Coaxial Cable With Twisted Conductor And Fluororesin Insulation
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Solution Overview
Problem
Existing coaxial cables face challenges in reducing signal attenuation and increasing mechanical strength while maintaining cost-effectiveness, as they require expensive processing and materials, and foam insulation can lead to variable electrical characteristics and poor productivity.
Innovation Solution
A coaxial cable design featuring a central conductor made of three single-element twisted wires with a specific twist pitch and fluororesin insulation, where the adhesive force between the conductor and insulation is one-third or less of the conductor's tensile strength, eliminating the need for foam insulation and allowing for reduced diameter and improved signal transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the diameter of the central conductor and insulation layer are reduced to achieve smaller cable diameter, then the cable diameter is reduced, but the mechanical strength and bending resistance deteriorate
Solution Approach 1:
The patent uses a composite structure combining fluororesin insulation with specific void configurations and twisted conductor geometry. The fluororesin material itself provides both mechanical strength and low dielectric constant properties, while the void structure within the insulation layer enhances electrical performance without compromising mechanical integrity. This composite approach allows simultaneous achievement of small diameter and high mechanical strength.
Solution Approach 2:
The patent introduces voids (air pockets) within the fluororesin insulation layer, creating a porous structure. These voids reduce the effective dielectric constant of the insulation, improving signal transmission characteristics. The voids are strategically positioned and sized to maintain mechanical strength while reducing electrical attenuation, resolving the contradiction between electrical performance and structural integrity in small-diameter cables.
2Volume of moving object
If foam insulation is used to reduce insulation thickness and cable diameter, then the cable diameter is reduced, but electrical characteristics become variable and productivity decreases
Solution Approach 1:
The patent extracts the foam structure from the insulation design, using solid fluororesin insulation instead. By removing the foam component entirely and replacing it with a solid material that incorporates controlled voids, the patent eliminates the variability issues associated with foam insulation while maintaining reduced insulation thickness. This extraction of the problematic foam element resolves the contradiction between compact size and electrical stability.
Solution Approach 2:
The patent changes the physical state of the insulation from foamed to solid fluororesin, fundamentally altering the material parameter. This parameter change from foam to solid state provides consistent electrical characteristics while maintaining thin insulation thickness. The controlled voids within the solid structure provide the necessary electrical performance without the instability of foam materials.
3Loss of energy
If silver content in the central conductor is increased to improve electrical conductivity, then signal attenuation is reduced, but manufacturing cost increases
Solution Approach 1:
The patent optimizes the silver content parameter in the copper alloy conductor to a specific range (1-3 wt%) rather than using high silver content. This parameter optimization achieves sufficient electrical conductivity and low signal attenuation while controlling material costs. The precise parameter control allows balancing performance and manufacturing cost effectively.
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
This design achieves the same electrical and mechanical characteristics as prior art while reducing costs and improving productivity, with enhanced bending resistance and signal transmission performance without the use of foam insulation.
Implementation Method 1
A fluororesin insulation is extruded on and covers the central conductor
Data Source
AI summary
A coaxial cable includes a central conductor, a fluororesin insulation, and outer conductor and a jacket covering the outer conductor. The central conductor has three single element twisted wires. The central conductor has an outer diameter and the three single element twisted wires having a predetermined twist pitch. The fluororesin insulation covers the central conductor such that all of the twisted single element wires of the central conductor contact the fluororesin insulation. The fluororesin insulation is a non-foam insulation material. A series of voids are defined between portions of the central conductor and an inner surface of the fluororesin insulation. The outer conductor is disposed on the external periphery of the insulation. The adhesive force between the central conductor and the insulation, and a breaking strength of the central conductor have the following relationship: adhesive force≦⅓ breaking strength.