Mixed-Gauge Data Cable for Insertion Loss and Flexibility

Solution Overview

Problem

Data carrying cables in data centers face challenges with insertion loss due to the combination of high-frequency data transmission requirements and the need for both flexibility and cooling airflow, which are not adequately addressed by using either thinner or thicker gauge conductors alone.

Innovation Solution

The use of data carrying cables with multiple gauge conductors, where thinner gauges are used for bending and connector areas and thicker gauges for reducing insertion loss, along with a method of soldering or drawing continuous conductors to transition between gauges, is employed to balance electrical and mechanical performance.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If thinner gauge conductors are used, then bending flexibility and manageability are improved, but insertion loss increases due to increased effective resistance

Engineering Contradiction:

Improvebending flexibilityVSAvoidinsertion loss

Core Design Contradiction:

Ease of operationVSLoss of energy

Solution Approach 1:

The cable is divided into multiple segments with different conductor gauges. The first cable portion uses a first gauge conductor optimized for flexibility near connectors, while the second cable portion uses a second gauge conductor optimized for low insertion loss in the main run. This segmentation allows each portion to be optimized for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the cable are given different conductor gauge properties to match local requirements. Thinner gauge conductors are used where flexibility is needed (near connectors and bends), while thicker gauge conductors are used where low resistance is critical (main cable length). This local optimization resolves the contradiction between flexibility and low insertion loss.

Inventive Principle:

Principle #3Local quality

2Loss of energy

If thicker gauge conductors are used, then insertion loss is reduced, but bending flexibility and manageability deteriorate

Engineering Contradiction:

Improveinsertion lossVSAvoidbending flexibility

Core Design Contradiction:

Loss of energyVSEase of operation

Solution Approach 1:

The cable is divided into multiple segments with different conductor gauges. The first cable portion uses a first gauge conductor optimized for flexibility near connectors, while the second cable portion uses a second gauge conductor optimized for low insertion loss in the main run. This segmentation allows each portion to be optimized for its specific function.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the cable are given different conductor gauge properties to match local requirements. Thinner gauge conductors are used where flexibility is needed (near connectors and bends), while thicker gauge conductors are used where low resistance is critical (main cable length). This local optimization resolves the contradiction between flexibility and low insertion loss.

Inventive Principle:

Principle #3Local quality

3Length of moving object

If cable length is increased to connect devices, then reach is improved, but insertion loss increases due to increased effective resistance

Engineering Contradiction:

Improvecable lengthVSAvoidinsertion loss

Core Design Contradiction:

Length of moving objectVSLoss of energy

Solution Approach 1:

The cable uses different conductor gauges in different portions to optimize performance for the specific application. Thicker gauge conductors are used in the main cable run to minimize resistance and insertion loss over longer distances, while thinner gauge conductors are used only where flexibility is needed. This allows achieving both longer reach and acceptable insertion loss.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The conductor gauge parameter is changed along the cable length to optimize performance. By varying the conductor size from thinner near connectors to thicker in the main run, the cable achieves both the flexibility needed for installation and the low insertion loss required for longer transmission distances.

Inventive Principle:

Principle #35Parameter changes

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 reduces insertion loss while maintaining flexibility and compatibility with high-speed data transmission, meeting the specific requirements of data center applications by optimizing conductor gauges and configurations along the cable length.

Implementation Method 1

an opposite end of the first conductor is soldered to one end of the second conductor

Methodology Applied

Scientific EffectSoldering: Soldering

Implementation Method 2

a continuous conductor is drawn into the first conductor having the first gauge and the second conductor having the second gauge. The continuous conductor is drawn to reduce the second gauge to the first gauge

Methodology Applied

Scientific EffectDrawing: Extrusion

Implementation Method 3

At high frequencies, current travels along an outer surface of the conductor due to field strength (inductance) (referred to as skin effect)

Methodology Applied

Scientific EffectSkin effect: Skin Effect

Data Source

PatentUS10304593B2Data carrying cable with mixed-gauge conductors to achieve longer reach and flexibility

Publication Date: 2019.05.28 MICROSOFT TECHNOLOGY LICENSING LLC

AI summary

A data carrying cable to connect computing devices includes a first cable portion including a first conductor having a circular cross-section and a first gauge. A first port connector is connected to one end of the first cable portion. A second cable portion includes a second conductor having a circular cross-section and a second gauge that is different than the first gauge. The first conductor and the second conductor are arranged in series and are configured to carry a data signal between the computing devices.