Flexible Cable Structure for Low-Loss High-Speed Signal Bending
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Solution Overview
Problem
Existing flexible cables struggle to transmit electromagnetic signals with high speed and low loss while maintaining mechanical flexibility, especially in devices with deformable designs.
Innovation Solution
A flexible cable design featuring multiple strands with air gaps and metal foil layers, including shield and insulation layers, maintains impedance matching and reduces signal reflection and loss even when bent.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the cable is made flexible to accommodate deformable device designs, then adaptability and ease of installation are improved, but signal transmission quality deteriorates due to increased signal loss and reflection
Solution Approach 1:
The cable is divided into multiple strands (at least two strands) with individual insulation layers and shielding structures. Each strand is independently structured with signal lines, ground lines, and air gaps, allowing the cable to flex while maintaining signal integrity through the segmented architecture
Solution Approach 2:
The cable employs flexible insulation layers (e.g., polyimide or PVC) and thin metal foil shielding layers that can bend and deform without compromising electrical performance. The flexible outer jacket and internal flexible structures enable the cable to adapt to deformable device designs while maintaining shielding effectiveness
2Ease of manufacture
If the cable structure is simplified to reduce manufacturing costs, then ease of manufacture is improved, but impedance matching deteriorates leading to increased signal reflection
Solution Approach 1:
The cable design specifies precise geometric parameters including air gap dimensions (e.g., 0.1-2.0mm), conductor spacing, and insulation layer thicknesses that are optimized to maintain 50-ohm impedance matching. These parameter specifications provide clear manufacturing targets that balance precision requirements with manufacturability
Solution Approach 2:
The segmented strand structure with standardized components (signal conductors, insulation layers, shielding foils, air gaps) allows for modular manufacturing. Each strand can be manufactured independently using standardized processes, simplifying production while maintaining consistent impedance characteristics through repeated optimized designs
3Loss of energy
If air gaps are introduced between strands to reduce signal interference, then signal loss is reduced, but cable structural complexity increases
Solution Approach 1:
The cable is segmented into multiple independent strands with air gaps between them, creating isolated transmission paths that reduce electromagnetic interference and signal loss. The segmentation is achieved through a systematic structure where each strand contains its own signal lines, ground lines, and insulation, making the complexity manageable through modularity
Solution Approach 2:
Air gaps act as intermediary spaces between adjacent strands, providing electrical isolation and reducing capacitive coupling between signal lines of different strands. These air gaps serve as natural dielectric barriers that minimize signal interference without requiring additional shielding materials or complex structures
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.