Flat high-speed data cable with special-shaped-structure wire cores and manufacturing method of flat high-speed data cable

Abstract

The invention relates to the technical field of high-speed data cables, in particular to a flat high-speed data cable with special-shaped structure wire cores and a manufacturing method, the flat high-speed data cable comprises a first wire core, a second wire core, a coating layer, a shielding layer and a protective layer, the coating layer, the shielding layer and the protective layer are sequentially coated on the outer sides of the first wire core and the second wire core from inside to outside, each of the first wire core and the second wire core comprises an inner conductor and an insulating layer, the insulating layer of the first wire core is provided with a first plane, the insulating layer of the second wire core is provided with a second plane, and the first plane and the second plane are matched with each other and are in fusion connection; by arranging the first plane and the second plane, the gap between the wire cores is eliminated, and the influence of an air flow channel between the two wire cores on signal transmission is eliminated; in addition, the first wire core and the second wire core can avoid the defect of a double-core co-extrusion process in the prior art through a mode of abutting and combining the first plane and the second plane, so that each wire core can adopt various structural forms, and the high transmission rate of the data cable is ensured.

Description

Technical Field

[0001] This invention relates to the field of high-speed data cable technology, specifically to a flat high-speed data cable with an irregularly shaped core and its manufacturing method. Background Technology

[0002] High-speed data cables are core infrastructure supporting modern data centers, communication networks, and high-performance computing, offering advantages such as ultra-high-speed transmission, low latency, high reliability, anti-interference, and low energy consumption. Currently, high-speed data cables on the market mainly have two structures: one where the core is manufactured separately, and then two cores are arranged in a parallel wrapped structure. The cores can be solid extruded, foamed extruded, or core-extruded. Cable extrusion typically uses an inner and outer die to shape the insulation material. The external shape of the extruded cable after cooling depends entirely on the shape of the outer die, while the inner die structure determines the internal structure of the cable. The shape, size, and number of internal holes in a core-extruded structure, as well as the position of the longitudinal holes, are usually determined by the inner die. Solid extrusion structures are formed directly after melting, and their dimensions also depend on the shape and size of the outer die. Foamed structures are similar to solid extrusion processes. Foamed insulation utilizes the thermal stability and melt characteristics of Teflon, forming controllable bubbles in the molten matrix through foaming agents or physical means, and then retaining a stable porous structure after shaping. In addition, according to currently available technology, the finest core of the coiled core structure can be mass-produced at 42AWG, which is currently impossible for the physical foamed structure.

[0003] The advantage of this product lies in its diverse structural forms. In particular, the foamed extrusion structure or the core structure can reduce the transmission loss of the insulating medium and improve the signal transmission rate during actual use.

[0004] However, the above-mentioned cable has certain defects: since the high-speed cable is composed of two single-core round wires wrapped together to form a parallel pair, there will be two triangular gaps between the two single-core round wires. This gap will increase the imbalance and asymmetry of the wire pair, which will affect the high-frequency transmission electrical performance of the high-speed cable and thus reduce the signal transmission quality.

[0005] Another type is the dual-core integrated co-extruded solid insulation structure, such as Samtec's Eye Speed® dual-core cable, which has an elliptical cross-section. This structure includes two conductors and an insulation structure that wraps around them. The two conductors are wrapped together during the extrusion process while the insulation structure is being formed. This structure ensures the stability and symmetry between the conductor pairs, reduces signal delay differences between conductor pairs, improves signal transmission quality, and reduces the bit error rate.

[0006] For example, Chinese patent application CN109003710A discloses a low-delay-difference high-speed transmission cable and its preparation method. The transmission cable includes two parallel conductors. The conductors are insulated by extruding through a parallel flat elliptical die to form a double-core flat cable. A layer of pure copper foil is tightly wrapped around the insulation material of the double-core flat cable. A layer of single-sided aluminum foil is then wrapped around the copper foil. A layer of hot-melt PET tape or a plastic sheath is then extruded around the aluminum foil.

