Composite Cable Signal Line Polygon Twisting for Noise Resistance
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Solution Overview
Problem
Conventional composite cables experience a decrease in resistance to external noise when the twist of twisted pair wires collapses due to a reduction in diameter, leading to increased outer diameter and compromised noise resistance.
Innovation Solution
A composite cable design featuring a plurality of power lines and a signal line unit, where the signal lines are paired and twisted at adjacent vertices of a polygon, with a different twisting direction for the power lines and signal line unit, reducing the cable diameter while maintaining noise resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the diameter of the composite cable is reduced by loosening the twist of twisted pair wires, then the cable becomes more flexible and easier to install, but the resistance to external noise decreases
Solution Approach 1:
The cable structure is segmented into distinct functional zones: twisted pair wires for signal transmission are separated from power lines, with each group maintaining its own twist structure. This segmentation allows the signal wires to maintain noise resistance through twisting while power lines can be arranged for flexibility, resolving the contradiction between noise resistance and flexibility.
Solution Approach 2:
The patent employs a nested structure where the twisted pair wires are arranged in a compact configuration within the cable cross-section, with signal wires twisted around a central axis. This nested arrangement maintains the protective twist structure for noise resistance while keeping the overall cable diameter reduced, preventing the trade-off between compactness and noise shielding.
2Object-affected harmful factors
If the twist of twisted pair wires is maintained to resist noise, then the cable diameter increases, but cable flexibility and installability decrease
Solution Approach 1:
Different parts of the cable are given different structural qualities: the twisted pair section maintains tight twisting for noise resistance, while the overall cable construction uses a more flexible arrangement of multiple wire groups. This local differentiation allows noise resistance in critical signal areas without compromising overall cable flexibility.
Solution Approach 2:
The patent transitions from a single-dimension twist structure to a multi-dimensional arrangement where twisted pairs are organized in specific geometric patterns (such as triangular or rectangular configurations). This dimensional reorganization maintains the protective twist effect while optimizing space utilization and cable flexibility in other dimensions.
3Ease of manufacture
If power lines and signal lines are twisted together in a conventional manner, then the cable structure is simple to manufacture, but the outer diameter becomes large and noise resistance decreases
Solution Approach 1:
The patent employs asymmetric arrangement where power lines and signal lines are positioned in different spatial configurations rather than symmetric twisting. Signal wires maintain their twist for noise resistance while power lines are arranged separately, creating an asymmetric but manufacturable structure that improves noise resistance without excessive complexity.
Data Source
AI summary
A composite cable includes a plurality of power lines, one signal line unit, and a sheath collectively covering the plurality of power lines and the one signal line unit. The signal line unit includes a plurality of pairs of signal lines, and an inner sheath covering a first assembled article. The first assembled article is formed by arranging the signal lines to be paired at each pair of adjacent vertices of a polygon with an even number of vertices in a cross-section perpendicular to a longitudinal direction of the signal line unit and twisting all the signal lines together. A twisting direction of a second assembled article formed by twisting the plurality of power lines and the one signal line unit together is different from a twisting direction of the first assembled article.