Coaxial Data Cable Shielding Composite for Faster Crimping

Solution Overview

Problem

Existing shielded data cables in the automotive industry face production inefficiencies due to slow braiding processes, high costs, and difficulty in crimping, especially when producing high-speed data transmission cables.

Innovation Solution

A coaxial data cable design featuring a core of conductor wires surrounded by an extruded shielding composite made of a matrix and continuous reinforcement wires, eliminating the need for braiding and allowing for faster production and easier crimping.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If braiding is used to create the shielding layer, then electromagnetic shielding is achieved, but production speed decreases and costs increase

Engineering Contradiction:

Improveelectromagnetic shieldingVSAvoidproduction speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The patent changes the fundamental parameter of shielding layer construction from braided wires to an extruded composite material. This parameter change transforms the manufacturing process from a complex braiding operation to a simpler extrusion process, dramatically increasing production speed while maintaining electromagnetic shielding effectiveness through the conductive properties of the extruded composite.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical braiding system with an extrusion system. Instead of using mechanical braiding machines to interweave wires, the invention uses an extrusion process to form the shielding layer as a continuous composite material, simplifying the manufacturing system and improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If braiding is used to create the shielding layer, then electromagnetic shielding is achieved, but production costs increase

Engineering Contradiction:

Improveelectromagnetic shieldingVSAvoidproduction cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the fundamental parameter of shielding layer construction from braided wires to an extruded composite material. This parameter change transforms the manufacturing process from a complex braiding operation to a simpler extrusion process, dramatically increasing production speed while maintaining electromagnetic shielding effectiveness through the conductive properties of the extruded composite.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical braiding system with an extrusion system. Instead of using mechanical braiding machines to interweave wires, the invention uses an extrusion process to form the shielding layer as a continuous composite material, simplifying the manufacturing system and improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If braided shielding is used, then electromagnetic shielding is achieved, but crimping and connector assembly become difficult

Engineering Contradiction:

Improveelectromagnetic shieldingVSAvoidcrimping ease

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent changes the fundamental parameter of shielding layer construction from braided wires to an extruded composite material. This parameter change transforms the manufacturing process from a complex braiding operation to a simpler extrusion process, dramatically increasing production speed while maintaining electromagnetic shielding effectiveness through the conductive properties of the extruded composite.

Inventive Principle:

Principle #35Parameter changes

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 extruded shielding composite enables faster production, reduced costs, and improved compatibility with existing cables, while maintaining or enhancing electromagnetic shielding and transmission properties.

Implementation Method 1

a shielding layer arranged around the conductor wires, made of an extruded shielding composite comprising a matrix and a reinforcement by continuous wires

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Implementation Method 2

a shielding layer arranged around the conductor wires, made of an extruded shielding composite

Methodology Applied

Scientific EffectExtrusion: Extrusion

Data Source

PatentEP4675648A1Data cables with coaxial wire reinforced composite for shielding

Publication Date: 2026.01.07 APTIV MANUFACTURING MANAGEMENT SERVICES GMBH

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AI summary

A coaxial data cable (30) comprises a core of conductor wires (1), and a shielding layer arranged around the conductor wires, made of an extruded shielding composite comprising a matrix (3) and a reinforcement by continuous wires (2). The continuous wires (2) preferably extend substantially parallel to each other.