FILTER WIRE AND CABLE

Abstract: A filter wire comprising an inner wire (311, 312) made of an electrically conductive metal covered with an outer layer of magnetic shielding (33). The outer layer comprises glass-coated microwires. The microwires are made of a soft ferromagnetic material. The outer layer may comprise a microwire being wound about the cable to form a thin ferromagnetic layer. A filter cable comprising a multi-wire cable made of an electrically conductive metal covered with an outer layer of magnetic shielding. The outer layer comprises glass-coated microwires. The microwires may be made of a soft ferromagnetic metallic alloy. In one embodiment, the cable comprises a twisted pair of wires.

Description: Filter Wire and Cable Technical Field This invention concerns shielded wires and cables for use in electronics The invention relates in particular to such wires and cables which include a magnetic shielding layer comprising glass-coated microwires Background Art Prior art methods for reducing noise in electronic systems include shielding of cables and filtering Modern electronic systems have to meet stringent requirements for Electromagnetic Compatibility (EMC) Electronic systems may generate electromagnetic noise during their operation This noise may interfere with other systems EMC standards and regulations for electronic equipment have been set up in many countries These standards define a maximum level of noise that may be generated by electronic equipment, and the sensitivity of electronic equipment to noise generated by others In many cases, ambient electromagnetic noise penetrates the electronic equipment through the electrical cables In system comprising several parts, noise or interference may be transferred from one part to the other, or the cable itself may act as an antenna to receive interfering signals, that penetrate the electronic system Moreover, signals transmitted through a cable may be transmitted to other cables in that system or to other systems, thus creating an additional noise or interference. Noise or interference reduction in electronic systems may be achieved using shielding of cables and filtering. US Patent No. 4,868,565 discloses shielded cables wherein a shield is made of copper strands and/or metal foil strips. Such cables may be used for transferring signals between electronic units, while achieving a reduction of undesirable electromagnetic radiation coming from the environment. The efficiency of such cables, however, may not be sufficient where noise protection is required between parts of a system that are connected by cables. For example, if noise is generated in one part of an electronic equipment, the cable may transfer that noise to another part of the equipment by an electrical conduction mechanism. To reduce the noise transferred by conduction, methods known in the art include additional filtering. One known method includes the mounting of ferrite rings onto the cable. US Patent 4,992,060 details such a method and apparatus for the reduction of radio-frequency noise. The disclosed apparatus includes ferrite core that is mounted inside a connector plug to surround all the connectors of a transmission line interconnecting device. The ferrite core functions to provide a substantially increased series impedance in the conductors, thus reducing high frequency noise that wouid otherwise be transferred by conduction. Another means for noise reduction includes EMI filters These filters may be divided into two categories Reactive filters and absorptive filters A L-C filter is an example of a reactive filter Ferrite beads or lossy wires operate as absorptive low-pass filters Attenuation in L-C filters is a result of impedance mismatch between the source and the filter input on one side, and between the filter output and the load A large attenuation is achieved because of energy reflections because of impedance mismatch conditions, at both the source and load ports of the filter The effectiveness of L-C EM I filters largely depends on the values of source and load impedance Capacitive filters have good attenuation properties when both the source and load impedance are high Series inductor filters are more efficient where both the source and load impedance are low To achieve good performance in other cases of source and load impedance combinations, more complex filter structures are required, having for example more poles in the frequency domain EMI filters have to operate in circuits having a wide range of source and load impedance Moreover, in many cases the values of the impedance is not known, so the