Flexible Cable Structure for High-Speed Low-Loss Bending
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Solution Overview
Problem
Existing flexible cables face challenges in transmitting electromagnetic signals with high speed and low loss while maintaining mechanical flexibility, especially in devices with deformable components.
Innovation Solution
A flexible cable design featuring a flexible cable portion with spaced apart wires and air gaps, combined with metal foil clad laminates and insulation layers, maintains impedance matching and reduces signal reflection and loss even when bent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a flexible cable uses traditional solid structure, then mechanical strength is maintained, but flexibility and bendability deteriorate
Solution Approach 1:
The cable core is divided into multiple wire bundles (first wire bundle, second wire bundle, third wire bundle) instead of using a solid structure. This segmentation allows the cable to bend more easily while maintaining mechanical strength through the distributed wire structure. The insulation layers and air gaps between bundles further enhance flexibility.
Solution Approach 2:
The cable employs thin insulation layers (first insulation layer, second insulation layer, third insulation layer) that wrap around the wire bundles. These thin film structures provide necessary electrical insulation while allowing the cable to bend and deform without breaking, thus improving flexibility while maintaining structural integrity.
2Speed
If a flexible cable transmits high-speed signals, then signal transmission speed is improved, but signal loss and reflection increase
Solution Approach 1:
Air gaps are introduced as intermediary spaces between the wire bundles (first wire bundle, second wire bundle, third wire bundle). These air gaps act as dielectric mediators that maintain controlled impedance and reduce signal reflection and loss, enabling high-speed signal transmission without significant energy loss.
Solution Approach 2:
Different regions of the cable structure are optimized for different functions: the wire bundles are arranged with specific spacing and insulation to control impedance locally, while air gaps are strategically positioned to minimize signal interference. This local optimization of structure quality enables high-speed transmission with reduced loss.
3Ease of manufacture
If the cable structure is simplified, then manufacturing cost is reduced, but impedance matching performance deteriorates
Solution Approach 1:
The cable is segmented into standardized wire bundles with consistent insulation layers and air gaps. This modular segmentation allows for simplified manufacturing processes while maintaining precise impedance control through repeated standard structures, thus reducing manufacturing cost without sacrificing impedance matching performance.
Solution Approach 2:
The impedance matching is achieved by controlling specific parameters such as the spacing between wire bundles, the thickness of insulation layers, and the size of air gaps. By optimizing these physical parameters, the cable achieves good impedance matching while maintaining a relatively simple and cost-effective manufacturing structure.
Data Source
AI summary
In accordance with an aspect of the disclosure, a cable comprises a flexible cable portion; and an end cable portion connected to one end of the flexible cable portion, wherein the flexible cable portion comprises: a first wire comprising one or more signal transmission lines; and a second wire comprising one or more fill-cut areas corresponding to the signal transmission lines and at least one or more ground lines.