Wavy Insulated Core Wire for Stable High-Frequency Transmission
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Solution Overview
Problem
Traditional insulating layers in core wires for cables are not uniformly foamed, leading to instability in high-frequency signal transmission due to high dielectric constants.
Innovation Solution
A core wire design featuring a wavy outer surface on the insulating layer that forms an air gap with the shielding layer, utilizing a solid material for the insulating layer to enhance mechanical strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional foaming technology is used to make the insulating layer, then the cable size is reduced and dielectric constant is lowered, but the foaming is not uniform which affects signal transmission stability
Solution Approach 1:
The patent uses foam material for the insulating layer to reduce the dielectric constant and cable size. The foam structure provides the necessary insulation properties while maintaining a lower dielectric constant compared to solid materials, directly addressing the need to improve electrical performance for high-frequency signal transmission.
Solution Approach 2:
The patent introduces a release agent application step before the foaming process to prevent adhesion between the insulating layer and shielding layer. This preliminary action ensures uniform separation and prevents defects in the foaming process, thereby improving both the uniformity of the insulating layer and the stability of signal transmission.
2Reliability
If a flat insulating layer surface is used, then the structure is simple, but the dielectric constant remains high and signal transmission stability is poor
Solution Approach 1:
The patent makes the outer surface of the insulating layer wavy instead of flat. This curved surface structure creates air gaps between the insulating layer and shielding layer, which lowers the effective dielectric constant and improves signal transmission stability by reducing electromagnetic interference and capacitance effects.
3Strength
If the insulating layer is made of solid material, then mechanical strength is improved, but the dielectric constant increases and signal transmission stability decreases
Solution Approach 1:
The patent uses foam material instead of solid material for the insulating layer. The foam structure provides adequate mechanical strength while significantly reducing the dielectric constant compared to solid materials, thereby improving signal transmission stability for high-frequency applications.
Solution Approach 2:
The wavy surface structure of the insulating layer creates air gaps that further reduce the effective dielectric constant while maintaining mechanical integrity. The curved geometry provides structural reinforcement similar to I-beam construction, ensuring adequate mechanical strength despite the porous foam material.
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 air gap reduces the dielectric constant, enhancing signal transmission stability and reducing attenuation loss, while maintaining mechanical integrity.
Implementation Method 1
an outer surface of the insulating layer is wavy to form an air gap between the shielding layer and the insulating layer... the dielectric constant of the cable is low, and signal transmission is more stable
Data Source
AI summary
A cable includes: a core wire comprising a pair of inner conductors; and an insulating layer covering the pair of inner conductors; and a shielding layer disposed outside the insulating layer; wherein an outer surface of the insulating layer is wavy so that an air gap is formed between the shielding layer and a wave trough of the insulating layer.