Flat Wire Cable with Integrated Annular Conductor for High-Speed Data
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Solution Overview
Problem
Traditional high-speed data cables for vehicular applications are costly and complex due to the need for metallic shielding and external plastic coating, which increases manufacturing costs and complexity, while existing flat cabling solutions lack the high-speed data transfer capabilities of round cables.
Innovation Solution
A flat wiring cable design incorporating an integrated annular signal conductor with a dielectric layer, where the protective jacket provides shielding, reducing the need for additional shielding or plastic coating, and allowing for high-speed data transfer with enhanced conductor density and manipulability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional rounded cabling with shielding and plastic coating is used for high-speed data transfer, then data transfer performance is improved, but manufacturing cost and complexity increase substantially
Solution Approach 1:
The patent extracts the essential shielding function from the traditional cable structure and applies it selectively only to the annular signal conductor that carries high-speed data signals, rather than shielding the entire cable bundle. This reduces manufacturing complexity while maintaining high-speed data transfer capability where needed.
Solution Approach 2:
The patent applies different structural qualities to different parts of the cable system: the annular signal conductor receives integrated shielding and dielectric protection, while other conductors use simpler insulation. This localized approach to shielding and protection reduces overall complexity and cost while preserving high-speed data transfer performance.
2Speed
If traditional rounded cabling with shielding and plastic coating is used for high-speed data transfer, then data transfer performance is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the shielding layer and dielectric layer into a single integrated structure that surrounds the annular signal conductor. This combined structure is formed as one component during manufacturing, reducing the number of separate manufacturing steps and material layers needed, thereby lowering production costs while maintaining high-speed data transfer capability.
Solution Approach 2:
The patent extracts the expensive shielding and plastic coating materials from the overall cable assembly and applies them only where high-speed data transfer is required (the annular conductor), rather than applying them to all conductors. This selective application significantly reduces material costs and manufacturing complexity.
3Area of stationary object
If flat cabling is used to increase conductor density and reduce space, then space efficiency is improved, but high-speed data transfer capability is lost
Solution Approach 1:
The patent segments the flat cable structure into distinct functional zones: elongate planar conductors for general-purpose low-speed connections and an integrated annular signal conductor for high-speed data transfer. This segmentation allows the cable to provide both space efficiency of flat cabling and high-speed capability where required.
Solution Approach 2:
The patent uses a composite structure combining planar conductors with an annular conductor that has integrated dielectric and shielding layers. This composite approach within a flat cable architecture enables high-speed data transfer capability to coexist with the space-saving benefits of flat cabling.
Data Source
AI summary
A wiring cable and a method of manufacturing a wiring cable are described. The wiring cable includes a plurality of elongate planar electrical conductors electrically insulated from one another and shielded by a protective jacket formed over the elongate electrical conductors. The protective jacket includes a substantially flat outer surface of the wiring cable. The wiring cable further includes a signal conductor with an annular outer profile integrated with the protective jacket at the substantially flat outer surface and at least partially shielded from interference by the protective jacket of the wiring cable. The annular signal conductor may be jacketless, without annular shielding or an annular protective coating.