Shielded Communication Cables With Laminated Conductive Layers
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Solution Overview
Problem
Existing shielded communications cables face challenges in achieving high transmission frequencies due to the use of braided shields, which are costly, heavy, and complex to manufacture, while also posing installation difficulties.
Innovation Solution
The implementation of a twisted pair communication cable design with individually insulated conductors wrapped in continuous electrically conductive material and an overall shield comprising a substrate with two layers of conductive material, all electrically shorted together, reduces manufacturing complexity and weight, and enhances electrical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If braided shields are used in shielded communications cables, then electromagnetic shielding performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The patent changes the fundamental parameter of shield construction from traditional braided copper to a laminated structure consisting of alternating conductive and non-conductive layers. This parameter change maintains electromagnetic shielding effectiveness while enabling continuous manufacturing processes that reduce complexity and cost.
Solution Approach 2:
The patent employs composite material construction by combining conductive materials (such as metal foils or coated fabrics) with non-conductive support layers to form a laminated shield. This composite approach provides the necessary electromagnetic protection while allowing for simpler, more cost-effective manufacturing compared to traditional braided shields.
2Object-affected harmful factors
If braided shields are used in shielded communications cables, then electromagnetic shielding performance is improved, but cable weight increases
Solution Approach 1:
The patent changes the shield construction parameter from dense braided copper to a laminated structure with alternating conductive and non-conductive layers. This parameter change reduces the overall material density and cable weight while preserving the electromagnetic shielding performance required for high-frequency data transmission.
Solution Approach 2:
The use of composite laminated materials combines thin conductive layers with lightweight non-conductive supports, creating a shield that provides effective electromagnetic protection with significantly reduced weight compared to traditional braided copper shields.
3Object-affected harmful factors
If braided shields are used in shielded communications cables, then electromagnetic shielding performance is improved, but manufacturing speed decreases
Solution Approach 1:
The patent changes the shield manufacturing parameter from complex braiding operations to a laminated layer structure that can be produced using continuous extrusion or winding processes. This parameter change enables higher manufacturing speeds and improved productivity while maintaining shielding effectiveness.
Solution Approach 2:
The patent replaces the mechanical braiding process with a more efficient lamination or extrusion process. This substitution eliminates the need for specialized braiding equipment and manual operations, allowing for continuous high-speed manufacturing of the shield structure.
4Object-affected harmful factors
If braided shields are used in shielded communications cables, then electromagnetic shielding performance is improved, but installation difficulty increases
Solution Approach 1:
The patent changes the shield structure parameter from a rigid braided configuration to a flexible laminated construction. This parameter change improves the cable's flexibility and ease of handling during installation, while the conductive layers maintain the necessary electromagnetic shielding performance.
Data Source
AI summary
A cable may include a plurality of twisted pairs of individually insulating electrical conductors, and a respective individual shield formed around each of the twisted pairs. Additionally, each individual shield may include electrically conductive material that is continuous in a longitudinal direction. An overall shield may be formed around the plurality of twisted pairs and individual shields. The overall shield may include a dielectric layer, a first layer of electrically conductive material that is continuous in the longitudinal direction formed on a first surface of the dielectric layer, and a second layer of electrically conductive material that is continuous in the longitudinal direction formed on a second surface of the dielectric layer opposite the first surface. The first and second layers of electrically conductive material and each of the individual shields may be in electrical contact with one another. Additionally, a jacket may be formed around the overall shield.