Cable Jacket with Embedded Discontinuous Shield Segments
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Solution Overview
Problem
Conventional communications cables are bulky due to the need for both a shielding layer and a barrier layer to prevent alien crosstalk, which increases their size and complexity.
Innovation Solution
A method of embedding a shielding tape with discontinuous conductive segments between the inner and outer layers of a cable jacket, where the shielding tape is co-extruded with the jacket material, eliminating the need for a separate shielding and barrier layer by bonding the materials together during the extrusion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a shielding layer and a barrier layer are both provided to prevent alien crosstalk, then the cable is protected against noise, but the cable becomes bulky
Solution Approach 1:
The patent combines the shielding layer and barrier layer into a single integrated structure. The shielding tape with discontinuous conductive segments is embedded directly within the jacket material, eliminating the need for separate shielding and barrier layers. This merging reduces cable bulk while maintaining both shielding and barrier functions through the co-extrusion process where the substrate material of the shielding tape and jacket material bond together.
Solution Approach 2:
The patent uses composite material structure by embedding shielding tape with conductive segments within the jacket material. The combination of substrate material and jacket material creates a composite structure that provides both shielding properties and barrier properties simultaneously, reducing the need for separate layers and thereby reducing overall cable volume.
2Object-affected harmful factors
If a shielding layer and a barrier layer are both provided to prevent alien crosstalk, then the cable is protected against noise, but the cable structure becomes complex
Solution Approach 1:
The patent merges two separate layers (shielding and barrier) into a single integrated structure by embedding the shielding tape within the jacket material. This reduces structural complexity from multiple discrete layers to a unified composite structure, while still providing both shielding and barrier functions through the co-extrusion process.
Solution Approach 2:
The integrated jacket structure serves multiple functions simultaneously: it provides mechanical protection, acts as a barrier layer, and incorporates shielding properties through the embedded conductive segments. This multi-functionality reduces the need for separate specialized layers, thereby simplifying the overall cable structure.
3Volume of moving object
If discontinuous conductive segments are used in the shielding tape, then the cable diameter is reduced, but the shielding effectiveness may be compromised
Solution Approach 1:
The shielding tape is divided into discontinuous conductive segments rather than using a continuous shield. This segmentation reduces the amount of conductive material needed and decreases cable diameter, while the segments are strategically positioned and bonded within the jacket material to maintain effective shielding performance through their distributed arrangement.
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
This approach reduces the overall diameter of the cable while effectively minimizing noise from external sources without grounding, maintaining consistent electrical properties and physical integrity of the jacket.
Implementation Method 1
co-extruding the shielding tape with the first and second jacket layers, wherein the substrate material of the shielding tape and the jacket material of the first and second jacket layers are the same such that during the co-extrusion step, the substrate and the first and second jacket layers bond together
Data Source
AI summary
A cable includes a jacket, a shielding tape, a pair of wires, an inner and outer jacket layer, and a separator. The shielding tape includes a substrate and a plurality of conductive shield segments disposed on the substrate. The pair of wires form a twisted pair. The inner and outer jacket layers are extruded onto inner and outer surfaces, respectively, of the substrate. The substrate, the inner jacket layer and the outer jacket layer are bonded together into a single layer that defines a circumference. Each of the conductive shield segments: extends only partially around the circumference of the single layer; is longitudinally spaced from each longitudinally adjacent one of the conductive shield segments; is radially spaced from, and overlaps a portion of, each immediately circumferentially adjacent one of the conductive shield segments; and is embedded in at least one of the inner jacket layer and the outer jacket layer.