Shielded Cable Assembly With Extruded Sheath for Stable 60 GHz Transmission

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Solution Overview

Problem

Conventional data transmission cables have low high-frequency test bandwidth and unstable performance due to inefficient winding methods, leading to production inefficiencies and structural deformations.

Innovation Solution

A cable design featuring a pair of conductors with an inner insulating layer, a conductive shielding layer, and an extruded or heat-shrinkable outer insulating sheath, which are circumferentially arranged to enhance stability and efficiency, allowing for frequencies up to 60 GHz.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If the outer insulating layer and shielding layer are wound turn by turn, then the cable structure is formed, but production efficiency is low

Engineering Contradiction:

Improveproduction efficiencyVSAvoidwinding process complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent replaces the traditional mechanical winding process with an extrusion process. The insulating sheath is formed by extruding molten material through a die that matches the cable's cross-sectional shape, eliminating the need for manual or automated winding operations. This substitution of mechanical winding with extrusion molding directly resolves the contradiction by dramatically improving production efficiency while simplifying the manufacturing process.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state and formation method of the insulating sheath from a wound solid layer to an extruded thermoplastic layer. By utilizing the plasticity and flow characteristics of molten polymer material during extrusion, the sheath is formed in a single continuous operation rather than through repetitive winding cycles, thereby resolving the production efficiency issue.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If conventional winding methods are used, then the cable is assembled, but structural deformations occur and high-frequency performance is unstable

Engineering Contradiction:

Improvehigh-frequency performance stabilityVSAvoidstructural deformation

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The extrusion process replaces the mechanical winding system, creating a seamless insulating sheath without the joints, overlaps, or tension variations inherent in wound structures. This eliminates structural deformations and ensures consistent electrical characteristics along the cable length, directly improving high-frequency performance stability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Instead of forming the insulating sheath by adding layers on the outside (winding approach), the patent inverts the approach by forming the sheath as a negative impression or mold around the conductor assembly during extrusion. This ensures perfect conformal contact and eliminates voids or deformations that would compromise structural and electrical stability.

Inventive Principle:

Principle #13The other way round (Inversion)

3Reliability

If conventional cable structure is used, then assembly is simple, but high-frequency test bandwidth is low

Engineering Contradiction:

Improvehigh-frequency test bandwidthVSAvoidcable structure complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent changes the material properties and formation method of the insulating sheath to achieve superior electrical characteristics. By using extruded thermoplastic materials with controlled dielectric properties and forming a seamless structure, the cable achieves higher bandwidth performance despite the increased complexity of the extrusion process and material specifications.

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

The new design improves production efficiency, eliminates structural deformations, and significantly increases high-frequency test bandwidth, ensuring stable data transmission at higher rates.

Implementation Method 1

The insulating sheath is at least one of an extruded layer and a heat shrinkable sleeve

Methodology Applied

Scientific EffectHeat shrinkage: Thermal Contraction

Data Source

PatentUS12542223B2Cable and cable assembly

Publication Date: 2026.02.03 TYCO ELECTRONICS DONGGUAN

AI summary

A cable includes a pair of conductors extending longitudinally and spaced apart from each other, an inner insulating layer circumferentially extending around an outside of the conductors and fixing the conductors, a conductive shielding layer circumferentially extending around an outside of the inner insulating layer, and an insulating sheath extending around an outer peripheral surface of the conductive shielding layer. The insulating sheath is at least one of an extruded layer and a heat shrinkable sleeve.