100 Gbps Copper Ethernet Cable Design for Data Centers

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Solution Overview

Problem

High bandwidth communication cables exceeding 7 meters in data centers become bulky, inflexible, and expensive due to the use of fiberoptic cables, which are undesirable for long-distance connections.

Innovation Solution

Development of novel cable designs and manufacturing methods for long, 100 Gbps cables using at least eight pairs of electrical conductors with transceivers that perform clock and data recovery, enabling differential NRZ signaling over multiple lanes, reducing the cross-sectional area and material costs while maintaining high performance over extended distances.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If fiberoptic cables are used for high bandwidth communication over distances greater than 7 meters, then signal integrity and communication bandwidth are improved, but cable cost, bulkiness, and inflexibility worsen

Engineering Contradiction:

Improvesignal integrityVSAvoidcable flexibility

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent changes the electrical signaling parameters by using differential PAM4 signaling at 26.5625 GBd per lane across two lanes, enabling 100 Gbps communication over copper cables without requiring fiberoptic infrastructure. This parameter change allows copper cables to achieve the performance previously only possible with expensive, rigid fiberoptic cables.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the mechanical/optical fiberoptic cable system with an electrical copper cable system using advanced differential PAM4 signaling. This substitution eliminates the need for expensive fiberoptic infrastructure while maintaining high bandwidth performance and improving cable flexibility and ease of installation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional copper cables are used for 100 Gbps communication beyond 7 meters, then cable cost and flexibility are improved, but signal integrity and communication performance worsen

Engineering Contradiction:

Improvecable flexibilityVSAvoidsignal integrity

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The patent employs differential PAM4 signaling with 4 levels of voltage modulation across two lanes, achieving 100 Gbps aggregate data rate. This advanced signaling parameter change enables conventional copper cables to maintain signal integrity at distances beyond the traditional 7-meter limit while preserving cable flexibility and cost advantages.

Inventive Principle:

Principle #35Parameter changes

3Length of stationary object

If cable length is increased beyond 7 meters for data center connections, then communication distance requirement is met, but cable bulkiness and weight increase

Engineering Contradiction:

Improvecable lengthVSAvoidcable weight

Core Design Contradiction:

Length of stationary objectVSWeight of stationary object

Solution Approach 1:

The patent uses differential PAM4 signaling that efficiently packs 100 Gbps of data across two lanes, achieving high bandwidth over extended distances without requiring excessively large cable cross-sections. This signaling efficiency allows long cables to remain relatively lightweight and manageable, avoiding the bulkiness that would otherwise be required to accommodate the necessary conductors and shielding.

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 solution provides a cost-effective, flexible, and high-performance cable solution for 100 Gbps communication over distances greater than 7 meters, reducing the need for expensive fiberoptic cables and maintaining signal integrity with reduced conductor size.

Implementation Method 1

each of the first and second connectors including a respective transceiver that performs clock and data recovery on the electrical input signal to extract and re-modulate the outbound data stream

Methodology Applied

Scientific EffectClock and data recovery:

Implementation Method 2

at least eight pairs of electrical conductors connected between a first connector and a second connector... conveying an outbound data stream from that host device

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS11218186B210-meter 100 Gbps copper wire ethernet cable

Publication Date: 2022.01.04 CREDO TECHNOLOGY GROUP LTD

AI summary

Novel cable designs and methods for mass-manufacturing long, 100 Gbps cables suitable for large communication centers. One illustrative cable embodiment includes: at least eight pairs of electrical conductors connected between a first connector and a second connector, each of said electrical conductors being 30 AWG or smaller in cross-section and about 10 meters or longer in length, each of the first and second connectors being adapted to fit into an Ethernet port of a corresponding host device, each of the first and second connectors including a respective transceiver that performs clock and data recovery on the electrical input signal to extract and re-modulate the outbound data stream for transit via at least four of the pairs of electrical conductors as differential NRZ (non-return to zero) electrical transit signals each having a signaling rate of at least 25 GBd to convey a total of at least 100 GBd in each direction.