Foamed and Solid Insulated Cable for Stable High-Frequency Signals
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Solution Overview
Problem
Existing cables with high dielectric constants and unstable electrical properties are challenging to manufacture consistently, affecting signal transmission stability and efficiency.
Innovation Solution
The cable design incorporates a pair of core wires with a first inner insulating layer made of solid material and a second inner insulating layer made of foamed material, along with a dual-layer insulating structure and a shielding layer, to achieve a smaller dielectric constant and improved electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single-material insulating layer is used, then the manufacturing process is simpler, but the dielectric constant is large and electrical characteristics are unstable
Solution Approach 1:
The insulating layer is divided into multiple sub-layers with different materials and structures. Specifically, it includes a first insulating layer (solid material) and a second insulating layer (foamed material), each contributing different properties to achieve stable electrical characteristics while maintaining manufacturing feasibility
Solution Approach 2:
The patent uses composite material structure in the insulating layer, combining solid material and foamed material in different layers. This composite approach reduces the overall dielectric constant while providing stable electrical properties, resolving the contradiction between simple manufacturing and reliable electrical performance
2Reliability
If foamed material is used for the inner insulating layer, then the dielectric constant is reduced, but the impedance fluctuation increases
Solution Approach 1:
Different regions of the insulating structure are assigned different materials based on local requirements. The first insulating layer uses solid material where impedance stability is critical, while the second insulating layer uses foamed material where dielectric constant reduction is prioritized, achieving both goals simultaneously
3Device complexity
If a single-layer insulating structure is used, then the structure is simpler, but the bending resistance is poor
Solution Approach 1:
The insulating layer is segmented into multiple layers with different materials and formation methods. The first layer provides structural integrity for bending resistance, while the second layer optimizes electrical properties, achieving both strength and simplicity
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
This design results in a cable with a smaller dielectric constant, better electrical properties, and enhanced bending resistance, ensuring stable and efficient high-frequency signal transmission.
Implementation Method 1
the first inner insulating layer is made of solid material and covers the inner conductor by extrusion molding
Implementation Method 2
the second inner insulating layer is made of foamed material and wraps the first inner insulating layer in a winding way
Implementation Method 3
the first insulating layer covers the pair of core wires in a winding way
Implementation Method 4
the second insulating layer covers the first insulating layer by extrusion molding, so that the cable has better bending resistance
Data Source
AI summary
A cable includes: a pair of core wires each including an inner conductor and an inner insulating layer covering the inner conductor; an insulating layer covering the pair of core wires; a shielding layer covering the insulating layer; and an outer layer covering the shielding layer; wherein the inner insulating layer includes a first inner insulating layer and a second inner insulating layer, the first inner insulating layer is made of solid material and covers the inner conductor by extrusion molding, the second inner insulating layer is made of foamed material and wraps the first inner insulating layer in a winding way, the insulating layer includes a first insulating layer and a second insulating layer, the first insulating layer covers the pair of core wires in a winding way, and the second insulating layer covers the first insulating layer by extrusion molding.