Automotive Data Line Shielding Foil Overlap Design
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Solution Overview
Problem
Existing data lines, particularly those used in the automotive industry, are costly and inflexible due to their rigid structures and complex shielding constructions, which limit their use in regions with alternating bending stresses and increase manufacturing costs.
Innovation Solution
A data line with a multi-layered shielding foil that features a non-conductive and conductive layer, where the conductive layer forms a complete circumferential connection through an overlap region without folding, combined with a simplified manufacturing process using extrusion and adhesive bonding for flexibility and cost-effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If multi-layered shielding construction is used, then shielding effectiveness is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The shielding foil is divided into multiple longitudinal strips that are folded back and overlapped, creating multiple shielding layers from a single continuous foil. This segmentation approach provides effective shielding while simplifying manufacturing compared to traditional multi-layer constructions.
Solution Approach 2:
Multiple shielding functions are merged into a single longitudinal folded foil structure. The foil serves as both the shielding element and the structural component, eliminating the need for separate braided shields or multiple independent shielding layers.
2Object-affected harmful factors
If multi-layered shielding construction is used, then shielding effectiveness is improved, but manufacturing speed decreases
Solution Approach 1:
The shielding foil is applied as a continuous longitudinal strip that is folded and overlapped during a single extrusion process. This continuous application method eliminates the need for multiple discrete shielding operations, maintaining high production speeds while achieving effective shielding.
3Object-affected harmful factors
If rigid cable structure is used, then shielding effectiveness is improved, but flexibility and adaptability decrease
Solution Approach 1:
The shielding structure uses a thin, longitudinally folded foil that provides effective electromagnetic shielding while maintaining cable flexibility. The folded foil design allows the cable to bend and flex without compromising shielding performance, making it suitable for automotive applications with alternating bending stresses.
4Object-affected harmful factors
If braided shielding is used, then shielding effectiveness is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The traditional mechanical braiding process is replaced with a simpler longitudinal folding and overlapping method. The shielding foil is applied continuously and folded back during extrusion, eliminating the need for complex braiding machines and manual operations while maintaining shielding effectiveness.
Data Source
AI summary
A data line that is designed as a coaxial cable and has a line core that extends in a line longitudinal direction. The line core has at least one conductor surrounded at least by insulation and is surrounded by a multi-layer shielding foil, which has a non-conductive layer and a conductive layer. In an overlap region, a free end edge overlaps a further partial region, wherein additionally a conductive connection of the conductive layer at the end edge to the further partial region is formed such that a transverse current flow perpendicular to the longitudinal direction within the conductive layer is enabled. The conductive connection is formed optionally as a conductive strip and/or by a beveled end edge. In particular, the data line is a data line shielded exclusively via the shielding foil. The data line is used in particular in a motor-vehicle electrical system.