[0007] However, in the actual production process of the above-mentioned high-speed transmission cables, the outer and inner molds of the extrusion process are slightly larger than the actual product structure size required. It is almost impossible to complete the small-sized double-core cable. The insulation structure can only be solid extrusion, and the double-core co-extrusion structure cannot be realized. At the same time, the wire diameter is thicker and occupies more space. The physical foaming structure is also difficult to achieve while maintaining a small cable volume.

[0008] Additionally, Chinese patent application CN120303750A discloses a biaxial cable comprising a first conductor having a length along a longitudinal direction and a second conductor parallel to the first conductor along the longitudinal direction. It also includes a main insulation member comprising a first core and a second core, the first core surrounding the first conductor and the second core surrounding the second conductor, each of the first and second cores being shaped as a horizontal cylindrical segment including a surface extending along the longitudinal direction. The surfaces of the first and second cores are configured to contact each other, and a first distance c between the first and second conductors is a ratio of 1.8 or less to the distance a between the edges of the first conductor and the main insulation member in a plane opposite to the second conductor.

[0009] The aforementioned cables employ a cutting method, creating two planes on the two cores. The symmetry of the wire pair is maintained by the contact of these two planes. However, the contact of the planes alone cannot guarantee the symmetry and stability of the wire pair during production. In other words, deviations may still occur between the wire pairs during production, causing relative displacement between the cores. Furthermore, the cutting method is not suitable for cables with foamed or coupled-core structures, as it would damage the internal structure of the insulation layer, making it difficult to ensure structural symmetry.

[0010] Therefore, a high-speed cable structure and manufacturing method are needed to ensure signal transmission integrity while maintaining high transmission rates and reducing signal transmission delay differences between wire pairs. Summary of the Invention

[0011] This invention provides a flat high-speed data cable with irregularly shaped core wires, which can reduce insulation loss, increase cable transmission distance, ensure signal transmission integrity, and reduce signal transmission delay difference between wire pairs while ensuring high transmission rate. The purpose of this invention is also to provide a manufacturing method for the above-mentioned flat high-speed data cable with irregularly shaped core wires.

[0012] To address the aforementioned problems, the present invention provides a flat high-speed data cable with an irregularly shaped core, employing the following technical solution: A flat high-speed data cable with an irregularly shaped core includes a first core, a second core, a sheathing layer, a shielding layer, and a protective layer. The sheathing layer, shielding layer, and protective layer are sequentially wrapped around the outer sides of the first core and the second core from the inside out. Both the first core and the second core include an inner conductor and an insulation layer. The insulation layer of the first core has a first plane, and the insulation layer of the second core has a second plane. The first plane and the second plane are aligned and fused together.

[0013] Furthermore, the inner conductor is any one of single or multiple stranded copper wires, copper alloy wires, graphene copper-based composite wires, plated copper wires, plated alloy copper wires, or plated graphene copper-based composite wires.

[0014] Furthermore, the insulating layer is made of any one of polyethylene, polypropylene, or Teflon, and its structure is a foamed structure, a solid structure, or a core structure. The longitudinal holes of the core structure are any one of circular, fan-shaped, or triangular. The dielectric constant of the insulating layer is 1.2 to 2.8. The cross-section of the insulating layer is arc-shaped or D-shaped.

[0015] Furthermore, the inner side of the covering layer or the outer side of the shielding layer has a ground wire, the ground wire being made of the same material as the inner conductor, and its cross-sectional shape being circular or flat.

[0016] Furthermore, the insulating layer has a groove for placing a ground wire, the shape of which matches the shape of the ground wire.

[0017] Furthermore, the covering layer is made of wrapping tape made of PTFE, PE, PP or Teflon material. The covering process is wrapping or drag wrapping. When using the wrapping process, the overlap ratio of adjacent wrapping tapes is 50%-52%. The cross-sectional shape of the wrapping tape is rhomboid, trapezoidal or crescent-shaped.

