Plated CNT Coaxial Cable Shielding for Lower Weight and Signal Loss
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Solution Overview
Problem
Existing coaxial cables with metal foil outer conductors are heavy, rigid, and prone to corrosion, affecting performance and weight in applications like aerospace.
Innovation Solution
The use of a carbon nanotube (CNT) substrate with metal layers applied through electroplating forms a lightweight, flexible outer conductive layer that reduces weight and enhances performance by eliminating the need for traditional foil layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional metal foil outer conductors are used, then electrical conductivity and shielding are provided, but weight increases significantly
Solution Approach 1:
The patent applies composite materials by combining carbon nanotubes with metal layers to create a hybrid outer conductor structure. The carbon nanotube substrate provides structural integrity and conductivity while the electroplated metal layer enhances electrical performance, achieving both lightweight properties and reliable electrical conductivity simultaneously
Solution Approach 2:
The patent changes the material parameters by transitioning from solid metal foil to a carbon nanotube-based composite structure with electroplated metal coating. This parameter change in material composition and structure reduces density and weight while maintaining or improving electrical conductivity through the unique properties of carbon nanotubes and controlled metal deposition
2Reliability
If thick metal foil is used for outer conductor, then electrical performance is maintained, but flexibility and conformability decrease
Solution Approach 1:
The patent employs flexible thin films by using carbon nanotube substrates that inherently possess flexibility and conformability. The electroplated metal layer is deposited as a thin coating that maintains the flexibility of the underlying carbon nanotube structure, allowing the outer conductor to conform to the cable's bending and shaping requirements while providing adequate electrical performance
Solution Approach 2:
The composite structure of carbon nanotubes with electroplated metal creates a material that combines the flexibility of carbon-based materials with the electrical conductivity of metals, resolving the contradiction between maintaining electrical performance and achieving flexibility
3Reliability
If copper-based foil is used, then conductivity is achieved, but corrosion risk increases
Solution Approach 1:
The patent applies a thin electroplated metal layer on the carbon nanotube substrate that serves as a protective barrier against corrosion. This thin coating provides corrosion resistance while maintaining electrical conductivity, replacing the need for thick corrosion-prone copper foils
Solution Approach 2:
The carbon nanotube-metal composite structure provides inherent corrosion resistance of carbon materials combined with the protective effect of the electroplated metal layer, eliminating the corrosion vulnerability of traditional copper-based foils while maintaining conductivity
4Ease of manufacture
If silver plated copper wire is flattened to form foil, then outer conductor is created, but surface finish becomes uneven causing signal reflections
Solution Approach 1:
The patent replaces the mechanical flattening process with electrochemical deposition. Instead of mechanically flattening wire to create foil, the electroplating process directly deposits metal onto the carbon nanotube substrate, forming a uniform surface without the mechanical deformation and surface irregularities inherent in wire flattening
Solution Approach 2:
The carbon nanotube substrate serves as an intermediary that enables uniform metal deposition. The electroplating process uses the carbon nanotube surface as a base layer that promotes even metal coating, eliminating the surface finish problems associated with directly flattening metal wire
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 CNT substrate-based outer conductive layer provides significant weight savings, improved shielding, reduced signal loss, increased mechanical strength, and enhanced thermal conductivity, while maintaining electrical performance.
Implementation Method 1
One or more metal layers are applied to the CNT substrate through a continuous electroplating process for forming a plated CNT substrate that has plating on both sides of the substrate
Implementation Method 2
The carbon nanotube filaments includes a carbon nanotube core and at least one metal layer applied to the carbon nanotube core through an electroplating process for forming a plated carbon nanotube filament
Data Source
AI summary
A cable includes at least one inner conductor and an insulation layer surrounding the inner conductor. An outer conductive layer surrounds the insulation layer and center conductor and includes a carbon nanotube substrate having opposing face surfaces and edges. One or more metals are applied as layer(s) to the opposing face surfaces and edges of the carbon nanotube substrate for forming a metallized carbon nanotube substrate. The metallized carbon nanotube substrate is wrapped to surround the insulation layer and center conductor for forming the outer conductive layer. Embodiments of the invention include a braid layer positioned over the outer conductive layer. The braid layer is woven from of plurality of carbon nanotube yarn elements made of a plurality of carbon nanotube filaments. The carbon nanotube filaments include a carbon nanotube core and metal applied as a layer on the carbon nanotube core for forming a metallized carbon nanotube filaments and yarns woven to form the braid layer.