Shielded Cable Layout That Eliminates Gaps and Simplifies Soldering
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Solution Overview
Problem
Existing cables suffer from electromagnetic interference and have complex assembly and soldering processes due to gaps in shielding layers and the need for separate wrapping and soldering steps.
Innovation Solution
A cable design with a shielding layer covering core wire groups from both sides, using transverse arrangement and heat-adhesive metal tapes to fix the groups in a row, eliminating gaps and simplifying assembly and soldering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a single high-speed transmission signal wire is wrapped or longitudinally covered with a metal shielding tape on the core surface, then electromagnetic shielding is provided, but gaps at the junctions affect shielding effectiveness and assembly complexity increases
Solution Approach 1:
The patent transitions from longitudinal wrapping of shielding tape to transverse arrangement where shielding layers are positioned above and below the core wire groups. This dimensional change eliminates gaps at junctions and allows the shielding layers to be directly soldered to contact parts, significantly simplifying assembly while maintaining electromagnetic shielding effectiveness.
Solution Approach 2:
The patent combines multiple shielding layers (first shielding layer, second shielding layer, third shielding layer) arranged transversely to form an integrated shielding structure. This merging of multiple shielding elements in the transverse direction creates continuous electromagnetic protection without gaps, resolving both the shielding effectiveness and assembly complexity issues.
2Object-affected harmful factors
If shielding layers are wrapped around core wires, then electromagnetic shielding is achieved, but the assembly and soldering process becomes complicated
Solution Approach 1:
The patent repositions shielding layers from longitudinal wrapping to transverse placement above and below core wire groups. This dimensional reconfiguration allows shielding layers to be directly soldered to contact parts of the cable, eliminating complex assembly steps while maintaining electromagnetic shielding effectiveness.
Solution Approach 2:
The shielding layers are pre-positioned in the transverse direction during cable assembly, with their contact parts prepared for direct soldering. This preliminary arrangement of shielding layers in the correct position simplifies subsequent soldering operations and reduces assembly complexity.
3Object-affected harmful factors
If multiple shielding tapes are wrapped around core wires, then electromagnetic shielding is improved, but production efficiency decreases due to complex assembly
Solution Approach 1:
The patent arranges multiple shielding layers transversely above and below core wire groups rather than wrapping them longitudinally. This transverse arrangement simplifies the assembly process and enables direct soldering, significantly improving production efficiency while maintaining or enhancing electromagnetic shielding effectiveness through multiple layers.
Data Source
AI summary
A cable includes: plural core wire groups sequentially arranged in a transverse direction and each including a pair of inner conductors and an inner insulating layer covering the pair of inner conductors; and a shielding layer covering the plurality of core wire groups, wherein the shielding layer has an upper part and a lower part covering the core wire groups, and the inner insulating layer includes a first insulating layer covering the pair of inner conductors and a second insulating layer covering the first insulating layer.