Coaxial Cable Braided Shield Bundle Segmentation
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Solution Overview
Problem
The existing coaxial cables used in wire electrical discharge machines require time-consuming separation of the core wire and shield during manufacturing, which hampers efficiency and increases the risk of impedance and electromagnetic noise leakage.
Innovation Solution
A coaxial cable with a braided shield structure where the bundles of wires are arranged in a mesh pattern, allowing easy separation of the core wire from the shield by widening the space between the bundles, thereby reducing the time and impedance issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the core wire and shield are tightly bound in conventional coaxial cables, then the cable structure is compact and stable, but the separation of core wire and shield during manufacturing becomes time-consuming and difficult
Solution Approach 1:
The shield is segmented into multiple bundles, each comprising multiple wires arranged side by side. These bundles are braided in a mesh pattern around the core wire portion, creating spaces between the bundles that facilitate easy separation of the core wire from the shield during manufacturing while maintaining cable stability
Solution Approach 2:
The shield structure implements local quality by having bundles with specific width dimensions (equal to or larger than the radius of the core wire portion) positioned at specific locations. This localized structural characteristic creates adequate space between bundles for core wire extraction without compromising the overall shielding effectiveness or cable integrity
2Reliability
If the shield is made with tightly braided wires, then the electromagnetic shielding effectiveness is improved, but the impedance increases and the core wire becomes difficult to extract
Solution Approach 1:
The shield is divided into multiple bundles arranged in a mesh pattern, creating spaces between the bundles. This segmentation maintains electromagnetic shielding effectiveness through the braided structure while reducing overall impedance by providing pathways for electrical field distribution and facilitating core wire extraction
Solution Approach 2:
The shield adopts a porous-like mesh structure with spaces between the bundles. This open structure reduces impedance by allowing better electrical field distribution while maintaining shielding effectiveness through the conductive braided configuration, and enables easy core wire removal
Data Source
Figure 1A~1B
Figure 2
Figure 3
AI summary
A coaxial cable (10) comprises: a core wire part (12) which is linear and which includes a core wire (16) and a tubular insulator (18) that covers the core wire (16); and a shield (14) that covers the core wire part (12). The shield (14) has a braided structure in which a plurality of bundles (20) having strands aligned therein are knit in a mesh shape. The width dimension (WD) of each of the plurality of bundles (20) is at least the radius (RD) of the core wire part (12).