Cable Shield Plating and Insulation Adhesion for Termination
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Solution Overview
Problem
Conventional cable shield formation methods using metal tape are inefficient and prone to air gap formation, making it difficult to achieve high adhesion strength between the shield and insulating materials while also complicating cable termination.
Innovation Solution
A cable design featuring a plating layer shield with a first electrical insulating member and a second insulating member, where the surface treatments like roughening and hydrophilizing enhance adhesion strength, and the second insulating member is selectively removed at cable ends to expose the shield for easy termination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the shield is formed by wrapping a tape composed of copper foil and electrical insulating film, then the shield and electrical insulating member can be formed concurrently, but the work efficiency is low and air gap formation occurs between the tape and electrical insulating member
Solution Approach 1:
The patent replaces the mechanical tape wrapping process with an electroplating process to form the shield. The electroplating process deposits a metal layer (such as copper or nickel) directly onto the conductor surface, eliminating the need for mechanical tape wrapping and associated air gap formation issues.
Solution Approach 2:
The patent changes the formation method parameters from mechanical wrapping to electrochemical deposition. By controlling plating conditions such as current density, plating solution composition, and plating time, the shield can be formed with uniform thickness and excellent adhesion, improving both manufacturing quality and efficiency.
2Strength
If the adhesion strength between the shield and electrical insulating material is made high, then the shield coating is improved, but it becomes difficult to remove the electrical insulating material and expose the shield during cable termination
Solution Approach 1:
The patent divides the cable structure into distinct segments: the shield layer, the electrical insulating material layer, and the exposed shield portion at the termination end. This segmentation allows the bulk of the cable to have strong adhesion for shielding effectiveness, while the termination end provides easy access to the shield for grounding or connection purposes.
Solution Approach 2:
The patent applies different properties to different parts of the cable structure. The main body of the shield has high adhesion strength to the electrical insulating material for effective shielding, while the end portion is designed with reduced adhesion or exposed shield to facilitate termination operations such as grounding connections.
3Manufacturing precision
If the shield is formed by plating treatment, then air gap formation is prevented, but the outer electrical insulating member must be formed in a separate step
Solution Approach 1:
The patent combines the shield formation and outer electrical insulating member formation into a single integrated process step. The electroplating process simultaneously creates the metallic shield layer and the adherent electrical insulating material layer, eliminating the need for separate formation steps and reducing overall manufacturing 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 cable achieves high adhesion strength between the shield and insulating members while allowing for easy termination by reducing adhesion at specific points, thus improving work efficiency and preventing air gap-induced transmission property degradation.
Implementation Method 1
a plating layer acting as a shield coating the electrical insulating member layer
Implementation Method 2
surface treatments like roughening and hydrophilizing enhance adhesion strength
Implementation Method 3
surface treatments like roughening and hydrophilizing enhance adhesion strength
Data Source
AI summary
A cable is composed of a linear shape conductor, a first electrical insulating member coating a periphery of the conductor, a shield made of a plating layer coating a surface of the first electrical insulating member, a second electrical insulating member coating a surface of the shield, and an exposed shield portion provided in at least one end portion of the cable with the second electrical insulating member being removed therefrom and the shield being exposed therein during termination. An adhesion strength between the shield and the second electrical insulating member in the exposed shield portion is lower than an adhesion strength between the shield and the second electrical insulating member in an other part of the surface of the shield.