Cable Connector Assembly Using Shielding Layer for High Current
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Solution Overview
Problem
High current transmission in cables results in significant power loss and temperature rise due to increased resistance, which existing cable designs fail to adequately address, especially in thin and flexible configurations like USB C and HDMI alternate mode cables.
Innovation Solution
A cable connector assembly that includes a circuit board connecting the shielding layer of the cable to a grounded housing, reducing resistance and heat generation by electrically linking the shielding layer and housing, thereby enabling higher current transmission with reduced power loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If the diameter of cable wire conductor is increased to reduce power loss during high current transmission, then power loss is reduced, but cable thickness and flexibility are compromised
Solution Approach 1:
The patent divides the current transmission path into multiple segments: the cable core wires and the shielding layer connected through housing and circuit board to ground. This segmentation allows current to flow through multiple parallel paths, effectively reducing the resistance of each individual path and thereby reducing power loss without increasing cable thickness.
Solution Approach 2:
The shielding layer, which traditionally serves only for electromagnetic interference shielding, is repurposed to also function as a current transmission path. By connecting the shielding layer to ground through the housing and circuit board, it becomes an additional conductor that carries return current, thereby reducing overall resistance and power loss while maintaining cable flexibility.
2Power
If high current is transmitted through the cable, then power delivery capability is improved, but temperature rise increases
Solution Approach 1:
The current path is segmented into multiple parallel conduction paths involving the core wires and the shielding layer-housing-circuit board-ground connection. This segmentation distributes the current load across multiple paths, reducing the current density and heat generation in any single path, thereby enabling high power delivery without excessive temperature rise.
3Loss of energy
If resistance is reduced to enable higher current transmission, then power loss is reduced, but device complexity increases
Solution Approach 1:
The patent makes the shielding layer multi-functional by using it both for electromagnetic shielding and as a current transmission path. This eliminates the need for additional dedicated ground wires or shielding structures, as the existing shielding layer is repurposed to carry current, thereby reducing power loss without significantly increasing device complexity.
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 allows for the efficient transmission of higher currents with minimal power loss and temperature rise, maintaining a voltage drop of 500 mV and temperature below 25°C, effectively addressing the limitations of existing cable designs.
Implementation Method 1
the cable connector assembly connects between the shielding layer and the housing through the circuit board, which reduces resistance to current flow
Implementation Method 2
reduces resistance to current flow, thereby reducing heat and permitting transmission of higher current
Data Source
AI summary
A cable connector assembly includes an electrical connector and a cable, the electrical connector comprising a plug mated with a mating connector, a circuit board connected between the plug and the cable, and a housing disposed outside the circuit board, the cable comprising a number of core wires and a shielding layer covering the core wires, the housing electrically connected to the shielding layer, wherein the housing is grounded to the circuit board.