[0018] Furthermore, the shielding layer is made of any one of aluminum foil, copper foil, or graphene copper-based composite material; the protective layer is made of any one of polyethylene terephthalate, polyvinyl chloride, polyethylene, Teflon, or polyimide film.

[0019] The beneficial effects of the flat high-speed data cable with irregularly shaped core provided by this invention are: 1. The present invention discloses a flat high-speed data cable with irregularly shaped cores. By respectively setting a first plane and a second plane on the first core and the second core, the first core and the second core can be tightly fitted together when combined, which helps to reduce the overall volume of the cable, making it flatter and saving space. The fusion bonding method enables the first plane and the second plane to achieve a seamless and firm combination, reducing or eliminating gaps between cores, avoiding displacement deviations between wire pairs, enhancing the symmetry and stability between cores, effectively reducing the delay difference between wire pairs, and ensuring the integrity and reliability of signal transmission. The fusion bonding method can overcome the limitations of existing technology, allowing each core to adopt a core-coupled structure, a foamed structure, or other structural forms, reducing dielectric loss, ensuring high transmission rates of the data cable, and increasing the transmission distance of the cable.

[0020] 2. By setting grooves on the insulation layer that match the shape of the ground wire, the ground wire can be inserted into the grooves, making the relative position between the ground wire and the wire core more stable. This prevents the ground wire from moving when the cable is bent or subjected to external forces, ensuring that the ground wire can always effectively perform its shielding and grounding functions, improving the electrical performance stability of the cable. At the same time, it can also prevent air gaps between the ground wire and the first and second wire cores, and keep the surface structure of the cable flat and smooth, which helps to reduce signal delay between wire pairs and improve signal transmission quality.

[0021] 3. By setting the cross-sectional shape of the wrapping tape to a rhombus, trapezoid, or crescent shape, the wrapping tape can be connected end to end during wrapping, ensuring that the thickness of the wrapping layer remains consistent. This avoids bulges on the surface of high-speed cables, thus maintaining the symmetry of the overall cable structure and helping to reduce signal reflection.

[0022] To address the aforementioned problems, the present invention provides a manufacturing method for a flat high-speed data cable with an irregularly shaped core, employing the following technical solution: A method for manufacturing a flat high-speed data cable with an irregularly shaped core, comprising the following steps: S1. An insulating layer is made by using an extrusion die with an arc or D-shaped cross section to wrap the inner conductor, thereby making the first core and the second core respectively. The inner conductor is in the form of a single or multiple stranded strands, and the insulating layer is a foamed structure, a solid structure, or a core structure. S2. The first plane of the insulation layer of the first wire core and the second plane of the insulation layer of the second wire core are fused together in a high-temperature heat treatment furnace to form an elliptical whole between the first wire core and the second wire core. S3. A cladding layer is jointly applied to the outside of the first and second cores; S4. Use a pressing die to press the first core, the second core and the covering layer to eliminate the air gap between the first core, the second core and the covering layer; S5. Cover the outside of the covering layer with a shielding layer, and then add a ground wire to the outside of the shielding layer. The arrangement of the ground wire is as follows: a single ground wire is arranged on the upper or lower side between the first wire core and the second wire core, or two ground wires are arranged on the left and right sides of the first wire core and the second wire core respectively. S6. Cover the outside of the shielding layer and the ground wire with a protective layer.

[0023] Furthermore, the specific steps for fusion bonding of the first plane and the second plane are as follows: A1. Clean the surfaces of the first and second core wires; A2. Use a high-temperature heat treatment furnace to melt the surfaces of the insulation layers where the first and second planes are located, and then perform fusion bonding. For the insulation layers of the core structure and the foam structure, a vertical sintering process is used for fusion bonding. A3. Cool the first and second cores that have been fused together.

