Longitudinally Wrapped Cable Assembly for Stable 112 GHz Transmission
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Solution Overview
Problem
Conventional data transmission cables have limited high-frequency bandwidth and unstable performance due to spirally wrapping structures, leading to echo loss and poor production efficiency, making them unsuitable for high-speed data transmission requirements like 448Gbps.
Innovation Solution
The cable design features longitudinally wrapped outer and conductive shielding layers, eliminating spirally wrapping structures, which increases frequency bandwidth to 112 GHz or higher and improves stability by integrating conductors with a single inner insulating layer and using semi-longitudinally wrapping conductive shielding, reducing production costs and equipment investment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a spirally wrapping structure is used for the outer insulating layer and/or shielding layer, then the cable can be manufactured with conventional equipment, but the high-frequency testing bandwidth is limited to only 40-60 GHz due to significant echo loss
Solution Approach 1:
The patent inverts the conventional spirally wrapping approach by using a longitudinally wrapping structure for both the outer insulating layer and shielding layer. This inversion eliminates the echo loss problems inherent in spiral wrapping, achieving a high-frequency testing bandwidth of 112 GHz or higher while remaining manufacturable with appropriate equipment.
Solution Approach 2:
The patent changes the wrapping parameter from spiral to longitudinal, fundamentally altering the structural configuration. This parameter change transforms the cable's high-frequency performance, enabling bandwidth of 112 GHz or higher by eliminating the echo loss that plagues conventional spiral wrapping structures.
2Ease of manufacture
If a spirally wrapping process is used, then the cable structure can be formed, but the grounding wire is taken away from the center resulting in unstable cable structure and poor SI performance stability
Solution Approach 1:
The patent inverts the wrapping direction from spiral to longitudinal, which keeps the grounding wire centered throughout the cable structure. This inversion prevents the grounding wire from being displaced to the side, thereby maintaining stable cable structure and consistent SI performance.
Solution Approach 2:
The longitudinal wrapping structure creates a more uniform and symmetric cable construction, maintaining the grounding wire in a central position throughout. This equipotential-like symmetry ensures stable electrical characteristics and consistent signal integrity performance.
3Ease of manufacture
If a spirally wrapping process is used, then the cable can be assembled, but burrs of the aluminum foil are easily generated affecting SI performance and production efficiency is low
Solution Approach 1:
The patent inverts the wrapping methodology from spiral to longitudinal, which eliminates the burr generation problem associated with spiral wrapping. The longitudinal structure allows for cleaner assembly without aluminum foil burrs, improving both SI performance and production efficiency.
Solution Approach 2:
The patent converts the potential harm of complex wrapping processes into benefit by using a simpler longitudinal wrapping approach. This eliminates the burr generation issue and reduces production complexity, transforming a harmful manufacturing challenge into a beneficial simplification.
4Manufacturing precision
If ultra-high speed precision wrapping equipment is used for spirally wrapping, then the cable can be manufactured with acceptable quality, but the production cost is high
Solution Approach 1:
The patent inverts the approach by using longitudinal wrapping instead of spiral wrapping, which reduces the precision requirements for wrapping equipment. This inversion allows for manufacturing high-quality cables with less expensive equipment, thereby reducing production costs while maintaining acceptable quality.
Data Source
AI summary
A cable comprises at least two conductors, an inner insulating layer, a conductive shielding layer, and an outer insulating layer. The at least two conductors extend longitudinally and are spaced apart from each other. The inner insulating layer is wrapped around an outside of the at least two conductors and fixes their position. The conductive shielding layer is circumferentially wrapped around an outer peripheral surface of the inner insulating layer. The outer insulating layer includes a full-longitudinally wrapping structure attached onto an outer peripheral surface of the conductive shielding layer. The full-longitudinally wrapping structure is formed in a tubular shape circumferentially wrapped around an outside of the whole conductive shielding layer and extends continuously and longitudinally along the entire length of the cable.