Coated Twisted Pair Cable Assembly for Sensor Data Transmission
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Solution Overview
Problem
Conventional cable assemblies used in medical and other industries for data transmission between sensors and control systems are bulky, heavy, and costly, making them difficult to maneuver and integrate, especially when numerous signal lines are required, and they impose strain on objects or animals during testing.
Innovation Solution
A cable assembly featuring coated twisted pairs with signal and ground conductors, where the twist exterior is coated with a less conductive material, eliminating the need for braided shields or conductive foils, allowing for reduced diameter and increased flexibility, and potentially lower production costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If conventional micro-coaxial conductors are used to transmit data between sensor and control system, then data transmission function is achieved, but cable assembly becomes bulky and heavy
Solution Approach 1:
The patent removes the braided shield or conductive foil layer from the cable assembly structure. By extracting this shielding component and replacing it with a twisted pair configuration where the ground conductor is positioned at the center, the cable assembly achieves reduced weight and simplified construction while maintaining data transmission functionality
Solution Approach 2:
The patent employs a composite structure consisting of signal conductors with insulation layers twisted around a central ground conductor. This composite arrangement of conductive and insulating materials creates an effective shielding mechanism without requiring separate braided shield layers, thereby reducing overall cable complexity and weight
2Adaptability or versatility
If numerous micro-coaxial conductors are bundled to provide sufficient signal lines, then data transmission capacity is improved, but cable assembly size increases and flexibility decreases
Solution Approach 1:
The patent divides the cable assembly into multiple independent twisted pairs, each capable of carrying differential signals. This segmentation allows the cable to provide sufficient signal transmission capacity through parallel twisted pairs while maintaining flexibility, as each pair can move independently without restricting the others
Solution Approach 2:
The patent transitions from a concentric radial arrangement of conductors to a twisted pair configuration where conductors are arranged along the longitudinal axis and twisted around each other. This dimensional change from radial to helical arrangement reduces cable stiffness and improves flexibility while maintaining signal integrity
3Reliability
If conventional cable assembly structure with braided shield is used, then electromagnetic shielding is provided, but production cost increases
Solution Approach 1:
The patent eliminates the braided shield or conductive foil layer from the cable assembly, removing this costly component and simplifying the manufacturing process. The electromagnetic shielding function is replaced by the twisted pair configuration itself, which provides effective shielding at lower production cost
Solution Approach 2:
The twisted pair structure serves multiple functions simultaneously: the signal conductors transmit data while the ground conductor provides both reference potential and electromagnetic shielding. This self-service approach eliminates the need for separate shielding components, reducing production cost and 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 solution reduces the weight and size of the cable assemblies, improves flexibility, and decreases jitter, while simplifying the construction process by eliminating the need for complex shielding, thus addressing the challenges of bulkiness and cost associated with conventional coaxial conductors.
Implementation Method 1
The twist exterior is coated with a conductive material... The cable assembly is devoid of a braided shield or conductive foil that immediately surrounds the coated twisted pair
Data Source
AI summary
Sensor assembly includes a modular device and a cable assembly configured to communicatively couple the modular device and a control system and transmit digital signals therethrough. The cable assembly includes a cable jacket surrounding a channel and a twisted pair extending through the channel. The coated twisted pair includes first and second signal wires that each include a respective signal conductor and an insulation layer that surrounds the respective signal conductor. The coated twisted pair also includes a ground conductor. The first and second signal wires are twisted about one another. A twist exterior is defined by corresponding exterior surfaces of the first and second signal wires and the ground conductor. The twist exterior is coated with a conductive material.