[0024] The beneficial effects of the manufacturing method of the flat high-speed data cable with irregularly shaped core provided by the present invention are: This invention discloses a method for manufacturing a flat high-speed data cable with irregularly shaped cores. The method involves first manufacturing the irregularly shaped cores separately, then using a fusion bonding process to combine the first and second cores into an elliptical integral structure, followed by wrapping. Compared to existing technologies that involve simultaneous extrusion and core cutting and splicing of dual cores, this invention reduces the manufacturing difficulty of elliptical pairs while eliminating the limitation of dual-core integral molding processes that can only extrude solid structures. This ensures the stability and reliability of the symmetrical structure of the pair, and allows for the manufacture of various structures such as coupled core structures or foamed structures. Consequently, the cable possesses both the low signal delay performance of elliptical pairs and excellent signal transmission quality and transmission rate.

[0025] Furthermore, since the first and second cores of this invention are manufactured separately, and the cable extrusion process is an existing production process, the concentricity of the cable and the consistency of the production process can be well controlled through the inner and outer molds. The cores can maintain a small wire diameter, and after fusion bonding, they can have a smaller wire diameter size compared with the dual-core integrated molding process, thereby reducing the cable wiring space and improving the utilization rate of the internal space of the equipment. Attached Figure Description

[0026] The above and other objects, features, and advantages of exemplary embodiments of the present invention will become readily apparent upon reading the following detailed description with reference to the accompanying drawings. In the drawings, several embodiments of the invention are illustrated by way of example and not limitation, and like or corresponding reference numerals denote like or corresponding parts, wherein: Figure 1 A schematic diagram of the structure of a flat high-speed data cable with an irregularly shaped wire core provided by the present invention; Figure 2 A schematic diagram of the combined structure of the first and second cores using a coupling core structure. Figure 1 ; Figure 3 A schematic diagram of the combined structure of the first and second cores using a coupling core structure. Figure 2 ; Figure 4 A schematic diagram of the combined structure of the first and second cores using a foamed structure. Figure 1 ; Figure 5 A schematic diagram of the combined structure of the first and second cores using a foamed structure. Figure 2 ; Figure 6 A schematic diagram of the combined structure of the first and second cores using a solid structure. Figure 1 ; Figure 7 A schematic diagram of the combined structure of the first and second cores using a solid structure. Figure 2 ; Figure 8 This diagram illustrates the relative positions of the ground wire, the first conductor, and the second conductor. Figure 1 ; Figure 9 This diagram illustrates the relative positions of the ground wire, the first conductor, and the second conductor. Figure 2 ; Figure 10 This diagram illustrates the relative positions of the ground wire, the first conductor, and the second conductor. Figure 3 ; Figure 11 This is a schematic diagram of the extrusion inner mold structure; Figure 12 This is a schematic diagram of the extrusion die structure; Figure 13 This is a schematic diagram showing the fit between the inner extrusion die and the outer extrusion die. Figure 14 Schematic diagram of the cross-section of the wrapping tape Figure 1 ; Figure 15 Schematic diagram of the cross-section of the wrapping tape Figure 2 ; Figure 16 Schematic diagram of the cross-section of the wrapping tape Figure 2 ; Figure 17 This is a schematic flowchart illustrating a method for manufacturing a flat high-speed data cable with an irregularly shaped core, as provided by the present invention.

[0027] Explanation of reference numerals in the attached figures: 1. First conductor; 2. Second conductor; 22. Groove; 3. Inner conductor; 4. Insulation layer; 5. Covering layer; 51. Wrapping tape; 6. Shielding layer; 7. Protective layer; 8. Ground wire; 9. Extrusion die; 91. Inner extrusion die; 92. Outer extrusion die; 93. Inner conductor wire passing die; 94. Longitudinal hole forming die. Detailed Implementation

[0028] The principles and spirit of the present invention will be explained in detail below with reference to several representative embodiments.

