Slit Metal Foil Shield Wire for Flexible Noise Protection

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Solution Overview

Problem

Shield wires with braid shields offer good flexibility but high manufacturing costs, while those with metal foil shields have low flexibility and high production costs due to inflexibility.

Innovation Solution

A shield wire design featuring a metal foil shield with linear slits along its length, allowing for extensibility and improved manufacturability by enabling the shield to be wound without creases, reducing production costs while maintaining flexibility.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of operation

If a braid shield is used, then flexibility is improved, but manufacturing cost increases

Engineering Contradiction:

ImproveflexibilityVSAvoidmanufacturing cost

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

The metal foil shield is divided into multiple longitudinal strips by forming slits along its length, allowing each strip to move independently and providing flexibility similar to braid shields while maintaining the low cost and simplicity of metal foil construction

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses a thin metal foil shield with longitudinal slits that can flex and conform to bends, replacing the traditional rigid metal foil with a flexible version that maintains shielding effectiveness while enabling easy installation and routing

Inventive Principle:

Principle #30Flexible shells and thin films

2Ease of manufacture

If a metal foil shield is used, then manufacturing cost decreases, but flexibility deteriorates

Engineering Contradiction:

Improvemanufacturing costVSAvoidflexibility

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

By cutting the metal foil shield into longitudinal strips separated by slits, the shield maintains the low manufacturing cost of metal foil while gaining the flexibility needed for practical installation and routing

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metal foil shield transitions from a static, rigid structure to a dynamic, flexible structure through the addition of longitudinal slits that allow the foil to expand and contract with movement

Inventive Principle:

Principle #15Dynamics

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 extensible metal foil shield provides a flexible and cost-effective solution for shielding wires, enhancing manufacturability and flexibility while maintaining effective noise shielding capabilities.

Implementation Method 1

The shield wire includes a covered wire having an electrical conductive core and a cover covering the core, a metal foil shield winding around an outer surface of the covered wire, and a sheath covering around the metal foil shield

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Data Source

PatentUS7554038B2Shield wire

Publication Date: 2009.06.30 YAZAKI CORP

AI summary

A shield wire has one covered wire, a metal foil shield wound around the covered wire, and a sheath covering around the metal foil shield and a sheath covering around the metal foil shield. In the metal foil shield, slits are formed linearly along a lengthwise direction of a core. The slits adjacent to each other with a space in a direction intersecting the lengthwise direction of the core are staggered along the lengthwise direction