Flat Shielded Cable Metal Filler Contact Resistance
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Solution Overview
Problem
Existing flat shielded cables lack stability in the electrical connection between conductors and shielding layers, leading to potential hindrances in noise grounding due to insufficient intervening substances between the drain wire and the shielding layer.
Innovation Solution
A flat shielded cable design featuring a shielding member with a first layer of shielding material and a second layer of binder resin containing metal filler, where the metal filler has a D90 particle diameter of 6 μm and a difference between D10 and D95 particle diameters of 6 μm or more, ensuring a strong electrical connection with a contact resistance of 100 mΩ or less and bonding strength of 0.3 N/19 mm or more, enhancing the stability of the connection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If an adhesive layer containing conductive filler or conductive paste is used as the intervening substance between the drain wire and the shielding layer, then the shielding structure can be formed, but the electrical connection stability is insufficient and noise grounding may be hindered
Solution Approach 1:
The patent changes the key parameters of the metal filler including particle size distribution (D90=6μm, D95-D10≥6μm), metal content (≥65 wt%), and shape (aspect ratio 0.01-10) to optimize both electrical conductivity and mechanical bonding properties, resolving the contradiction between connection stability and noise grounding effectiveness
Solution Approach 2:
The patent creates a composite material consisting of binder resin combined with specifically characterized metal filler particles, where the composite exhibits both adequate adhesion strength and excellent electrical conductivity, simultaneously achieving reliable electrical connection and effective noise grounding
2Reliability
If the metal filler particle size is reduced to improve contact resistance, then electrical connection improves, but bonding strength may be compromised
Solution Approach 1:
The patent optimizes the particle size distribution parameters (D90=6μm, D95-D10≥6μm) to achieve a balance where particles are small enough to ensure good contact and low resistance, yet large enough to provide sufficient mechanical interlocking and bonding strength
Solution Approach 2:
The patent specifies aspect ratio constraints (0.01-10) for metal filler particles, allowing the filler to have elongated shapes that can bridge gaps and improve electrical contact while maintaining structural integrity and bonding strength
3Reliability
If the metal filler content is increased to improve electrical connection, then contact resistance decreases, but the material becomes more difficult to process and apply
Solution Approach 1:
The patent sets the metal filler content at ≥65 wt% while controlling particle characteristics (D90=6μm, aspect ratio 0.01-10) to ensure the mixture remains processable despite high metal content, achieving both excellent electrical connection and manufacturing feasibility
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 effectively suppresses contact resistance and ensures robust bonding, preventing excessive noise resistance and shielding member peeling, thereby securing reliable noise grounding and shielding performance.
Implementation Method 1
the metal filler contained in the binder resin in an amount of 65 wt % or more... the electrical connection between the conductor serving as a drain wire and the first layer serving as a shielding layer can be carried out while the contact resistance therebetween is suppressed
Data Source
AI summary
A flat shielded cable includes conductors arranged in parallel, an insulating jacket section that covers the conductors and has an exposed conductor section which exposes a part of at least one of the conductors, and a shielding member that covers the jacket section. The conductor is electrically connected to the shielding member via the exposed conductor section. The shielding member has a first layer made of shielding material and a second layer made of binder resin containing metal filler. A D90 particle diameter of the metal filler is 6 μm and a difference between a D10 particle diameter and a D95 particle diameter of the metal filler is 6 μm or more, and the metal filler is contained in the second layer in an amount of 65 wt % or more.