Shielded Communication Cable High-Strength Conductor Impedance
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Solution Overview
Problem
There is a demand for reducing the diameter of shielded communication cables while maintaining the required characteristic impedance for high-speed communication applications, such as in automobiles, as thinner insulation coatings in existing cables result in characteristic impedance falling below the necessary range for Ethernet communication.
Innovation Solution
A shielded communication cable with a twisted pair of insulated wires having conductors with a tensile strength of 400 MPa or higher, a conductor cross-sectional area smaller than 0.22 mm², and an insulation coating thickness of 0.35 mm or smaller, along with a braided or metal foil shield, which allows for a reduced diameter while maintaining a characteristic impedance of 100±10Ω.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of stationary object
If the thickness of the insulator is reduced to decrease the cable diameter, then the cable diameter is reduced, but the characteristic impedance falls below the required range
Solution Approach 1:
The patent changes the material parameter of the conductor by specifying a tensile strength of 400 MPa or higher, which enables the use of thinner insulation (0.35 mm or less) while maintaining the required characteristic impedance of 100±10Ω. This parameter change in conductor strength allows the insulation thickness to be reduced without compromising electrical performance.
Solution Approach 2:
The patent employs a composite structure combining a high-strength conductor material with thin insulation coating. The conductor's high tensile strength (400 MPa or higher) compensates for the reduced insulation thickness, maintaining the characteristic impedance within the required range while achieving a smaller overall cable diameter.
2Length of stationary object
If the conductor diameter is reduced to decrease the cable diameter, then the cable diameter is reduced, but the strength of the conductor decreases
Solution Approach 1:
The patent specifies that the conductor must have a tensile strength of 400 MPa or higher, which allows the conductor diameter to be reduced while maintaining sufficient mechanical strength. This parameter change in material strength enables the cable to achieve a smaller diameter without compromising conductor integrity.
3Length of stationary object
If the insulation coating is made thinner to reduce the cable diameter, then the cable diameter is reduced, but the characteristic impedance control becomes difficult
Solution Approach 1:
The patent sets the insulation thickness to 0.35 mm or less and specifies that the conductor must have a tensile strength of 400 MPa or higher. This combination of parameters allows the insulation to be thinner while maintaining precise characteristic impedance control within the 100±10Ω range, resolving the contradiction between thin insulation and impedance control.
Data Source
AI summary
A communication cable that has a reduced diameter while ensuring a required magnitude of characteristic impedance. The shielded communication cable contains a twisted pair containing a pair of insulated wires twisted with each other. Each of the insulated wire contains a conductor that has a tensile strength of 400 MPa or higher, and an insulation coating that covers the conductor. The shielded communication cable 1 further contains a shield that is made of a conductive material and surrounds the twisted pair. The shielded communication cable has a characteristic impedance of 100±10Ω.