Magnetic Sheath Communication Cable for Clean Terminal Processing
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Solution Overview
Problem
In communication cables, the removal of a shield layer containing powdery magnetic material can lead to the formation of deposits that affect electrical and physical connections, especially when a metal braid shield is used, as the particles tend to exfoliate and clog the braid structure, disrupting the connection between the cable and external members.
Innovation Solution
A communication cable design featuring a magnetic sheath layer with magnetic material particles of average diameter not exceeding 50 μm and an aspect ratio of not greater than 4, dispersed in a polymer material, which suppresses the formation of powdery substances during processing, thereby preventing attachment to conductors or external members and maintaining noise shielding effectiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a shield layer containing powdery magnetic material is provided on the outer circumference of the core wire, then noise shielding effectiveness is improved, but deposits form and exfoliate during processing, affecting electrical and physical connections
Solution Approach 1:
The patent changes the particle size parameter of the magnetic material to an average diameter of not more than 50 μm and controls the aspect ratio to not greater than 4. This parameter optimization prevents the magnetic particles from forming exfoliable deposits during processing while maintaining effective noise shielding, thus resolving the contradiction between shielding effectiveness and connection reliability
Solution Approach 2:
The patent uses composite material structure where magnetic particles are dispersed in a polymer matrix to form the shield layer. This composite approach allows the magnetic particles to be held firmly within the polymer structure, preventing them from detaching and forming deposits during cable processing, while still providing the required magnetic shielding effect
2Ease of operation
If a shield layer with powdery magnetic material is removed to connect terminal portions, then ease of connection is improved, but magnetic particles form deposits that clog the braid structure and affect connection quality
Solution Approach 1:
By optimizing the particle size to not more than 50 μm and aspect ratio to not greater than 4, the patent prevents the formation of cohesive powdery deposits during shield layer removal. This allows the shield to be removed cleanly without leaving residual deposits that would interfere with terminal connections, thus maintaining both ease of operation and manufacturing precision
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 solution effectively prevents the dispersion and exfoliation of magnetic material deposits, ensuring stable electrical and physical connections and enhanced noise shielding properties, even when processing the cable's terminal portions.
Implementation Method 1
a magnetic sheath layer that covers an outer side of the insulating coating, and the magnetic sheath layer contains a magnetic material
Data Source
AI summary
A communication cable includes a coating layer that contains a powdery magnetic material and that can suppress the occurrence of a powdery substance containing the magnetic material when processing the coating layer. The communication cable further includes a conductor, an insulating coating that covers an outer circumstance of the conductor, and a magnetic sheath layer that covers an outer side of the insulating coating, and the magnetic sheath layer contains the magnetic material and the magnetic material has a particle shape with an average particle diameter of not more than 50 μm and an aspect ratio of not greater than 4.