Micro Coaxial Cable Over-Foaming Prevention
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Micro coaxial cables with diameters of 1 mm or less face issues with abnormal foam growth and non-uniform dielectric constants due to the thin insulation layer, leading to irregularities in transmission characteristics.
Innovation Solution
Incorporating an over-foaming preventing layer with a lower melt temperature than the insulation layer, made of materials like polyethylene terephthalate, to surround the insulation layer, ensuring uniform foaming cell formation through co-extrusion or tandem extrusion, which prevents local dielectric constant variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If the insulation layer thickness is reduced to achieve smaller cable diameter, then the cable size is reduced, but the foaming uniformity deteriorates causing local dielectric constant variations
Solution Approach 1:
The patent applies local quality by creating a specific layer structure where the insulation layer containing foaming cells is surrounded by a dense resin layer. This dense outer layer provides structural support and constraints that ensure uniform foaming throughout the insulation layer, even when the overall cable diameter is reduced to 1mm or less. The different densities and functions of each layer address the foaming uniformity issue locally without requiring increased overall cable size.
2Speed
If foaming is increased to lower dielectric constant, then transmission rate improves, but foaming uniformity becomes difficult to maintain in thin insulation layers
Solution Approach 1:
The patent utilizes parameter changes by controlling the melt temperatures of different resin layers. The insulation layer resin is maintained at a higher temperature to promote foaming and reduce dielectric constant, while the surrounding dense resin layer is kept at a lower temperature to provide structural constraints. This temperature parameter differentiation enables high transmission rates through effective foaming while maintaining foaming uniformity through thermal control.
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
This approach enables uniform foaming cell formation, maintaining consistent dielectric constants and enhancing transmission characteristics, even at high frequencies, allowing for effective signal transmission in extremely small sizes.
Implementation Method 1
The over-foaming preventing layer (25) is in contact with the insulation layer (23) and has a lower melt temperature than the insulation layer (23)
Data Source
AI summary
A micro coaxial cable includes an inner conductor; an insulation layer having foaming cells and formed to surround the inner conductor; an over-foaming preventing layer formed to surround the insulation layer for the purpose of uniform forming of the foaming cells; a metal shield layer formed to surround the over-foaming preventing layer; and a protective coating layer formed to surround the metal shield layer.