Automotive Cable with Central Insulating Strand
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Solution Overview
Problem
Modern vehicles require numerous electronic control units (ECUs) connected by costly and weight-added jacketed unshielded twisted pairs (JUTPs) communications cables, which are expensive to manufacture and add significant weight, while also lacking flexibility in permittivity adjustment and ease of stripping.
Innovation Solution
A communications cable design featuring a pair of twisted conductors within a cable jacket with two or more insulating strands, including a central strand between the conductors, which reduces weight, simplifies manufacturing, allows for permittivity adjustment, and enhances noise immunity by maintaining twist and facilitating easier stripping and connector attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional JUTP cable design with individual insulators for each conductor is used, then electrical insulation is ensured, but the cable diameter increases leading to greater weight and higher cost
Solution Approach 1:
The patent merges the insulating function from individual conductor insulation to a shared cable jacket insulation. Instead of each conductor having its own insulator, the cable jacket itself provides the insulating barrier between conductors, eliminating redundant insulating layers and reducing overall cable diameter and weight.
Solution Approach 2:
The cable jacket serves multiple functions simultaneously: it provides mechanical protection, environmental shielding, and electrical insulation between conductors. This multi-functional design eliminates the need for separate individual conductor insulators, simplifying the overall cable structure while maintaining insulation effectiveness.
2Ease of manufacture
If conventional JUTP manufacturing process with individual conductor insulators is used, then reliable insulation is achieved, but manufacturing cost and complexity increase
Solution Approach 1:
The manufacturing process merges multiple insulation applications into a single cable jacket extrusion step. Instead of applying individual insulators to each conductor separately, the insulating material is extruded as a continuous jacket around all conductors simultaneously, reducing manufacturing steps and improving consistency.
Solution Approach 2:
The patent segments the insulating function from the conductor structure and assigns it to the cable jacket layer. This separation allows the jacket to be manufactured as a unified protective and insulating barrier, simplifying the manufacturing process while ensuring consistent insulation properties across all conductors.
3Ease of operation
If conventional JUTP cable structure is used, then conductor protection is provided, but stripping difficulty and connector attachment complexity increase
Solution Approach 1:
The patent combines the cable jacket and insulating layers into a single removable unit. During stripping, the entire jacket and insulating structure is removed together in one operation, exposing the conductors cleanly for connector attachment. This eliminates the need to separately remove individual insulators, reducing complexity and improving reliability of connector installation.
Data Source
AI summary
An automotive communications cable includes a cable jacket, a pair of twisted conductors disposed within the cable jacket, and two or more insulating strands disposed within the cable jacket. The two or more insulating strands include a central insulating strand disposed between a first conductor in the pair of twisted conductors and a second conductor in the pair of twisted conductors.