[0029] Embodiment 1 of a flat high-speed data cable with irregularly shaped core provided by the present invention: like Figures 1 to 17 As shown, a flat high-speed data cable with an irregularly shaped core according to the present invention includes a first core 1, a second core 2, a sheathing layer 5, a shielding layer 6, a ground wire 8, and a protective layer 7. The first core 1 and the second core 2 are arranged in parallel. The sheathing layer 5 covers both the first core 1 and the second core 2. The shielding layer 6 covers the outside of the sheathing layer 5 to shield against electromagnetic interference. The protective layer 7 covers the outside of the shielding layer 6 to protect the cable from physical damage and environmental corrosion.

[0030] First, such as Figures 1 to 9 As shown, both the first core 1 and the second core 2 include an inner conductor 3 and an insulation layer 4. To ensure good conductivity of the inner conductor 3, the inner conductor 3 uses any one of the following: bare copper wire, tinned copper wire, silver-plated copper wire, silver-copper alloy wire, graphene copper-based composite material wire, plated copper wire, plated alloy copper wire, or plated graphene copper-based composite material wire. It can be single or multiple stranded. Multiple strands increase the flexibility of the inner conductor 3, facilitating cable bending and laying. The insulation layer 4 uses polyethylene, polypropylene, or Teflon material, where Teflon is not limited to FEP, PFA, PTFE, etc., to ensure good insulation performance. The insulation layer 4 has a solid structure, a foamed structure, or a core structure to reduce dielectric loss, improve the high-frequency electrical transmission performance of the cable, and reduce signal attenuation.

[0031] Specifically, the insulation layer 4 of both the first core 1 and the second core 2 has an arc-shaped or D-shaped cross-section. The plane on the outer surface of the insulation layer 4 of the first core 1 is defined as the first plane, and the plane on the outer surface of the insulation layer 4 of the second core 2 is defined as the second plane. The first plane and the second plane fit together and abut against each other. The first core 1 and the second core 2 are fused together through the first plane and the second plane to form a double-core integrated structure with an elliptical cross-section. This allows for a seamless and robust connection between the first and second planes, reducing or eliminating gaps between cores, preventing displacement deviations between pairs, enhancing the symmetry and stability between cores, and effectively reducing delay differences between pairs, thus ensuring the integrity and reliability of signal transmission. Furthermore, the fusion bonding of the first core 1 and the second core 2 through the first and second planes avoids the defects of the existing double-core co-extrusion process, reduces the difficulty of process implementation, ensures structural diversity of the cores, and allows each core to adopt a core-coupled structure, a foamed structure, or other structural forms, thereby ensuring a high transmission rate for the data cable.

[0032] Furthermore, such as Figure 1 , Figure 8 , Figure 9 , Figure 14 , Figure 15 , Figure 16 As shown, the covering layer 5 adopts a structure of wrapping tape 51. The wrapping tape 51 is made of PTFE with a density of 0.5-1.6 grams per cubic centimeter and a thickness of 50-150 micrometers. The cross-sectional shape of the wrapping tape 51 is rhomboid, trapezoidal, or crescent-shaped. The wrapping process is either drag wrapping or wrapping. When using the wrapping process, the overlap rate between adjacent wrapping tapes 51 is 50%-52% to ensure that the wrapping tapes 51 are connected end to end, so that the thickness of the covering layer 5 is consistent, avoiding the formation of protrusions on the surface of the high-speed cable, thereby maintaining the symmetry of the overall cable structure, which helps to reduce signal reflection and improve signal transmission quality.

