Shielded Wire Cable Assembly for High-Speed Automotive Infotainment

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Solution Overview

Problem

Current electrical connection systems fail to efficiently transmit high-speed digital signals at rates of 5 Gb/s or higher while being cost-effective and flexible enough for applications like automotive infotainment systems, which require resistance to environmental factors and low mass.

Innovation Solution

A shielded wire cable assembly with a pair of conductors and a conductive sheet, braided conductor, and dielectric belting to maintain consistent impedance, combined with a plug and receptacle connector design featuring mirrored terminals and shields to minimize capacitive coupling and ensure reliable high-speed signal transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Speed

If fiber optic cable is used to achieve high data transfer rates up to 100 Gb/s, then data transfer rate is improved, but cost increases significantly

Engineering Contradiction:

Improvedata transfer rateVSAvoidcost

Core Design Contradiction:

SpeedVSEase of manufacture

Solution Approach 1:

The patent employs copper-based shielded wire cable instead of expensive fiber optic cable to achieve 5 Gb/s data transfer rates. This substitution uses a more cost-effective transmission medium that, while having lower maximum potential speed than fiber, adequately meets the 5 Gb/s requirement for automotive infotainment systems at a significantly lower cost point

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

2Object-affected harmful factors

If coaxial cable is used to achieve good electromagnetic interference immunity, then shielding effectiveness is improved, but data transfer rate is limited to 100 Mb/s

Engineering Contradiction:

Improveelectromagnetic interference immunityVSAvoiddata transfer rate

Core Design Contradiction:

Object-affected harmful factorsVSSpeed

Solution Approach 1:

The patent uses a composite cable construction combining twisted pair conductors with both foil and braided shield layers. This composite shielding structure maintains electromagnetic interference immunity while enabling 5 Gb/s data transfer rates by reducing capacitive coupling and maintaining signal integrity at high frequencies

Inventive Principle:

Principle #40Composite materials

3Speed

If twisted pair cable with multiple pairs is used to achieve 5 Gb/s data transfer rate, then data transfer rate is improved, but cable mass increases

Engineering Contradiction:

Improvedata transfer rateVSAvoidcable mass

Core Design Contradiction:

SpeedVSWeight of moving object

Solution Approach 1:

The patent employs a flexible cable construction with thin dielectric belting and streamlined shielding layers that reduce overall cable mass. The cable maintains 5 Gb/s capability through optimized conductor geometry and shielding configuration while minimizing weight for automotive applications

Inventive Principle:

Principle #30Flexible shells and thin films

4Speed

If shielded wire cable is used to achieve 5 Gb/s data transfer rate with low mass, then data transfer rate and weight are improved, but flexibility for routing in vehicle harness becomes challenging

Engineering Contradiction:

Improvedata transfer rateVSAvoidflexibility for routing

Core Design Contradiction:

SpeedVSAdaptability or versatility

Solution Approach 1:

The patent incorporates flexible cable construction with movable shielding elements and compliant dielectric belting that allow the cable to bend and route through vehicle harnesses. The cable maintains its 5 Gb/s transmission capability while adapting to various installation configurations through its dynamic flexibility

Inventive Principle:

Principle #15Dynamics

5Manufacturing precision

If connector design maintains consistent spacing between conductors to preserve impedance, then impedance control is improved, but connector complexity increases

Engineering Contradiction:

Improveimpedance controlVSAvoidconnector structure

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent divides the connector into modular sections with standardized terminal geometries and spacing. This segmentation allows consistent impedance control through repeated geometric patterns while simplifying manufacturing and assembly processes

Inventive Principle:

Principle #1Segmentation

6Reliability

If mirrored terminal pair configuration is used to minimize capacitive coupling, then signal integrity is improved, but manufacturing precision requirements increase

Engineering Contradiction:

Improvesignal integrityVSAvoidterminal alignment

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent uses slightly asymmetric terminal geometries within the mirrored pair configuration that are deliberately designed to compensate for manufacturing tolerances. This asymmetric design ensures consistent capacitive coupling characteristics even with variations in terminal alignment during assembly

Inventive Principle:

Principle #4Asymmetry

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 solution enables reliable transmission of digital signals up to 5 Gb/s with controlled impedance and reduced insertion loss, meeting USB 3.0 and HDMI 1.4 performance specifications while being cost-effective and flexible for automotive applications.

Implementation Method 1

dielectric belting to maintain consistent impedance

Methodology Applied

Scientific EffectDielectric: Dielectric

Implementation Method 2

mirrored terminals and shields to minimize capacitive coupling

Methodology Applied

Scientific EffectCapacitive coupling: Capacitance

Data Source

PatentEP3480899B1Electrical connection system for shielded wire cable

Publication Date: 2023.02.08 APTIV TECHNOLOGIES LTD

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AI summary

An electrical connection system configured to terminate electrical conductors (102, 104) and to transmit digital electrical signals having a data transfer rate of 5 Gigabits per second (Gb/s) or higher. The system includes a first parallel mirrored pair of terminals (160, 162) having a planar connection portion (164, 166) and a second pair of parallel mirrored terminals (132, 134) having a cantilever beam portion (136, 140) and a contact point (138, 142) configured to contact the planar connection portion (164, 166) of the first terminals (160, 162).