Shielded Cable With Segmented Adhesive Films For Mass Termination
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Solution Overview
Problem
Conventional electrical cables, such as coaxial and shielded cables, are not suitable for mass-termination techniques and have limitations in high-speed signal transmission, flexibility, and cost-effectiveness, making them inadequate for modern high-speed electrical and electronic applications.
Innovation Solution
A shielded electrical cable design featuring a conductor set with two parallel shielding films and a conformable adhesive layer that bonds the shielding films on both sides of the conductor set, allowing for mass-termination and improved flexibility, while maintaining the cross-sectional shape of the conductors to preserve electrical characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional coaxial or shielded cables are used, then electrical signal transmission is achieved, but mass-termination techniques cannot be applied and manufacturing complexity increases
Solution Approach 1:
The cable structure is segmented into distinct functional layers: multiple insulated conductors are separated and individually accessible, while shielding films are divided into segments that can be independently terminated. This segmentation allows each conductor to be terminated separately using standard mass-termination techniques without requiring complex custom connectors.
Solution Approach 2:
The cable design achieves multi-functionality by combining features of both traditional shielded cables (signal transmission and shielding) and open-structure cables (mass-termination capability). The universal structure accepts standard termination methods while maintaining electromagnetic shielding, eliminating the need for specialized connectors.
2Adaptability or versatility
If traditional shielded cable structures are used, then shielding is provided, but flexibility and ability to conform to different configurations is reduced
Solution Approach 1:
The shielding structure uses thin film configurations instead of rigid shield layers. These flexible films can conform to various cable bends and configurations while maintaining their shielding function. The thin film structure provides the necessary adaptability without compromising the protective shielding capability.
3Reliability
If shielding films are bonded rigidly, then structural stability is improved, but signal attenuation and buckling of shielding films increase
Solution Approach 1:
The bonding parameters are optimized to achieve the right balance: the adhesive strength is tuned to provide sufficient mechanical support without creating rigid constraints that would cause buckling. The bond strength parameter is specifically controlled to prevent signal attenuation while maintaining adequate structural stability.
4Productivity
If conventional cable structures are used, then electrical connection is achieved, but cost-effectiveness for high-speed applications is reduced
Solution Approach 1:
The cable is manufactured with pre-prepared conductor ends and pre-positioned shielding films that are ready for mass-termination. This preliminary preparation eliminates time-consuming manual assembly steps and enables high-speed manufacturing processes, improving productivity while maintaining the cable's high-speed signal transmission capabilities.
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
Enables efficient mass-termination and high-speed signal transmission while being cost-effective, suitable for various applications, and reduces the likelihood of signal attenuation and buckling of shielding films.
Implementation Method 1
a conformable adhesive layer disposed between the shielding films and bonding the shielding films to each other on both sides of the conductor set
Data Source
Figure 1~2b
Figure 2c~2e
Figure 3~6
AI summary
The present invention provides a shielded electrical cable (2) comprising: a plurality of spaced apart conductor sets, each conductor set including one or more substantially parallel longitudinal insulated conductors; at least one longitudinal ground conductor extending in substantially the same direction as the insulated conductors; two generally parallel shielding films disposed around the conductor sets and the at least one longitudinal ground conductor; a conformable adhesive layer disposed between the shielding films and bonding the shielding films to each other on both sides of each conductor set; and a plurality of longitudinal splits (18) disposed between and separating the conductor sets.