Shielded Cable Film Structure for Sharp Bending Impedance Stability
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Solution Overview
Problem
Current shielded electrical cables face limitations in mass-production, termination flexibility, and electrical performance, particularly in high-speed applications exceeding 1 Gb/s, due to impedance discontinuities caused by bending and stiffness issues.
Innovation Solution
A shielded electrical cable design featuring conductor sets with insulated conductors and shielding films arranged in a pinched configuration, allowing for sharp bending without significant impedance variation, with adhesive layers bonding the shielding films to maintain electrical integrity and flexibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional shielded electrical cables are bent to improve routability, then flexibility is improved, but impedance discontinuities occur causing signal integrity degradation
Solution Approach 1:
The cable structure is segmented into multiple conductor sets with independent shielding films for each set. This segmentation allows each conductor set to be shielded independently, reducing electromagnetic interference and maintaining impedance stability during bending operations.
Solution Approach 2:
The patent employs thin shielding films instead of rigid shielding structures. These flexible films can conform to bent cable configurations without creating impedance discontinuities, thereby maintaining signal integrity while enabling cable flexibility and sharp bending capability.
2Strength
If cable stiffness is increased to maintain structural integrity, then strength is improved, but routing flexibility deteriorates
Solution Approach 1:
The cable construction uses composite materials including flexible shielding films, insulating jackets, and conductor sets arranged in specific configurations. This composite structure provides both the necessary structural integrity and the flexibility required for easy routing and sharp bending.
3Reliability
If traditional termination methods are used to ensure connection reliability, then reliability is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The cable design features universal connector interfaces that can be mass-terminated using automated processes. The standardized conductor sets and shielding configurations enable the cable to work with various connector types, reducing termination costs and manufacturing complexity while maintaining connection reliability.
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 maintains high electrical performance and flexibility, enabling sharp bending and reduced stiffness, which enhances routability and signal integrity in high-speed applications while reducing termination costs and impedance variations.
Implementation Method 1
a first adhesive layer bonding the first shielding film to the second shielding film in the pinched portions of the cable
Data Source
AI summary
A shielded electrical cable includes conductor sets extending along a length of the cable and spaced apart from each other along a width of the cable. First and second shielding films are disposed on opposite sides of the cable and include cover portions and pinched portions arranged such that, in transverse cross section, the cover portions of the films in combination substantially surround each conductor set. An adhesive layer bonds the shielding films together in the pinched portions of the cable. A transverse bending of the cable at a cable location of no more than 180 degrees over an inner radius of at most 2 mm causes a cable impedance of the selected insulated conductor proximate the cable location to vary by no more than 2 percent from an initial cable impedance measured at the cable location in an unbent configuration.