selection of an effective filter type may be difficult To address various impedance values, complex filters are used A useful EMI filter uses a combination of series inductor and filter capacitors connected to chassis In other cases, where capacitors cannot be connected to chassis (for example where the housing is made of a non-conductive material) , filtering of high- impedance EMI noise may be difficult. Absorptive filters operate on the principle of energy absorption in a lossy medium surrounding the cable. Noise and interference filtering is achieved due to the fact that energy absorption is low at low frequencies (the desired signal) and high at high frequencies (the interference) . Absorptive filtering effectiveness is, to a great extent, independent of the source and load impedance. Power loss in a magnetic material increases with the magnetic field. Thus, the higher amplitude noise currents will result in larger magnetic fields in the lossy material, and will be attenuated. The lossy effect is expected to be larger for lower source and load impedance, where the current is larger. The impedance of ferrite beads and Common-Mode Chokes (CMC) based on ferrite core materials demonstrate a complex behavior, being partly inductive and partly dissipative. Thus, ferrite beads and CMCs also operate as absorptive filters. A significant difference between ferrite beads and lossy wires is that lossy wires operate as a distributed component, whereas ferrite beads and CMCs are lumped components. This achieves different properties with respect to noise attenuation - lumped components result in a non-uniform noise current distribution along the wire or cable to be shielded. It is known that high frequency currents are not constant along a long cable, but there may be locations of minimum and maximum current thereon. For each frequency, the location of these minima/maxima of current is different, depending on the wavelength and other factors. If the location of the lumped element on the cable is close to a null in the current distribution, then the filtering device will not be effective or will achieve just a small attenuation. If the ferrite is located in a place of maximum current, a significant attenuation will result. Since the minima/maxima locations change with frequency, a ferrite bead at a specific location may achieve good attenuation at specific frequencies, and unsatisfactory attenuation at other frequencies. The best location for series EMI filters is as close as possible to a capacitor connected to chassis. The capacitor creates a point of maximum current, so the strong noise current will be attenuated in the series element. In cases where the ferrite bead/CMC cannot be located near a capacitor, or where a capacitor cannot be used, it is to be expected that a poor filtering will result at specific frequencies. For cables with a distributed lossy structure, better attenuation may be achieved over a wide frequency range, since there will be an absorbing element at each location on the cable where the current maximum may be To achieve this effect, the length of the distributed lossy element should be more than half wavelength of the expected noise frequency Thus, distributed lossy wires should preferably be long enough to achieve good attenuation over a wide range of frequencies For lower frequencies, the wavelength is longer so the distributed filter will envelope a larger part of the cable A complete cable may be manufactured of lossy wire Lossy cables and wires as known in the art are manufactured, for example, by the following firms 1 Raychem manufactures lossy wires according to MIL-C-85485 2 Capcon Inc (USA) manufactures coaxial and other cables with a lossy material replacing the regular dielectric "Lossylme" tubing may be added to harness assemblies EMI absorptive filters with wire coils embedded in a lossy media 3 Kabelwerk Eupen AG (Belgium) manufactures EMC cables as lossy wires, cables and cable assemblies, all based on a polymer material mixed with up to 90% of a homogeneously fine ferrite powder The lossy compound is extruded about the copper conductors In all the above examples, a significant attenuation was only achieved at frequencies above 300 MHz Raychem, for example, specifies attenuation properties for its wires only above 100 MHz In measurements performed by the present inventors, a significant attenuation was found only above 200 MHz BICC manufactures similar cables In a 30 cm (centimeter) long cable, the inventors found a significant attenuation only above 200 MHz Commercially available lossy wires and cables are coated with