High Frequency Cable Crack Suppression Resin Film
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Solution Overview
Problem
High frequency signal transmission cables used in imaging and electronic devices face issues with signal attenuation and flexibility when bent, due to the 'suck out' phenomenon caused by tightly wrapped copper tape outer conductors, leading to cracking and difficulty in wiring in narrow spaces.
Innovation Solution
A high frequency signal transmission cable design featuring a conductor, insulator, plating layer, and sheath, with a crack suppressing layer made of a resin film between the insulator and plating layer, which is self-fused to form a cylindrical shape to prevent cracking during bending, allowing the cable to maintain signal integrity and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the tape member is cylindrically wrapped around while adhering tightly to the entire periphery of the insulator, then the suck out phenomenon is suppressed, but the cable becomes hard and difficult to bend
Solution Approach 1:
The outer conductor is divided into two functional segments: a tape member for electromagnetic shielding and a separate crack suppressing layer for mechanical flexibility. This segmentation allows each layer to perform its specific function independently, resolving the contradiction between signal transmission reliability and cable pliability.
Solution Approach 2:
The crack suppressing layer acts as an intermediary between the tape member and the insulator. It mediates the mechanical stress during bending, preventing crack propagation in the tape member while allowing the cable to maintain flexibility. This intermediary layer resolves the contradiction by decoupling the shielding function from the mechanical constraint.
2Ease of operation
If the coaxial cable is bent, then it can be wired in narrow spaces, but cracking in the tape member occurs leading to deterioration in high frequency signal transmission properties
Solution Approach 1:
The crack suppressing layer is installed beforehand to cushion and absorb mechanical stress during bending operations. This preventive measure protects the tape member from cracking when the cable is bent for wiring in narrow spaces, thereby maintaining signal transmission reliability while enabling wiring flexibility.
Solution Approach 2:
The crack suppressing layer is designed as a thin film structure that provides flexibility to the cable assembly. This thin film allows the cable to bend without causing cracks in the rigid tape member, resolving the contradiction between wiring flexibility and signal transmission reliability.
3Ease of manufacture
If the tape member is helically wrapped, then it is easy to manufacture, but the suck out phenomenon causes rapid attenuation in predetermined frequency band
Solution Approach 1:
The outer conductor structure is segmented into the helically wrapped tape member for easy manufacturing and the cylindrically wrapped crack suppressing layer for signal transmission reliability. This segmentation allows the tape member to be manufactured using simple helical wrapping while the additional layer compensates for the suck out phenomenon.
Solution Approach 2:
The outer conductor is constructed as a composite structure combining the tape member and the crack suppressing layer. This composite design leverages the manufacturing simplicity of the helically wrapped tape while adding the signal transmission properties of the cylindrically wrapped layer, resolving the contradiction between ease of manufacture and signal attenuation properties.
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 cable effectively suppresses signal attenuation and maintains high frequency transmission properties even when bent and wired in narrow spaces, ensuring reliable performance in electronic devices.
Implementation Method 1
the crack suppressing layer comprises a resin film and suppresses the occurrence of a cracking in the plating layer by bending while moving in a longitudinal direction of the cable relative to a bending of the insulator
Implementation Method 2
heating the resin film to form a fused or amalgamated portion with a lapped portion of the resin film fusing or amalgamating to itself
Data Source
AI summary
A high frequency signal transmission cable includes a conductor, an insulator provided over a periphery of the conductor, a plating layer provided over a periphery of the insulator, and a sheath provided over a periphery of the plating layer. A crack suppressing layer is provided between the insulator and the plating layer, in such a manner as to remain in contact with the insulator while being provided with the plating layer over an outer surface of that crack suppressing layer. The crack suppressing layer is composed of a resin film to suppress the occurrence of a cracking in the plating layer by bending while moving in a longitudinal direction of the cable relative to a bending of the insulator.