Ultrafine Coaxial Cable Coating Structure for Smaller Diameter
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Solution Overview
Problem
Traditional coaxial cables used in medical devices have larger diameters, limiting flexibility and ease of navigation in confined spaces, and conventional manufacturing processes restrict the production of thinner cables.
Innovation Solution
The development of a coaxial cable with a wire gauge of 54 AWG or smaller, manufactured using an additive process that includes a center conductor, a dielectric coating forming an insulator, a metallization layer forming a cable shield, and an outer jacket, utilizing techniques such as dip coating, plating, and aerogel structures to reduce thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If conventional extrusion processes are used to manufacture coaxial cables, then manufacturing simplicity is maintained, but cable diameter cannot be reduced below approximately 0.0008 inch (50 AWG)
Solution Approach 1:
The cable is constructed with segmented layers (center conductor, dielectric coating, metallization layer, outer jacket) where each layer is applied independently through sequential coating processes, enabling precise control of each layer's thickness to achieve ultrafine overall diameter
Solution Approach 2:
The invention changes the manufacturing parameters by transitioning from extrusion-based processes to dip-coating and plating processes, allowing wall thicknesses to be reduced below conventional extrusion limits of 0.0008 inch while achieving 54 AWG (0.00062 inch) and smaller gauges
2Ease of operation
If coaxial cable diameter is reduced to improve flexibility and navigation in confined spaces, then ease of operation is improved, but manufacturing precision requirements increase due to thinner walls
Solution Approach 1:
The invention replaces mechanical extrusion processes with dip-coating and plating processes that provide more precise control over thin wall thicknesses, enabling consistent manufacturing of walls thinner than 0.0008 inch with controlled impedance and electrical performance
Solution Approach 2:
The cable employs thin dielectric coatings and metallization layers applied through dip-coating and plating, creating flexible structures with precise thickness control that enable cables 54 AWG and smaller to achieve both flexibility for navigation and manufacturing precision for electrical performance
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 resulting ultrafine coaxial cable achieves reduced diameter, improved flexibility, and enhanced electrical performance, enabling better navigation in intricate procedures and increased cable density within medical devices.
Implementation Method 1
The coating may comprise the step of dip coating the dielectric coating
Implementation Method 2
a metallization layer applied to the insulator forms a cable shield surrounding the insulator
Data Source
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AI summary
A coaxial cable (100) includes a center conductor (110), a dielectric coating (122) applied to the center conductor forming an insulator (120) surrounding the center conductor (110), a metallization layer (132) applied to the insulator (120) forming a cable shield (130) surrounding the insulator (120), and an outer jacket (140) covering the cable shield (130), wherein the coaxial cable (100) has a wire gauge of 54 AWG or smaller. A method of manufacturing a coaxial cable (100) includes providing a center conductor (110), coating the center conductor (110) with a dielectric coating (122) to form an insulator (120) surrounding the center conductor (110), covering the insulator (120) with a metallization layer (132) to form a cable shield (130) surrounding the insulator (120), and covering the cable shield (130) with an outer jacket (140), wherein the coaxial cable (100) has a wire gauge of 54 AWG or smaller.