a thin layer of plastic including a ferrite powder This method and structure cannot achieve good attenuation at low frequencies, since known ferπte-coating materials can only contain a low percentage of ferrite particles A higher percentage of ferrite particles would result in rigidity of the cables The distance between ferrite particles in the lossy layer is rather large, with the resulting demagnetization factor providing for an additional decrease in the effective permeability In many applications, the attenuation achieved with presently used lossy wires is not sufficient Due to low ferrite concentration in composite materials used for lossy wires, these wires do not achieve a sufficient attenuation at the lower frequencies High energy losses are usually achieved at frequencies above 200 MHz The effective permeability of the ferrite layer is low because of the low percentage of ferrite in that layer Thus, presently used lossy wires usually do not have enough attenuation at frequencies below 200 MHz. Attenuation could be increased with a thick layer of ferrite, however this would make the wire rigid rather than flexible. It is an objective of the present invention to provide for a filter wire and cable with means for overcoming the abovedetailed deficiencies. Disclosure of Invention It is an object of the present invention to provide wires and cables with a microwire energy absorbing layer achieve higher attenuation values at lower frequencies. According to one aspect of the present invention, the energy absorbing layer uses a glass coated microwire, with the microwire made of a soft ferromagnetic metallic alloy. According to a second aspect of the present invention, the energy absorbing layer is made with the microwire being wound about the cable to form a thin ferromagnetic layer. According to a third aspect of the invention, a lossy cable includes a layer of lossy ferromagnetic microwires, an electrically conductive shielding layer and insulation layers. Accorαing to another aspect of the invention, the microwire layer may be used in a multi-wire cable or twisted pair cables or flat cables to achieve good EMI protection therefor The microwire windings achieve a ferromagnetic layer having a higher permeability, which achieves a higher attenuation per unit length of cable The soft ferromagne t ic material in the microwire may be either an amorphous alloy or a nano-crysta!lιne alloy or a micro-crystalline alloy or a combination thereof The microwire-coated cable is flexible, because of the very high flexibility of the microwires Further objects, advantages and other features of the present invention will become obvious to those skilled in the art upon reading the disclosure set forth hereinafter Brief Description of Drawings Fig. 1 A illustrates a side view of a microwire, and with Fig. 1 B illustrates a cross-sectional view of the microwire Fig. 2 illustrates the magnetic hysteresis characteristic of the microwire Figs. 3A and 3B illustrate the permeability of a microwire as a function of frequency, with Figs 3A and 3B detailing the two components of the permeability Fig 4 details the structure of a lossy cable Fig 5 details the attenuation in the cable as a function of frequency Fig 6 details the structure of a cable with a twisted pair Fig. 7 illustrates the structure of a cable with one embodiment of the microwire layer Fig. 8 illustrates the structure of a cable with another embodiment of the microwire layer Fig. 9 details the attenuation in a cable as a function of frequency Modes for Carrying out the Invention A preferred embodiment of the present invention will now be described by way of example and with reference to the accompanying drawings Fig. 1 A illustrates a side view of a microwire, and with Fig 1 B illustrates a cross-sectional view of the microwire Thus, the microwire has a metallic core 11 and a glass coating 12. Microwires as illustrated are known in the art. British Patent No. 1 ,120,247 details a method for manufacturing microwires. The diameter of the microwire core 1 1 may be in the range of about 6-8 microns, with the thickness of the glass coating 12 about 2-3 microns. Until now, however, these microwires were not used in EMI-protected cables or wires. To be usable for coating wires with an energy-absorbing layer according to the present disclosure, core 11 may be made either of an amorphous alloy or a nano-crystalline alloy or a micro-crystalline alloy. In other embodiments of the present invention, a combination of the above alloys may be used. In a preferred embodiment, core 11 is made of a (CoMe)BSi alloy, where M