Helical Counter-Wound Cable Shielding for Stable EMC Performance
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Solution Overview
Problem
Existing cable shields are prone to mechanical stress, leading to reduced service life and instability in electrical properties due to friction, tensile, and shear stresses, as well as formation of nests and holes.
Innovation Solution
A cable shield design featuring a first wire winding and a second wire winding with counter-rotating helical configurations, where turns of each winding intersect at multiple points along the longitudinal axis, forming a stable helical pattern that enhances mechanical durability and electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If a braided shield with counter-rotating wire winding is used, then mechanical service life is improved, but the shield may shift forming nests and holes which degrades electrical properties
Solution Approach 1:
The shield is divided into multiple discrete wire windings (first wire winding and second wire winding) with different winding directions. Each winding is segmented into multiple turns that intersect at specific points, creating a modular structure that maintains mechanical flexibility while preventing collective shifting that would cause nests and holes.
Solution Approach 2:
The first and second wire windings are designed with asymmetric properties: they wind in opposite directions (first direction vs. second direction), have different pitches (first pitch vs. second pitch), and create intersection points at different positions along the longitudinal axis. This asymmetry prevents the symmetric shifting patterns that lead to nest formation while maintaining counter-rotational mechanical stability.
2Reliability
If foil and braided shielding are combined in alternating layers, then shielding efficiency is improved, but device complexity increases
Solution Approach 1:
The patent combines the advantages of foil shielding and braided shielding by integrating a braided wire winding structure with foil-like characteristics. The wire windings are arranged and intersected to create a continuous shield effect similar to foil, while maintaining the mechanical flexibility of braided structures, thereby achieving high shielding efficiency without the complexity of multiple alternating layers.
Solution Approach 2:
The wire winding structure serves multiple functions simultaneously: it provides mechanical protection (like braided shielding), achieves electromagnetic shielding (like foil shielding), and maintains flexibility. This multi-functional design eliminates the need for separate foil and braided layers, reducing structural complexity while maintaining comprehensive shielding performance.
Data Source
Figure 1a
Figure 1b
AI summary
The invention relates to a cable shielding and an electrical conductor having such a cable shielding. The cable shielding has a first wire winding and a second wire winding. The first wire winding has a plurality of turns. The first wire winding is wound in a first direction with a first pitch about a longitudinal axis. The second wire winding has a plurality of turns. The second wire winding is wound in a second direction, which is different from the first direction, with a second pitch about the longitudinal axis. Turns of the plurality of turns of the first wire winding and corresponding turns of the plurality of turns of the second wire winding cross one another in each case at a first crossing point in such a way that a plurality of first crossing points of the first wire winding and the second wire winding are present in the direction of the longitudinal axis. The plurality of first crossing points run at least approximately helically in the direction of the longitudinal axis.