Helical Shielded Signal Cable With Crack-Resistant Batch Plating
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Solution Overview
Problem
Conventional coaxial cables experience rapid attenuation and degradation in shielding effect due to 'suck-out' phenomena, especially when bent, leading to crack formation and peeling of the shield layer, which compromises noise shielding and signal transmission.
Innovation Solution
A signal transmission cable design featuring a shield layer with a lateral winding portion of helically wrapped metal wires and a batch plating portion using hot dip plating, where the thickness of the batch plating is less than half the diameter of the metal wire, ensuring no cracks occur when bent within a 35% strain, thereby maintaining shielding effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a plating shield layer is used to suppress suck-out, then rapid attenuation in predetermined frequency band is suppressed, but crack formation and peeling occur when the cable is repeatedly bent, leading to degradation in shielding effect
Solution Approach 1:
The shield layer is divided into two distinct portions: a lateral winding shield portion made of metal wires helically wrapped around the insulator, and a batch plating portion made of hot dip plating covering the periphery of the lateral winding shield portion. This segmentation allows each portion to fulfill different functions - the lateral winding structure provides flexibility and bending resistance, while the batch plating provides continuous shielding to suppress suck-out phenomena.
Solution Approach 2:
The shield layer combines two different shielding structures (lateral winding metal wires and batch plating) into a composite configuration. The metal wires provide mechanical flexibility and resistance to cracking during bending, while the plating layer provides continuous electromagnetic shielding. This composite approach resolves the contradiction between maintaining shielding effectiveness and preventing crack formation during repeated bending.
2Reliability
If the batch plating thickness is increased to improve shielding, then shielding effect is enhanced, but crack formation occurs during bending
Solution Approach 1:
The thickness of the batch plating portion is precisely controlled within the range of 0.01 mm to 0.05 mm. This parameter optimization ensures that the plating is thick enough to provide effective electromagnetic shielding and suppress suck-out phenomena, while remaining thin enough to prevent crack formation during cable bending. The lateral winding shield portion further supports the plating structurally, allowing the use of thinner plating without compromising shielding effectiveness.
3Ease of manufacture
If a conventional shield layer structure is used, then manufacturing is simple, but suck-out phenomena occur causing rapid attenuation in predetermined frequency band
Solution Approach 1:
The lateral winding shield portion is formed by helically wrapping metal wires around the insulator before applying the batch plating. This preliminary action creates a flexible backbone structure that prevents suck-out phenomena and maintains signal transmission integrity in predetermined frequency bands. The subsequent batch plating then provides additional shielding coverage. This sequence of operations achieves both manufacturing simplicity and reliable frequency band transmission.
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 prevents degradation in shielding effect and rapid attenuation across a predetermined frequency band, enhancing the coaxial cable's flexibility and bending life while maintaining stable impedance and noise characteristics.
Implementation Method 1
a batch plating portion comprising a hot dip plating, which is covering a periphery of the lateral winding shield portion
Data Source
AI summary
A signal transmission cable includes a conductor, an insulator covering a periphery of the conductor, and a shield layer covering a periphery of the insulator. The shield layer includes a lateral winding shield portion composed of a plurality of metal wires being helically wrapped around the periphery of the insulator to cover the periphery of the insulator, and a batch plating portion composed of a hot dip plating, which is covering a periphery of the lateral winding shield portion. Where a diameter of the metal wire is d and a thickness of the batch plating portion from an outer surface of the metal wire is t, a formula t<0.5d is met over an entire cable circumference. When the signal transmission cable is bent in a U-shape within a range of a bending strain of 35% or less, no cracks occur in the batch plating portion.