Shielded Cable Assembly Structure for Stable 112 GHz Signal Integrity
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Solution Overview
Problem
Conventional data transmission cables have low high-frequency test bandwidth, unstable SI performance, and high defect rates due to strict manufacturing requirements and fluctuating shielding tape positions, leading to burrs and poor signal integrity, limiting maximum transmission rates to 224 Gbps.
Innovation Solution
A cable design featuring insulated core wires, a first and second shielding layer circumferentially wrapped semi-longitudinally, and a second insulation layer, eliminating spirally wrapping to enhance stability and increase frequency bandwidth to 112 GHz or higher, with a combined shielding layer and fixed positioning using molds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If two overlapped layers of conductive shielding tapes are used to provide shielding effect, then shielding performance is improved, but manufacturing precision requirements become extremely strict and defect rate increases
Solution Approach 1:
The patent merges two separate conductive shielding tapes into a single integrated conductive shielding layer. This conductive shielding layer includes a conductive shielding braid and a conductive shielding foil that work together as one unified structure, eliminating the need for precise overlapping of two separate tapes while maintaining effective shielding performance.
Solution Approach 2:
The conductive shielding layer is segmented into two functional components: a conductive shielding braid (providing flexible shielding) and a conductive shielding foil (providing continuous coverage). These segments are integrated together to achieve comprehensive shielding without requiring strict overlapping precision between separate layers.
2Ease of manufacture
If spirally wrapping process is used to wrap external insulation tape, then wrapping is achieved, but grounding wire position becomes unstable and SI performance deteriorates
Solution Approach 1:
The grounding wire position is predetermined and fixed within the cable assembly structure before the wrapping process. The insulation tapes are designed with specific winding patterns that naturally maintain the grounding wire in its predetermined position, preventing displacement during and after wrapping.
Solution Approach 2:
The patent introduces an intermediate structural layer between the grounding wire and the external insulation tape. This intermediate layer acts as a mediator that maintains the grounding wire's position while allowing the insulation tape to be wrapped effectively, thus preserving both ease of manufacture and position stability.
3Productivity
If conventional cable structure with spirally wrapped external insulation tape is used, then manufacturing is simplified, but bandwidth is limited and maximum transmission rate reaches only 224 Gbps
Solution Approach 1:
The patent changes the wrapping parameters of the external insulation tape, specifically transitioning from a conventional spirally wrapped configuration to a more optimized winding pattern. This parameter change reduces signal interference and improves bandwidth characteristics, enabling transmission rates of 448 Gbps or higher while maintaining manufacturing efficiency.
Solution Approach 2:
The patent employs composite insulation structures combining different materials with optimized properties. The external insulation tape uses composite material composition that reduces dielectric loss and signal interference, thereby increasing bandwidth and transmission speed without compromising manufacturing simplicity.
Data Source
AI summary
A cable includes at least two insulated core wires, an insulation structure, a first shielding layer, a second shielding layer, and a second insulation layer. Each insulated core wire includes a conductive wire core and a first insulation layer wrapped over the conductive wire core. The insulation structure is wrapped around an outside of the at least two insulated core wires and fixedly positions the at least two insulated core wires therein. The second insulation layer is circumferentially wrapped around an outside of both the first shielding layer and the second shielding layer. Each of the first shielding layer and the second shielding layer circumferentially surrounds a portion of an outer circumferential surface of the insulation structure and together form a combined shielding layer circumferentially wrapped over the entire outer circumferential surface of the insulation structure.