High-Frequency Cable Structure to Prevent Shield Layer Cracking
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Solution Overview
Problem
High frequency signal transmission cables face attenuation and flexibility issues during long-distance transmission, especially in the GHz band, due to the 'suck out' phenomenon and rigidity of coaxial cables with tape members, which restricts routing and leads to signal deterioration upon bending.
Innovation Solution
A high frequency signal transmission cable design featuring a compressed stranded wire conductor, a foamed resin insulator, a braided metal shield layer, and a crack suppressing layer between the insulator and plating layer, which maintains contact and flexibility to prevent cracking and maintain signal integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a tape member such as copper tape is helically wrapped around the insulator to form a coaxial cable, then the cable structure is simplified and manufacturing is easier, but the 'suck out' phenomenon causes sharp attenuation in the GHz frequency band
Solution Approach 1:
The patent changes the wrapping angle parameter of the tape member from the conventional helical wrap to a specific angle range (0° to 30° relative to the cable axis), which eliminates the suck out phenomenon while maintaining manufacturing simplicity. This parameter optimization resolves the contradiction between ease of manufacture and signal transmission reliability.
2Strength
If the insulator adheres tightly to the inner conductor and tape member to maintain structural integrity, then the cable has good mechanical strength, but the cable becomes rigid and difficult to bend, causing deterioration in high frequency signal transmission properties
Solution Approach 1:
The patent applies different adhesive properties to different regions of the cable structure. The insulator has strong adhesion to the inner conductor for mechanical strength, but controlled adhesion to the tape member to allow relative movement. This local differentiation of adhesive quality enables the cable to maintain both mechanical strength and pliability.
3Adaptability or versatility
If the cable is bent during routing, then the cable can be installed in various paths, but the insulator compresses the inner conductor or the tape member cracks, leading to deterioration in high frequency signal transmission properties
Solution Approach 1:
The patent designs the insulator with predetermined cushioning capacity and controlled adhesion to the tape member, which allows the tape member to move relative to the insulator during bending. This beforehand cushioning design prevents cracking and compression damage, maintaining signal transmission reliability while enabling routing flexibility.
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 includes a non-cross-linked polyethylene 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 entire periphery of a roughened outer surface of the crack suppressing layer. The crack suppressing layer is unadhered to the insulator. The plating layer is adhered to the crack suppressing layer. The crack suppressing layer suppresses an occurrence of a cracking in the plating layer by bending together with the plating layer while being integral and moving with the plating layer in a longitudinal direction of the cable.