[0033] Furthermore, the shielding layer 6 is a metal layer, and its covering material is aluminum foil, copper foil, or graphene composite film. The covering process is drag wrapping or wrapping to improve the cable's anti-interference capability against external signals. Figure 10 As shown, the ground wire 8 can be a single or double wire, arranged in parallel outside the first conductor 1 and the second conductor 2 and outside the shielding layer 6. Specifically, it is located above or below the first conductor 1 and the second conductor 2, or on the left or right sides of the first conductor 1 and the second conductor 2. The ground wire 8 is made of the same material as the inner conductor 3, and its cross-sectional shape is circular or flat. In this embodiment, the ground wire 8 is laid separately and located outside the shielding layer 6, such as... Figure 8 and Figure 9As shown, in other embodiments, the ground wire 8 can be placed between the first core 1, the second core 2 and the wrapping layer, or it can be used as the ground wire 8 instead of being laid separately.

[0034] In particular, such as Figure 8 , Figure 9 As shown, the outer surface of the insulation layer 4 also has a groove 22 corresponding to the ground wire 8. The cross-sectional shape of the groove 22 matches the cross-sectional shape of the ground wire 8 so that the ground wire 8 can be installed in the groove 22, making the relative position between the ground wire 8 and the wire core more stable. This prevents the ground wire 8 from moving when the cable is bent or subjected to external force, ensuring that the ground wire 8 can always effectively play its role in shielding and grounding, improving the electrical performance stability of the cable. At the same time, it can also prevent air gaps from being generated between the ground wire 8 and the first wire core 1 and the second wire core 2, and keep the surface structure of the cable flat and smooth, which is beneficial to reducing the signal delay between wire pairs and improving the signal transmission quality.

[0035] Furthermore, the protective layer 7 is made of one or more layers of PET material. In other embodiments, the protective layer 7 may also be made of any one of polyethylene terephthalate, polyvinyl chloride, polyethylene, Teflon, or polyimide film.

[0036] The operating principle of a flat high-speed data cable with an irregularly shaped core, as described in this invention, is summarized as follows: By setting a first plane and a second plane that are fused together on the first core 1 and the second core 2 respectively, the first core 1 and the second core 2 can form an elliptical structure, avoiding wobbling between the wire pairs, ensuring the symmetry and stability of the overall structure, and effectively reducing the delay between the wire pairs. In addition, the fusion bonding of the first plane and the second plane can reduce the difficulty of the process implementation, while ensuring the structural diversity of the cores, allowing each core to adopt a core-coupled structure, a foamed structure, or other structural forms, thereby ensuring the high transmission rate of the data cable.

[0037] Embodiment 2 of a flat high-speed data cable with irregularly shaped wire core provided by the present invention: Its main difference from Example 1 is: In Example 1, the first core and the second core are fused together to form an elliptical integral structure.

[0038] In this embodiment, as Figure 3 , Figure 5 , Figure 7 As shown, the first and second cores are fused together to form a gourd-shaped structure.

[0039] Example 1 of a method for manufacturing a flat high-speed data cable with an irregularly shaped core provided by the present invention: A method for manufacturing a flat high-speed data cable with irregularly shaped wire cores, such as... Figure 16 As shown, the specific steps are as follows: S1, such as Figures 11 to 13 As shown, the insulation layer 4 is made by extruding the inner conductor 3 through an extrusion die 9 with a cross-sectional extrusion shape of bow or D, and the inner conductor 3 is wrapped with it to form the first core 1 and the second core 2 respectively. The inner conductor 3 is in the form of single or multiple strands twisted together, and the insulation layer 4 is a foamed structure, a solid structure or a core structure. S2. The first plane of the insulation layer 4 of the first core 1 and the second plane of the insulation layer 4 of the second core 2 are fused together in a high-temperature heat treatment furnace to form an elliptical whole between the first core 1 and the second core 2. S3. A sheathing layer 5 is jointly covered on the outside of the first wire core 1 and the second wire core 2. The sheathing layer 5 is made of PTFE wrapping tape 51. The cross-sectional shape of the wrapping tape 51 is rhomboid, trapezoidal or crescent-shaped. The wrapping process is wrapping or drag wrapping. When using the wrapping process, the overlap ratio of adjacent wrapping tapes 51 is 50%-52%. S4. Use an elliptical compression mold to compress the first core 1, the second core 2 and the covering layer 5 to eliminate the air gap between the first core 1, the second core 2 and the covering layer 5. S5. Cover the outer side of the covering layer 5 with a shielding layer 6, and then add a ground wire 8 to the outer side of the shielding layer 6. The arrangement of the ground wire 8 is as follows: a single ground wire 8 is arranged on the upper or lower side between the first core 1 and the second core 2, or two ground wires 8 are arranged on the left and right sides of the first core 1 and the second core 2 respectively. The cross-sectional shape of the ground wire 8 is circular or flat. S6. A protective layer 7 is wrapped around the outside of the shielding layer 6 and the ground wire 8.

