replaced in its entirety.

As noted above, in a preferred embodiment, the plastic material 24 is molded material. As shown in Fig. 4, tissue-like structure 30 is mainly made by injection molding. The main injection hole designated by the number 36. The molten molding material is injected through the main injection hole 36, and then it flows through the injection channel 38 to the individual injection holes 40. In an advantageous embodiment, icia individual injection holes should be such that so that molding material at the same time did in all weave. Therefore, all narrow strips 28 should be formed almost simultaneously.

Excess molding material out through the outlet 42 from the opposite side of the molded cable with respect to the input holes 40. Molded cable will be fully operational when the excess molding material will come out of all the vents. This ensures complete formation of all narrow strips 28 to removal from molds 50.

The first operation of the method of manufacturing a molded cable 10 according to this invention is in the manufacture of molds 50, shown in Fig. 5. The mould 50 is made one of the known in the art methods. Form 50 has a slit 52, tissue-like interlocking channels 30, the inlet 40 and the outlet 42. Slit 52 correspond to the size, number and the desired configuration of the wires 12 in visitors the cable 10. Injection form 50 has a main injection hole 36 to enter the molding material. In an advantageous embodiment, has a main injection hole 36 with the injection channel 38, where through a separate injection holes 40 produce tissue-like fill per the weave. Also has a solid plot 44 for the initial base 26 and a solid plot 46 to limit the base 34.

After injection moulding tools, the next step is the introduction of the wires 12 in the slit 52 and the end of the Assembly, plastic injection moulds 52 with the wires 12 with the pre-filling of the molding material.

Then the molten molding material is injected through the main injection hole 36 in any known in the art by the way. Molding material flows through the injection channel 38 and through a separate injection holes 40 in tissue-like interlocking channels 30. After filling in tissue-like weave of the channels 30, the excess molding material out through the outlet 42.

Further, depending on the particular molding material hold the cure for molding material properly stiffened and hardened. After appropriate curing, remove the mould 50, took out of molded cable 10. To obtain the finished product cable should be cleaned of all surplus and wyprostowac.

From the detailed description of the invention it is clear that there are various modifications of the invention without deviation from the set here its basic principle is gaining are not restrictive. The scope of the invention defined by the attached claims and their equivalents.

1. Molded cable containing forming the cable wires including a first wire, the second wire and so on until the last wire and separated by certain intervals, as well as plastic material that holds the wire at a distance relative to each other and forming data wires tissue-like structure in which the plastic material is first formed the initial basis around the wires, then Opletal the first wire at the top, a second bottom wire, the third wire on top, then continuing such tissue-like structure to the last wire, Opletal it and twist the wire in the reverse order to the first wire, spletna wires together, characterized in that that plastic material made in the form of narrow strips, and repeats tissue-like structure to the end position, where it forms around the wire end basis.

2. The cable under item 1, characterized in that the plastic material is a plastic material that is molded around the wires in the form of a tissue-like structure.

3. The cable under item 1 or 2, characterized in that the wire is introduced in the definition.

4. The cable according to any one of paragraphs.1 to 3, characterized in that the wires are led out from the cable in several places in and around each of these wires formed leaf base.

5. The cable according to any one of paragraphs.1 to 4, characterized in that as a molding material used silicone.

6. The cable according to any one of paragraphs.1 to 4, characterized in that the quality of molded polyurethane material used.

7. Molded cable containing forming the cable wires including a first wire, the second wire and so on until the last wire and located at a distance relative to each other, as well as plastic material that holds the wire at a distance and forming with wires tissue-like structure, in which the plastic material first forms the wires around the initial basis, then Opletal the first wire from the top, second from the bottom, third from the top, continuing this dovetailing to the last wire then passes around the last wire in the reverse order to the first wire, weaving wire together, characterized in that that plastic material made in the form of narrow strips, and repeats such tissue-like structure to the end position, in Coll cable length with the formation of several primary reasons and removed from the cable in several places along the length of the cable with the formation of multiple leaf bases.

8. The cable under item 7, characterized in that the plastic material is a plastic material that is molded around the wires in the form of a tissue-like structure.

9. The cable under item 8, characterized in that the molding material is a silicone.

10. The cable under item 8, characterized in that the molding material is a polyurethane.

11. A method of manufacturing a molded cable, including the manufacture of plastic injection moulds, installing wires in it, including the first wire, the second wire and so on until the last wire, injection molded material, curing and removing the molding material together with the wires from moulds, characterized in that the injection mold has a slit corresponding wires of a predetermined configuration, and tissue-like interlocking channels perpendicular to these cracks, and holes for injecting molding material into tissue-like interlocking channels, injection molded material spend so to direct the flow of molding material in tissue-like interlocking channels this moulds.

12. The method according to p. 11, wherein the tissue-like interlocking channels forms a trajectory, and always let the about above the first wire, under the second, over the third, continuing this woven structure to include the last wire, then passing around it and back around these wires in reverse order to the first wire, weaving wire together and holding them at a distance when a predetermined configuration, repeating tissue-like structure to the end position, with the formation of an end of the base around the wires.

13. The method according to p. 11, characterized in that the molding material is a silicone.

14. The method according to p. 11, characterized in that the molding material is a polyurethane.

 

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