3D-Printed Core Wire Insulation for Stable High-Frequency Signals
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Solution Overview
Problem
Traditional foaming methods for cable insulating layers limit air content to about 35%, leading to uneven foaming and instability in high-frequency signal transmission.
Innovation Solution
A core wire with an insulating layer made by 3D printing, comprising a first and second semi-insulating layer with grooves matching the inner conductor, allowing for higher air content and uniform distribution, enhancing signal transmission stability and reducing cable size.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional foaming methods are used for insulating layers, then the manufacturing process is simple, but the air content is limited to about 35% and foaming is uneven affecting signal transmission stability
Solution Approach 1:
The patent changes the manufacturing method from traditional chemical/physical foaming to 3D printing technology, fundamentally altering the production parameters and process to achieve superior air content distribution and signal transmission stability
Solution Approach 2:
The insulating layer structure is pre-designed with specific groove patterns and air pocket distributions during the 3D printing process, allowing precise control of air content and uniformity before assembly
2Volume of stationary object
If traditional foaming methods are used, then the manufacturing process is straightforward, but the cable size cannot be reduced further while maintaining impedance matching
Solution Approach 1:
By transitioning to 3D printing technology, the patent enables precise control of insulating layer geometry and air pocket distribution, allowing cable size reduction while maintaining impedance matching requirements
Solution Approach 2:
The 3D printing process introduces three-dimensional precision control, allowing complex internal groove structures and air pocket arrangements that optimize cable dimensions without compromising electrical performance
3Manufacturing precision
If traditional foaming methods are used, then the insulating layer can be produced easily, but the air content distribution is uneven affecting dielectric coefficient uniformity
Solution Approach 1:
The patent employs 3D printing technology to precisely control air pocket size, shape, and distribution within the insulating layer, achieving uniform dielectric coefficient and eliminating the uneven air content distribution of traditional foaming methods
Solution Approach 2:
The 3D printing process allows different regions of the insulating layer to have precisely controlled air content and groove structures, optimizing local dielectric properties to ensure uniform overall performance
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 3D printed insulating layer achieves improved electrical and mechanical characteristics, increased air content, and smaller cable size while maintaining impedance matching, resulting in faster and more stable high-frequency signal transmission.
Implementation Method 1
the insulating layer is made by 3D printing process
Data Source
AI summary
A core wire includes: an inner conductor; and an insulating layer covering the inner conductor, wherein the insulation layer is made by 3D printing process, the insulating layer includes a first semi-insulating layer and a second semi-insulating layer, each of the first semi-insulating layer and the second semi-insulating layer has a groove that matchingly accommodates the shape of the inner conductor, and the first semi-insulating layer and the second semi-insulating layer are combined together.