is a metal from a set of Fe, Mn, Ni and/or Cr. Fig. 2 illustrates the magnetic hysteresis characteristic of the microwire, which has "flat" shape. Thus, the magnetic field is illustrated as a function of the magnetic intensity, with magnetic intensity axis 21 (a/m) and magnetic field axis 22 (tesla). This is the magnetic flux density exhibiting a linear region 23 and a saturation region 24 for higher values of the magnetic intensity. Figs. 3A and 3B illustrate the relative permeability of a microwire as a function of frequency. Fig. 3A details the real component 42 of the permeability in a complex space, versus frequency 41 . Fig. 3B details the imaginary component 43 of the permeability in a complex space, versus frequency 41 . Together, Figs. 3A and 3B detail the magnitude and phase of the relative permeability of a microwire as a function of frequency. The graphs detail the relative permeability with the magnetic intensity as parameter, for three values of that parameter: graphs 51 indicate permeability for a magnetic intensity of 150 A/m; graphs 52 indicate permeability for a magnetic intensity of 300 A/m; graphs 53 indicate permeability for a magnetic intensity of 750 A/m. Fig. 4 details one embodiment of a lossy cable. The cable includes a central conductor 31 (the signal-carrying wire) with an insulation layer 32 to provide electrical insulation, and a layer of glass-coated microwire 33, wound on layer 32 to form a thin magnetic layer thereon. Thus, the energy absorbing layer 33 uses a glass coated microwire, with the microwire made of a soft ferromagnetic metallic alloy. Layer 33 is used for absorbing the EMI energy as desired, to achieve a lossy cable. Layer 33 may be deposited over a sizable part of cable 31 , to achieve a distributed lossy structure capable of good attenuation at low frequencies. The soft ferromagnetic material in the microwire may be either an amorphous alloy or a nano-crystalline alloy or a micro-crystalline alloy or a combination thereof. The cable further includes a second insulator layer 34 ( a plastic layer for example), an electrical shield 35 (for example a copper wire mesh) and an outer coating/insulator layer 36. The electrical shield 35 further increases the attenuation of lossy cables using microwires. The electrical shield 35 may be used as the second conductor of a transmission line, with the central conductor 31 acting as the first conductor of that transmission line. This achieves better confinement of the field within the lossy material 33 with respect with a cable having only layer 33 without shield 35. As a result, greater energy losses and better attenuation is achieved per unit cable length. Another benefit of the electrical shield 35 is that it decreases the amount of energy radiation from the cable. Usually, cables may radiate energy as electromagnetic waves. These waves interact with other parts of a system or with other systems to generate interference. Moreover, radiated energy may also be received at the other side of a lossy cable, thus bypassing the lossy cable to result in interference there. The use of an electrical shield 35 helps prevent or attenuate this bypassing effect. Electrical shield 35 may be implemented with a (not shown) tubular electrically conductive shield, for example a braid of good conductivity wires and/or a conductive foil sheath and/or electrical conductors wound about the microwire layer Experimental results indicate that a better attenuation per unit cable length is achieved at low frequencies with the novel microwire-coated cable, with respect to existing lossy cables Attenuation measurement results versus frequency are indicated in Table 1 , for a microwire-coated cable as well as for existing cables Table 1 Thus, it appears that the new microwire-coated cable may be suitable for solving EMI-related problems at frequencies above about 10 MHz, and is most effective at frequencies above about 30 MHz. Thus, better EMI performance is achieved with respect to existing lossy cables. The microwire windings achieve a ferromagnetic layer having a higher permeability, which achieves a higher attenuation per unit length of cable. The length-to-diameter ratio is very large for microwires, therefore the effect of demagnetization is negligible. For example, in a typical microwire the amorphous core diameter is about 10 microns, whereas the wire length may be about 1 km. Good attenuation in a lossy cable made with a microwire layer is achieved in the frequency range wherein the microwire has a good attenuation. Apparently the microwires form a magnetic layer that, through