Macro Cell Foamed Coaxial Cable for Low Signal Loss
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Solution Overview
Problem
Conventional coaxial cables with small size porous cells face challenges in achieving high foaming rates, leading to increased signal loss and return loss due to cell collapse and unbalanced external appearance, making them unsuitable for long-distance high-speed signal transmission.
Innovation Solution
A highly foamed coaxial cable design utilizing macro cells with diameters of at least 300µm, achieving a foaming rate of 78.9% to 94.7% and a density range of 0.05g/cm³ to 0.20g/cm³, with a relative dielectric constant of 1.085 to 1.291, allowing for stable signal transmission with reduced signal loss and avoiding undesired uniformity and return loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If traditional small size cell foaming method is used to increase foaming rate, then dielectric constant decreases and signal transmission speed increases, but cell collapse and unbalanced external appearance occur leading to increased return loss
Solution Approach 1:
The patent changes the critical parameter of cell diameter from traditional small size (90-130μm) to macro size (at least 300μm). This parameter change allows achieving high foaming rate (78.9% to 94.7%) without cell collapse, because larger cells have better structural stability while still maintaining low dielectric constant (1.085 to 1.291) for high signal transmission speed
Solution Approach 2:
Instead of continuing to reduce cell size to achieve higher foaming rates, the patent inverts the approach by using larger macro cells. This reverse strategy achieves the same goal of high foaming rate without the harmful side effects of small cell collapse, thereby reducing return loss while maintaining signal transmission speed
2Speed
If extremely high foaming rate is used to decrease foaming density, then signal transmission speed increases, but cell collapse occurs causing unbalanced external appearance and increased return loss
Solution Approach 1:
The patent changes the cell size parameter to macro scale (at least 300μm diameter), which fundamentally alters the foaming behavior. This parameter change enables the system to achieve extremely high foaming rates (78.9% to 94.7%) while maintaining external appearance uniformity, because macro cells provide structural stability that prevents collapse even at high foaming rates
3Quantity of substance
If small size porous cell structure is used, then foaming density decreases and dielectric constant reduces, but foaming stability deteriorates due to cell collapse
Solution Approach 1:
The patent changes the cell dimension parameter from micro-scale to macro-scale (at least 300μm diameter). This parameter transformation enables achieving low foaming density (0.05g/cm³ to 0.20g/cm³) with high stability, as macro cells maintain structural integrity better than small cells during the foaming process, preventing collapse and ensuring composition stability
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 design enables stable foaming density reduction, enhancing signal transmission speed to 88% to 96% of air transmission speed while maintaining cable uniformity and minimizing return loss, thus supporting long-distance, low-signal-loss communication.
Implementation Method 1
a chemical foaming method which foaming the mixture of chemical foaming agent and said materials, and a gas foaming method which foaming said materials with injected gas
Data Source
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AI summary
A highly foamed coaxial cable comprising, an inner conductor disposed in the cable, and a foamed insulator comprising porous cells and surrounding the inner conductor, and an outer conductor surrounding said insulator, and a sheath surrounding said outer conductor, and in said insulator, the total area of macro cell which has a diamter of at least 300/M is larger than the total area of micro cell which has a diameter smaller than 300/M at cross section of cable.