Cable Assembly Insulating Protective Layer Short Circuit Prevention
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Solution Overview
Problem
Conventional cables face issues with short circuits due to contact between folded metal layers, which affect electromagnetic compatibility during signal transmission.
Innovation Solution
A cable assembly and manufacturing method that includes an insulating protective layer at the axial end part of the second metal covering layer to prevent the outer metal layer from contacting the second metal covering layer, thereby preventing short circuits and maintaining electromagnetic compatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the outer metal layer is folded outward to form a grounding configuration, then electromagnetic compatibility is improved, but the risk of short circuit with other metal layers increases
Solution Approach 1:
An insulating protective layer is introduced as an intermediary between the outer metal layer and the second metal covering layer. This insulating layer acts as a mediator that prevents direct contact between the metal layers during the folding process, thereby eliminating the short circuit risk while maintaining the electromagnetic compatibility benefits of the folded grounding configuration.
Solution Approach 2:
The insulating protective layer is applied to the second metal covering layer before the outer metal layer is folded outward. This preliminary action ensures that the insulation is already in place before the folding operation, preventing any potential contact between metal layers during the forming process and ensuring reliable electromagnetic compatibility in the final cable assembly.
2Reliability
If multiple metal layers are provided to enhance electromagnetic compatibility, then shielding performance is improved, but the complexity of preventing short circuits between layers increases
Solution Approach 1:
Instead of providing continuous insulation along the entire length of all metal layers, the insulating protective layer is applied locally only to the second metal covering layer at the specific region where the outer metal layer will be folded. This local quality approach provides the necessary insulation to prevent short circuits while avoiding the complexity of insulating the entire cable structure, thus maintaining simple manufacturing processes.
Data Source
AI summary
A cable having a transmission wire, a first metal covering layer, an inner insulating layer, a second metal covering layer, an outer insulating layer, an insulating protective layer, and an outer metal layer and method of making such. The transmission wire, a first metal covering layer , and inner insulating layer extend along a first direction, wherein the first metal covering layer and inner insulating layer cover the transmission wire. The first metal covering layer comprises a first axial end part. The inner insulating layer comprises a second axial end part. The second metal covering layer extends along the first direction and covers the inner insulating layer. The second metal covering layer comprises a third axial end part. The outer insulating layer extends along the first direction and covers the second metal covering layer. The outer insulating layer comprises a fourth axial end part.