re-magnetization, absorbs interference energy at a given frequency as well as its harmonics. Moreover, the microwire-coated cable is flexible, because of the very high flexibility of the microwires. In other embodiments (not shown), some of the abovedetailed layers may be disposed with. For example, since the microwire is already insulated, layer 32 and/or 34 may be disposed with. The shielding 35 may not be necessary in applications where the microwire provides enough electrical shielding, since the microwire is also electrically conductive. In yet another embodiment, one layer 33 may include both electric wire (copper) and microwire (magnetic) together, to combine both functions. The outer isolation 36 is optional, to be used in applications where a loose cable may cause a short circuit. In other cases, the outer coating 36 may not be necessary. Fig. 5 details the attenuation in a microwire-coated cable as a function of frequency, as illustrated in a graph with an attenuation axis 44 vs. a frequency axis 41 . It refers to a cable with a microwire shield as detailed with reference to Fig. 4. The graph indicates the experimental results for a lossy cable that is 30 cm (centimeters) long and having an 1.0 gram of microwire coating layer distributed thereon. This structure achieves an about 9 dB attenuation at 30 MHz, and about 40 dB attenuation at 300 MHz. It is evident that a microwire-coated cable may be used in applications where a sufficient attenuation is required above 30 MHz. Thus, wires and cables with a microwire energy absorbing layer achieve higher attenuation values at lower frequencies with respect to existing lossy cables. From an attenuation effectiveness point of view, when comparing microwires with existing lossy wires, cables with a microwires layer have significantly better performance in the 30-300 MHz frequency range. A large part of the EMI radiated emission and radiated susceptibility problems fall into this frequency band. At frequencies above 300 MHz, lossy wires as known in the art have sufficient attenuation as well. Fig 6 details the structure of a cable with a twisted pair comprising a central pair of conductors 31 1 , 312 , each with its separate insulation layer 321 , 322 respectively A common layer of glass-coated microwire 33 is wound on the insulated conducted pair as illustrated The layer 33 may be coated with an insulator layer 34, using for example a plastic layer The cable may also include an electrical shield 35, made for example of a copper wire mesh The cable may also have an outer coating/insulator layer 36 Thus, the microwire layer 33 may be used in a multi-wire cable or twisted pair cables or flat cables to achieve good EMI protection therefor Fig 7 illustrates the structure of a cable including two twisted pairs, that is a first conductor pair with wires 31 1 , 312 and a second conductor pair with wires 313, 314 Each of the wires 31 1 , 312, 313 and 314 has its insulation layer 321 , 322, 323 and 324 respectively Each conductor pair has its layer of glass-coated microwire 331 and 332, wound on the insulated conducted pair (31 1 , 312) and (313, 314) respectively A common insulator layer 34 covers the two pairs of conductors with magnetic shielding thereon The lossy cable may further include an electrical shield 35 and an outer coating/insulator layer 36 More conductors and/or conductor pairs may be included in the cable, using a similar structure and method of manufacture thereof. The structure achieves good magnetic field isolation between the conductor pairs, because of the separate magnetic shielding of each pair. Fig. 8 illustrates another embodiment of a lossy cable, wherein the cable includes two conductor pairs, a first conductor pair with wires 31 1 , 312 and a second conductor pair with wires 313, 314 Each of the wires 31 1 , 312, 313 and 314 has its insulation layer 321 , 322, 323 and 324 respectively In this structure, a common layer of glass-coated microwire 33 is wound on the two conductor pairs. This is a lower cost solution, however there may be undesired interference coupling from one conductor pair to the other A common insulator layer 34 covers the two pairs of conductors with magnetic shielding thereon. The lossy cable may further include an electrical shield 35 and an outer coating/insulator layer 36. More conductors and/or conductor pairs may be included in the cable, using a similar structure and method of manufacture thereof Fig 9 details the attenuation in a cable as a function of frequency, in a graph with frequency axis 41 and attenuation axis 44 The three graphs relate each to a sample of a cable of length 30 cm, with a magnetic layer (microwire) of 0 3 gram/10 cm The graph 54 illustrates the attenuation function for one twisted pair, as illustrated in Fig 6 The graph 55 illustrates the attenuation function for two twisted pairs, as illustrated in Fig 7 The graph 56 illustrates the attenuation function for two twisted pairs having a common magnetic shield, as illustrated in Fig 8 It will be recognized that the foregoing is but one example of an apparatus and method within the scope of the present invention and that various modifications will occur to those skilled in the art upon reading the disclosure set forth hereinbefore

