Cable Shielding Using Polymer-Carbon Composite
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Solution Overview
Problem
Conventional shielding layers in cables, particularly those using metal materials, are heavy and inefficient, leading to increased weight and energy consumption in large-scale applications, while carbon-based solutions require additional costly processes and have inferior conductivity.
Innovation Solution
A cable design featuring a crosslinked polymer-carbon composite shielding layer with carbon-based particles dispersed in a polymer matrix, combined with a metal-based shielding layer, allowing for high electrical conductivity and shielding efficiency without the need for extra processes or machines, achieved through a conventional melt extrusion process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional metal shielding layers are used, then shielding efficiency is high, but cable weight increases
Solution Approach 1:
The patent employs a composite shielding layer structure combining metal foil (inner layer) with carbon fiberreinforced polymer (outer layer). This composite approach leverages the high conductivity of metal at the core while using the lightweight carbon-fiber composite to provide additional shielding and structural support, thereby reducing overall weight while maintaining or enhancing shielding efficiency
Solution Approach 2:
The shielding structure is designed with spatially varying properties: the inner metal foil layer provides baseline shielding close to the conductor, while the outer carbon-fiber composite layer extends shielding coverage and adds mechanical strength. Each layer is optimized for its specific function and position, creating a gradient of shielding effectiveness from inner to outer layers
2Weight of moving object
If carbon aggregates are used for shielding, then cable weight decreases, but electrical conductivity and shielding efficiency are inferior
Solution Approach 1:
The patent creates a hybrid composite shielding layer that combines carbon fibers with polymer matrix materials. The carbon fibers provide the necessary electrical conductivity and shielding performance, while the polymer matrix binds the fibers together and provides mechanical integrity. This composite structure achieves both lightweight properties and sufficient conductivity without requiring metal plating or doping processes
Solution Approach 2:
The patent optimizes the carbon fiber content, fiber orientation, and polymer matrix composition to achieve the desired balance between weight and conductivity. By controlling the volume fraction of carbon fibers and their alignment within the polymer matrix, the shielding layer's electrical properties are tuned to meet performance requirements while maintaining lightweight characteristics
3Reliability
If carbon fibers are used with doping or plating processes, then shielding efficiency improves, but manufacturing complexity and cost increase
Solution Approach 1:
The patent extracts and eliminates the complex doping and metal plating processes from the manufacturing workflow. Instead, it uses a straightforward composite material approach where carbon fibers are directly embedded in a polymer matrix through conventional composite manufacturing techniques, thereby achieving shielding efficiency without the need for additional costly and complex processing steps
Solution Approach 2:
The patent adopts a cost-effective carbon fiber composite material that can be manufactured using standard composite processing methods. This approach replaces expensive and time-consuming metal plating or doping processes with a more economical composite material solution that achieves comparable or superior shielding performance while simplifying manufacturing
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 cable achieves significant weight reduction while maintaining high shielding efficiency, suitable for large-scale applications, and can be easily integrated into existing manufacturing lines without additional equipment or processes.
Implementation Method 1
a first shielding layer surrounding the core unit and being formed of a crosslinked polymer-carbon composite in which carbon-based particles are dispersed in a matrix of a polymer material, the first shielding layer having an electrical resistance of 10 Q-m or less
Implementation Method 2
a first shielding layer surrounding the core unit and being formed of a crosslinked polymer-carbon composite
Data Source
Figure 1
AI summary
The present invention relates to a cable for power transmission or communication, the cable comprising: a core unit comprising at least one conductor and an insulating layer surrounding each conductor; a first shielding layer surrounding the core unit and being formed of a polymer-carbon composite in which carbon-based particles are dispersed in a matrix of a polymer material, the first shielding layer having an electrical resistance of 10 Ω·m or less; and a metal-based second shielding layer surrounding the first shielding layer.