Shielded Twin-Core Cable Layout for High-Frequency Bandwidth
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Solution Overview
Problem
Conventional high-speed data transmission cables have low high-frequency test bandwidth and poor electromagnetic shielding, leading to instability and poor performance when bent.
Innovation Solution
The cable design includes a pair of insulation core wires with a central conductor and wire insulation layers, wrapped with first and second insulation tape layers to fix the core wires and reduce the center-to-center distance, along with a metal shielding layer for improved electromagnetic shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a conventional cable structure with insulation core wires, metal shielding layer, and insulating layer is used, then the cable can transmit data, but the high-frequency test bandwidth is low and electromagnetic shielding effect is poor
Solution Approach 1:
The cable structure is segmented into distinct functional layers: inner insulation layer, first insulation tape layer, second insulation tape layer, and metal shielding layer. Each layer serves a specific purpose in optimizing both electromagnetic shielding and high-frequency bandwidth performance.
Solution Approach 2:
The cable employs composite material structure combining different insulation materials (inner insulation layer and insulation tape layers) with metal shielding material. This composite approach enhances electromagnetic shielding effectiveness while maintaining high-frequency signal transmission capability.
2Reliability
If the conventional cable structure is used, then the cable can be manufactured, but the insulating core wire shifts easily during bending and use, resulting in poor performance stability
Solution Approach 1:
The insulation tape layers are applied in advance to firmly bind the insulation core wires together, pre-preventing any potential wire shifting before bending or usage occurs. This preliminary fixation ensures stable wire positions throughout the cable's operational life.
Solution Approach 2:
The insulation tape layers act as flexible binding elements that conform to the wire arrangement while providing sufficient friction and mechanical constraint to prevent wire displacement during cable bending and handling.
3Productivity
If the center-to-center distance between insulation core wires is reduced, then bandwidth increases, but the cable structure becomes more compact and difficult to manufacture
Solution Approach 1:
The insulation system is divided into multiple discrete tape layers that can be independently applied and controlled during manufacturing. This segmentation allows for precise control of wire spacing and facilitates easier manufacturing of compact cable structures.
Solution Approach 2:
The cable design optimizes the thickness and material properties of insulation layers to achieve the desired center-to-center distance between core wires. By adjusting these parameters, the cable achieves high bandwidth while remaining manufacturable with standard equipment.
Data Source
AI summary
A cable includes a pair of insulation core wires arranged to extend longitudinally parallel to each other, each of the insulation core wires has a central conductor and a wire insulation layer circumferentially wrapped around the center conductor, a first insulation tape layer and a second insulation tape layer wrapped outside the first insulation tape layer, and a metal shielding layer wrapped outside the second insulation tape layer. The first insulation tape layer is wrapped outside the wire insulation layers of the pair of insulation core wires to fix the pair of insulation core wires and cause the wire insulation layers of the pair of insulation core wires to abut against each other and deform at outer peripheries of a pair of sides of the wire insulation layers facing each other.