Flat Wire Cable With Integrated Shielding for High-Speed Signals
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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 structural rigidity and high-speed data transfer capabilities of round cables.
Innovation Solution
A flat wiring cable design featuring integrated annular signal conductors with a dielectric layer and a protective jacket that provides shielding, reducing the need for external coatings and allowing for high-density conductor arrangements with improved structural rigidity and ease of installation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional rounded cabling with shielding and plastic coating is used for high-speed data transfer, then signal protection and data transfer capability are improved, but manufacturing cost and complexity increase substantially
Solution Approach 1:
The patent merges the shielding function and structural protection into a single integrated protective jacket layer, eliminating the need for separate shielding materials and external plastic coating. The protective jacket is formed as one continuous layer that simultaneously provides both shielding and mechanical protection, reducing manufacturing steps and complexity while maintaining signal protection capabilities.
Solution Approach 2:
The protective jacket is designed to perform multiple functions simultaneously: it provides electromagnetic shielding, mechanical protection, and structural integrity all in one component. This multi-functional design eliminates the need for separate shielding layers and external coatings, reducing the number of manufacturing processes required while maintaining comprehensive signal protection.
2Reliability
If traditional rounded cabling with shielding and plastic coating is used for high-speed data transfer, then signal protection is improved, but manufacturing cost increases
Solution Approach 1:
The protective jacket combines shielding materials and structural protection into a single integrated layer, eliminating the need for separate shielding and coating processes. This reduction in the number of manufacturing steps and materials required directly lowers production costs while maintaining comprehensive signal protection.
Solution Approach 2:
The patent extracts and eliminates the separate external plastic coating layer that traditionally followed the shielding layer. By integrating the shielding function directly into the protective jacket structure, the design removes unnecessary manufacturing steps and material costs while preserving all essential protection functions.
3Ease of operation
If flat cabling is used to reduce space and improve manipulability, then space efficiency and ease of installation are improved, but structural rigidity and high-speed data transfer capability deteriorate
Solution Approach 1:
The patent applies local quality by providing enhanced shielding and structural reinforcement specifically at critical locations within the flat cable structure. The protective jacket is designed with varying thickness or material properties in different regions to maintain rigidity where needed for high-speed data transfer while preserving overall flexibility and manipulability of the flat cable.
Solution Approach 2:
The protective jacket utilizes composite materials that combine the properties of flexibility and structural rigidity. By incorporating multiple materials with complementary characteristics into the protective jacket, the design achieves both the manipulability required for flat cable installation and the structural integrity necessary for high-speed data transfer performance.
4Ease of manufacture
If flat cabling without integrated shielding is used, then manufacturing simplicity is improved, but signal protection from interference deteriorates
Solution Approach 1:
The protective jacket merges the shielding function with the structural protection function in a single integrated layer. This combination provides comprehensive electromagnetic interference protection while maintaining manufacturing simplicity, as the shielding is built into the jacket structure rather than requiring separate shielding components and assembly steps.
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 enables cost-effective, high-performance flat cabling that supports both high-speed data transfer and low-speed signals, offering reduced manufacturing complexity and enhanced manipulability for installation in vehicles.
Implementation Method 1
shielded by a protective jacket formed over the elongate electrical conductors... at least partially shielded from interference by the protective jacket of the wiring cable
Data Source
Figure 1A~1B
Figure 2~3
Figure 4~5
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.