Optical Cable Shielding with Metal-Coated Yarn Strands
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional electromagnetic shielding materials for optical communication cables, such as copper braiding, are inefficient in preventing electromagnetic interference (EMI) while being cumbersome and slow to produce, and they do not effectively utilize space within the cable jacket.
Innovation Solution
A shielded combined optical communication and conductor cable design featuring a helically wrapped metal-bearing yarn strand and longitudinally extending unwrapped metal-bearing strands, which provide effective EMF shielding while improving physical performance and production speed by eliminating the need for copper braiding and optimizing cable diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional copper braiding is used for electromagnetic shielding, then EMI protection is provided, but the cable becomes cumbersome and production speed decreases
Solution Approach 1:
The patent changes the structural parameters of the shielding material from traditional copper braiding to metal-coated yarn strands arranged in specific patterns (helical and longitudinal). This parameter change maintains EMI shielding effectiveness while enabling faster production through simpler manufacturing processes and improved cable flexibility.
Solution Approach 2:
The patent uses composite material structure by coating metal materials onto yarn strands, creating a hybrid material that combines the EMI shielding properties of metal with the flexibility and processability of textile materials. This composite approach resolves the contradiction between shielding effectiveness and production efficiency.
2Reliability
If conventional copper braiding is used for electromagnetic shielding, then EMI protection is provided, but the cable diameter increases
Solution Approach 1:
The patent employs thin metal-coated yarn strands instead of bulky copper braiding. These flexible, thin-film-like structures provide effective EMI shielding while occupying minimal space, thus reducing the overall cable diameter while maintaining protection effectiveness.
Solution Approach 2:
By changing the physical form of shielding material from thick braided copper to thin metal-coated yarns with optimized arrangement patterns, the patent achieves the same EMI protection with significantly reduced cross-sectional area, allowing for smaller cable diameters.
3Productivity
If helically wrapped metal-bearing yarn strand is used, then production speed improves, but shielding effectiveness must be maintained
Solution Approach 1:
The patent divides the shielding structure into segmented components: helically wrapped yarn strands and longitudinal yarn strands arranged in specific patterns. This segmentation allows for easier manufacturing and faster production while maintaining continuous EMI coverage through the coordinated arrangement of segments.
Solution Approach 2:
The patent transitions from traditional two-dimensional braided shielding to a three-dimensional structured arrangement combining helical and longitudinal yarn strands. This dimensional change enables more efficient space utilization and faster production while preserving shielding effectiveness through multi-directional EMI blockage.
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 cable design effectively limits electromagnetic fields, enhances tensile strength, flexibility, and reduces cable diameter, offering improved performance and faster production compared to conventional EMF shielding materials.
Implementation Method 1
The metal material acts to limit electromagnetic fields from traversing the across the electromagnetic shield
Implementation Method 2
The metal material acts to limit electromagnetic fields from traversing the across the electromagnetic shield
Data Source
Figure 1~3
Figure 4
Figure 5~6
AI summary
A shielded combined optical communication and conductor cable is provided. The cable includes a cable body having an inner surface defining a channel within the cable body. The cable includes an optical transmission element located within the channel and an electrical conducting element located within the channel. The cable includes an electromagnetic shield located within the channel and surrounding at least the electrical conducting element. The electromagnetic shield includes an elongate yarn strand or other strand material that supports a metal material that acts to limit electromagnetic fields from traversing across the electromagnetic shield. The strands may be unbraided and may be helically wrapped or longitudinally positioned within the cable body.