Twin-Axial Cable Shielding Structure for Stable High-Speed Bending

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Solution Overview

Problem

Conventional high-speed data transmission cables have low high-frequency test bandwidth, poor performance stability due to easily displaced core wires, and insufficient electromagnetic shielding, especially during bending movements.

Innovation Solution

A twin-axial cable design featuring a pair of insulated core wires with a central conductor and core insulation, wrapped with two sequential metal shielding layers and an outer insulation layer, providing improved electromagnetic shielding and stability through staggered joints in the shielding layers and an additional inner insulation layer to fix the core wires.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a single metal shielding layer is used in conventional cables, then the cable structure is simple, but the electromagnetic shielding effect is insufficient

Engineering Contradiction:

Improveelectromagnetic shielding effectVSAvoidshielding layer structure

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The single metal shielding layer is segmented into two separate metal shielding layers (first and second metal shielding layers) wrapped around the insulated core wires. This segmentation enhances the electromagnetic shielding effect by providing multiple shielding barriers, while each layer can be independently optimized for specific frequency ranges and shielding requirements.

Inventive Principle:

Principle #1Segmentation

2Stability of the object's composition

If core wires are fixed by only one insulation layer in conventional cables, then the manufacturing process is simple, but the core wires are easily displaced and performance stability is poor

Engineering Contradiction:

Improvecore wire position stabilityVSAvoidinsulation layer structure

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The single insulation layer is segmented into two distinct insulation layers: a first insulation layer wrapped around each insulated core wire, and a second insulation layer wrapped around the metal shielding layer. This segmentation provides dual fixation for the core wires, significantly improving position stability and performance consistency while maintaining manageable structural complexity.

Inventive Principle:

Principle #1Segmentation

3Strength

If a conventional cable structure is used, then the cable is easy to manufacture, but the metal shielding layer is easily broken during bending movements

Engineering Contradiction:

Improvebending resistanceVSAvoidcable manufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The cable structure is segmented into multiple independent layers (insulated core wires, first insulation layer, metal shielding layer, second insulation layer) that can move relative to each other during bending. This segmentation allows the cable to flex without concentrating stress on the metal shielding layer, preventing breakage while maintaining manufacturing feasibility through standardized layering processes.

Inventive Principle:

Principle #1Segmentation

4Speed

If a conventional single shielding layer cable is used, then the cable structure is simple, but the high-frequency test bandwidth is low

Engineering Contradiction:

Improvedata transmission rateVSAvoidcable structure

Core Design Contradiction:

SpeedVSDevice complexity

Solution Approach 1:

The cable employs segmented insulation and shielding layers that reduce signal interference and maintain signal integrity at high frequencies. The first insulation layer provides dielectric isolation for each core wire, while the second insulation layer provides additional isolation around the shielding layer, enabling high-frequency test bandwidth and fast data transmission rates despite increased structural complexity.

Inventive Principle:

Principle #1Segmentation

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 enhanced high-frequency performance, increased bending resistance, and improved electromagnetic shielding, ensuring stable data transmission rates above 10 Gbps with reduced risk of core wire displacement.

Implementation Method 1

A first metal shielding layer is wrapped around the pair of insulated core wires. A second metal shielding layer is wrapped around the first metal shielding layer.

Methodology Applied

Scientific EffectElectromagnetic shielding: Faraday Cage

Implementation Method 2

Each of the insulated core wires includes a central conductor and a core insulation layer wrapped around the central conductor in a circumferential direction.

Methodology Applied

Scientific EffectElectrical insulation: Dielectric

Data Source

PatentUS12131844B2Cable

Publication Date: 2024.10.29 TE CONNECTIVITY SOLUTIONS GMBH

AI summary

A cable has a pair of insulated core wires extending parallel to each other in a longitudinal direction. Each of the insulated core wires includes a central conductor and a core insulation layer wrapped around the central conductor in a circumferential direction. A first metal shielding layer is wrapped around the pair of insulated core wires. A second metal shielding layer is wrapped around the first metal shielding layer. An outer insulation layer is wrapped around an outer circumferential surface of the second metal shielding layer.