Spiral-Sheathed Cable Structure for Flexible High-Speed Signal Transmission
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Solution Overview
Problem
Existing cables used for transmitting high-frequency signals are not easy to bend and lack stability in their core wire structure, which affects signal transmission reliability.
Innovation Solution
A cable design featuring a core wire with two inner core wires in contact, an insulating layer extruded around them, and a sheath wrapped in a spiral manner to facilitate bending, while maintaining good electrical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the insulating layer and sheath layer are both extruded by extrusion molding, then the cable structure is stable, but the cable becomes not easy to bend
Solution Approach 1:
The cable structure is divided into distinct functional layers: the insulating layer is extruded first to provide stable insulation, then the sheath layer is separately wrapped in a spiral winding manner to provide flexibility. This segmentation allows each layer to perform its specific function without compromising the other, resolving the contradiction between structural stability and bending ease.
Solution Approach 2:
The sheath layer is applied in a spiral winding manner rather than being rigidly extruded, introducing a dynamic element to the cable structure. This spiral configuration allows the sheath to flex and adapt during bending while maintaining the stability provided by the underlying insulating layer, thus enabling both structural integrity and flexibility.
2Reliability
If the two inner core wires are separated by thick insulating material, then the electrical insulation is improved, but the outer diameter of the cable increases
Solution Approach 1:
The insulating layer is designed with optimized thickness parameters that provide sufficient electrical insulation between the two inner core wires while minimizing the overall cable diameter. By carefully controlling the insulating layer thickness to the minimum required for reliable insulation, the cable achieves good electrical properties without excessive volume.
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 cable achieves improved stability and ease of bending, with reduced outer diameter and enhanced electrical performance for high-speed signal transmission.
Implementation Method 1
the insulating layer is extruded and molded around the two inner core wires, so that the two core wires form an integral structure
Implementation Method 2
the sheath is wrapped outside the insulating layer, making the cable easier to bend
Data Source
AI summary
A cable includes: a core wire; a sheath covering the core wire; a shielding layer covering the sheath; and an outer insulating layer covering the shielding layer; wherein the core wire includes a pair of inner core wires and an insulating layer covering the pair of inner core wires by extrusion molding, each of the pair of inner core wires includes an inner conductor and an inner insulating layer covering the inner conductor, and the sheath wraps the insulating layer in a spiral winding way.