Cable Assembly With Wire Thickness Transition For Low Insertion Loss
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Solution Overview
Problem
High-speed signal transmission over longer distances in high-density systems faces challenges due to increased channel insertion loss, which is exacerbated by the need for thicker conductive wires that cannot be accommodated in small form factor connectors with high-density pin arrangements.
Innovation Solution
A cable assembly with a bulk cable section of thicker conductive wires and a cable transition section where wires gradually change thickness from thicker to thinner, allowing for lower insertion loss while enabling connection to high-density systems and longer distances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If thicker conductive wires are used in the bulk cable section, then insertion loss is reduced, but the cable cannot be connected to high-density connectors with small form factors
Solution Approach 1:
The cable is divided into distinct segments: a bulk cable section with thicker conductive wires for low-loss signal transmission, and a cable transition section with gradually thinning wires that adapt to high-density connectors. This segmentation allows each section to be optimized for its specific function without compromising the other.
Solution Approach 2:
Different sections of the cable have different wire thicknesses tailored to their specific requirements. The bulk cable section uses thicker wires (e.g., 24-28 gauge) to minimize insertion loss over distance, while the cable transition section gradually transitions to thinner wires (e.g., 30-34 gauge) that can be accommodated by high-density connectors with small form factors.
2Reliability
If thicker conductive wires are used, then signal transmission quality is improved, but component size must increase
Solution Approach 1:
The cable assembly is segmented into a bulk section with thicker wires for signal integrity and a transition section with thinner wires for compactness, allowing the overall assembly to maintain small form factor while preserving transmission quality in the critical bulk section.
Solution Approach 2:
Thicker wires are localized only to the bulk cable section where they are needed for low-loss transmission, while the cable transition section and connector interface use thinner wires to minimize overall cable assembly volume and enable high-density packaging.
3Length of stationary object
If the cable is designed for long-distance transmission, then signal loss increases, but high-speed transmission becomes difficult
Solution Approach 1:
The bulk cable section is specifically designed with thicker conductive wires optimized for long-distance, low-loss signal transmission, while the cable transition section handles the adaptation to high-density connectors, allowing the overall system to achieve both long distance and high-speed capability.
Data Source
AI summary
In accordance with embodiments disclosed herein, there is provided a high-density low-loss cable and connector assembly. A cable assembly includes a first cable connector, a bulk cable section, and a first cable transition section. The bulk cable section includes a first plurality of conductive wires of a first wire thickness. The first cable transition section includes a second plurality of conductive wires that has a first distal end connected to the bulk cable section and a second distal end connected to the first cable connector. Each of the second plurality of conductive wires transitions from the first wire thickness at the first distal end to a second wire thickness that is less than the first wire thickness at the second distal end. Each of the second plurality of conductive wires in the first distal end is connected to a corresponding conductive wire of the first plurality of conductive wires.