Silicone-Supported Cable Structure for Stable Wire Group Positioning
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Solution Overview
Problem
Existing high-frequency signal cables suffer from instability, twisting, and extrusion issues, which negatively impact their SI performance and roundness.
Innovation Solution
The cable design incorporates an inner support member with grooves and fan-shaped portions made of silicone, providing stable positioning and contact points for wire groups, reducing twisting and extrusion, and enhancing roundness while maintaining good SI performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If traditional cable structures are used without inner support members, then the cable structure is simpler, but the cable suffers from instability, twisting, and extrusion issues
Solution Approach 1:
An inner support member made of silicone is introduced as an intermediary element between the wire groups and the outer insulating layer. This support member includes grooves that receive wire groups and fan-shaped portions that contact the insulating layer, acting as a mediator to maintain cable structure stability and prevent twisting and extrusion.
Solution Approach 2:
The support member is made of silicone material, changing the physical parameters of the inner support structure to provide both flexibility and stability. The grooves are designed with specific cross-sectional areas to match the wire groups, and the fan-shaped portions are configured to contact the insulating layer at optimal points, adjusting geometric parameters to achieve stable cable formation.
2Manufacturing precision
If wire groups are not properly positioned, then the cable structure is simpler to manufacture, but the SI performance and roundness deteriorate
Solution Approach 1:
The inner support member is pre-formed with grooves of equal cross-sectional areas designed to receive wire groups. This preliminary preparation of the support structure ensures that wire groups are automatically positioned correctly during assembly, achieving precise positioning without complex manufacturing processes. The grooves are pre-configured to match the wire group dimensions and spacing requirements.
Solution Approach 2:
The support member acts as an intermediary tool that facilitates precise wire group positioning. The grooves provide physical guides for wire placement, while the fan-shaped portions provide contact points with the insulating layer to secure the wire groups in their correct positions, making the manufacturing process easier while achieving high positioning precision.
3Reliability
If the cable lacks proper support structure, then the manufacturing process is simpler, but the cable experiences twisting and extrusion affecting SI performance
Solution Approach 1:
The silicone support member serves as an intermediary structural element that prevents twisting and extrusion of the cable. The grooves hold the wire groups in fixed positions, while the fan-shaped portions contact the insulating layer to prevent cable deformation. This intermediary structure ensures reliable SI performance by maintaining cable geometry during use.
Solution Approach 2:
The support member uses silicone material with specific elastic and damping properties to resist twisting and extrusion forces. The grooves are designed with cross-sectional areas matched to the wire groups, and the fan-shaped portions are configured with optimal contact surfaces, adjusting physical and geometric parameters to provide reliable structural support while maintaining simplicity.
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 stabilizes the cable structure, improves roundness, and maintains excellent signal integrity (SI) performance by minimizing twisting and extrusion, ensuring reliable high-frequency signal transmission.
Implementation Method 1
the inner support member being made of silicone
Data Source
AI summary
A cable includes: plural wire groups; a first insulating layer covering the plurality of wire groups; a first shielding layer covering the first insulating layer; a second shielding layer covering the first shielding layer; an outer insulating layer covering the second shielding layer; and an inner support member disposed inside the first insulating layer; wherein the inner support member includes a plurality of grooves with equal cross-sectional areas, one side of each wire group is disposed in the groove and in close contact with the inner support member, the other side of each wire group is in close contact with the first insulating layer to fix the position of each wire group, and the inner support member is made of silicone.