Shielded Wire Cable System for High-Speed Signal Transmission

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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, particularly in automotive and other applications where cost, flexibility, and electromagnetic interference resistance are critical, as existing coaxial cables are economically and reliably unsuitable, and fiber optic cables are too expensive.

Innovation Solution

A shielded wire cable system with a pair of conductors and a braided conductor, encased in dielectric materials, featuring a plug and receptacle connector design with mirrored terminals and shields to maintain consistent impedance and reduce capacitive coupling, allowing for reliable high-speed signal transmission.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If coaxial cable is used to transmit high-speed digital signals, then electromagnetic interference resistance is improved, but data transfer rate capability deteriorates

Engineering Contradiction:

Improveelectromagnetic interference resistanceVSAvoiddata transfer rate

Core Design Contradiction:

Object-affected harmful factorsVSSpeed

Solution Approach 1:

The cable is divided into multiple twisted pairs, each pair providing differential signaling capability. This segmentation allows the cable to achieve higher data transfer rates by utilizing multiple parallel communication channels while each pair maintains electromagnetic interference resistance through its twisted structure and shielding.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The cable employs a composite structure combining twisted pair conductors with braided shield and dielectric materials. This composite design integrates the electromagnetic interference resistance of shielding with the high-speed signal transmission capability of twisted pairs, achieving both protection and performance.

Inventive Principle:

Principle #40Composite materials

2Speed

If fiber optic cable is used to achieve high data transfer rates, then data transfer rate is improved, but cost deteriorates

Engineering Contradiction:

Improvedata transfer rateVSAvoidcost

Core Design Contradiction:

SpeedVSEase of manufacture

Solution Approach 1:

The patent employs copper-based twisted pair cable with shielding instead of expensive fiber optic cable. This cheaper alternative achieves sufficient performance for 5 Gb/s and 10 Gb/s applications over typical automotive cable lengths, providing cost-effective high-speed data transmission without requiring the expensive infrastructure of optical fiber.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Speed

If twisted pair cable is used to transmit signals, then data transfer rate is improved, but electromagnetic interference resistance deteriorates

Engineering Contradiction:

Improvedata transfer rateVSAvoidelectromagnetic interference resistance

Core Design Contradiction:

SpeedVSObject-affected harmful factors

Solution Approach 1:

The twisted pair conductors are nested within a braided shield structure. This nested configuration allows the inner twisted pairs to provide differential signaling for high-speed data transmission while the outer braided shield provides electromagnetic interference protection, combining both functions in a hierarchical structure.

Inventive Principle:

Principle #7Nested doll (Nesting)

4Speed

If shielded wire cable is designed for high data transfer rates, then data transfer rate is improved, but cable mass deteriorates

Engineering Contradiction:

Improvedata transfer rateVSAvoidcable mass

Core Design Contradiction:

SpeedVSWeight of moving object

Solution Approach 1:

The cable uses a thin braided shield structure and flexible dielectric belting materials that provide necessary electromagnetic protection and signal isolation without excessive weight. The streamlined construction with optimized layer thicknesses reduces overall cable mass while maintaining shielding effectiveness for high-speed signal transmission.

Inventive Principle:

Principle #30Flexible shells and thin films

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 system effectively transmits digital signals at up to 5 Gb/s with controlled impedance and reduced electromagnetic interference, meeting USB 3.0 and HDMI 1.4 standards while being cost-effective and flexible enough for automotive applications.

Implementation Method 1

The wire pair is encased within dielectric belting that helps to provide a consistent radial distance between the wire pair and the shield

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Implementation Method 2

The dielectric belting may also help to maintain a consistent twist angle between the wire pair if they are twisted

Methodology Applied

Scientific EffectDielectric insulation: Dielectric

Data Source

PatentUS10109958B2Electrical connection system for shielded wire cable

Publication Date: 2018.10.23 APTIV TECHNOLOGIES AG

AI summary

An electrical connection system configured to terminate electrical connectors 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 having a planar connection portion and a second pair of parallel mirrored terminals having a cantilever beam portion and a contact point configured to contact the first terminals.