Claims: Claims What is claimed is: 1 . A filter wire comprising an inner wire made of an electrically conductive metal covered with an outer layer of magnetic shielding, wherein the outer layer comprises glass-coated microwires, and wherein the microwires are made of a soft ferromagnetic material. 2. The filter wire according to claim 1 , wherein the outer layer comprises a microwire being wound about the cable to form a thin ferromagnetic layer. 3. The filter wire according to claim 1 , wherein the microwires are made of a lossy ferromagnetic alloy. 4. The filter wire according to claim 3, further including a second outer layer made of an electrically conductive material. 5. The filter wire according to claim 1 , further including an outer layer made of an insulative material. 6. The filter wire according to claim 1 , wherein the microwires are made of an energy absorbing metal or alloy. 7. The filter wire according to claim 1 , wherein the microwires are made of metal or a metallic alloy. 8. The filter wire according to claim 1 , wherein the microwires are made of an amorphous alloy. 9. The filter wire according to claim 1 , wherein the microwires are made of a nano-crystalline alloy. 10. The filter wire according to claim 1 , wherein the microwires are made a micro-crystalline alloy. 11 . The filter wire according to claim 1 , wherein the microwires are made of a combination of an amorphous alloy, a nano-crystalline alloy and/or a micro-crystalline alloy. 12. The filter wire according to claim 1 , wherein the microwires are made of a (CoMe)BSi alloy, where M is a metal from a set of Fe, Mn, Ni and/or Cr. 13. A filter cable comprising a multi-wire cable made of an electrically conductive metal covered with an outer layer of magnetic shielding, wherein the outer layer comprises glass-coated microwires, and wherein the microwires are made of a soft ferromagnetic metallic alloy. 14. The filter cable according to claim 13, wherein the cable comprises a twisted pair of wires 15 The filter cable according to claim 13, wherein the cable comprises a flat cable 16 The filter cable according to claim 13, wherein the outer layer is made with a microwire being wound about the cable to form a thin ferromagnetic layer. 17 The filter cable according to claim 13, wherein the microwires are made of a lossy ferromagnetic alloy 18. The filter cable according to claim 13, further including a second outer layer made of an electrically conductive material 19. The filter cable according to claim 13, further including an outer layer made of an insulative material 20. The filter cable according to claim 13, wherein the microwires are made of an energy absorbing metal or alloy 21 . The filter cable according to claim 13, wherein the microwires are made of metal or a metallic alloy 22. The filter cable according to claim 13, wherein the microwires are made of an amorphous alloy. 23. The filter cable according to claim 13, wherein the microwires are made of a nano-crystalline alloy. 24. The filter cable according to claim 13, wherein the microwires are made a micro-crystalline alloy. 25. The filter cable according to claim 13, wherein the microwires are made of a combination of an amorphous alloy, a nano-crystalline alloy and/or a micro-crystalline alloy. 26. The filter cable according to claim 13, wherein the microwires are made of a (CoMe)BSi alloy, where M is a metal from a set of Fe, Mn, Ni and/or Cr.

Inventors: ANTONENCO ALEXANDRU, AXELROD ALEXANDER, MANOV VLADIMIR, RUBSHTEIN ALEXANDER, SORKINE EVGENI, ANTONENCO, ALEXANDRU, AXELROD, ALEXANDER, MANOV, VLADIMIR, RUBSHTEIN, ALEXANDER, SORKINE, EVGENI
Applicants: ADVANCED FILTERING SYSTEMS LTD, ANTONENCO ALEXANDRU, AXELROD ALEXANDER, MANOV VLADIMIR, RUBSHTEIN ALEXANDER, SORKINE EVGENI, ADVANCED FILTERING SYSTEMS LTD., ANTONENCO, ALEXANDRU, AXELROD, ALEXANDER, MANOV, VLADIMIR, RUBSHTEIN, ALEXANDER, SORKINE, EVGENI
Application year: 1999
Main classification: H01B11
IPC codes: H01B11