[0040] In this embodiment, in step S1, the pores of the lotus root core structure are arranged in a complete circle or a portion of a circle. For example... Figures 11 to 13As shown, the extrusion die 9 includes an inner extrusion die 91 and an outer extrusion die 92. The outer extrusion die 92 has a cylindrical structure with a D-shaped or arc-shaped cross-section. The inner extrusion die 91 includes an inner conductor wire guide die 93 located at the center of the die and a plurality of longitudinal hole forming dies 94. Each of the longitudinal hole forming dies 94 is circumferentially distributed on the outside of the inner conductor wire guide die 93. The outer extrusion die 92 is coaxially sleeved on the outside of the inner extrusion die 91. During core manufacturing, the insulating material and extrusion die 9 are first preheated. The insulating material is heated to a molten state, and then extruded between the inner extrusion die 91 and the outer extrusion die 92. Simultaneously, the inner conductor 3 is pulled at a constant speed through the inner conductor die 93, causing the insulating material to wrap around the surface of the inner conductor 3 in a lotus root shape. The insulating material, in a molten state, is shaped by the extrusion die 9. After forming, it is stretched to a certain proportion in a molten state to obtain the required core size and structure. Then, it is uniformly introduced into a cooling water tank, where water cooling rapidly solidifies the lotus root-shaped insulating material, thus giving the core a D-shaped or arc-shaped cross-section while maintaining the lotus root structure. The production process for solid and foamed structures is the same as that for the lotus root structure; only the structure of the extrusion die 9 needs to be changed to obtain the corresponding core shape and size, which will not be elaborated here.

[0041] In this embodiment, step S2, the specific steps for fusion bonding of the first plane and the second plane, include: A1. Clean the surface of the first core 1 and the second core 2 of dust or foreign matter, for example by using an air gun, to ensure the cleanliness of the core surface before the melting process. A2. The surfaces of the insulation layer 4 containing the first and second planes are melted using a high-temperature heat treatment furnace, and then fusion bonding is performed. In order to avoid the problem of the insulation layer 4 material sagging during the melting process due to gravity, the insulation layer 4 of the core structure and the foam structure are fusion bonded using a vertical sintering process. Furthermore, the high-temperature treatment process includes preheating treatment, heat preservation treatment and sealing treatment in sequence. The high-temperature heat treatment furnace has three temperature zones corresponding to the three treatment processes. The temperature of each temperature zone is determined according to the melting point of the insulating material. Among them, the temperature T1 of the preheating treatment stage is < the temperature T2 of the heat preservation treatment stage < the temperature T3 of the sealing treatment stage. Taking FEP insulation material as an example, the melting temperature of FEP material is 250-270℃, so the temperature of the preheating treatment stage is 200℃, the temperature of the heat preservation treatment stage is 230℃, and the temperature of the sealing treatment stage is 280℃.

[0042] A3. The first core 1 and the second core 2, which have been fused together, are cooled by air cooling to obtain a one-piece molded double core wire.

[0043] It should be noted that this embodiment is a manufacturing method for a single pair of core wires. According to existing processes, it is possible to manufacture 2-pair, 4-pair, 8-pair, and 16-pair core wires, which will not be described in detail here.

[0044] Based on the above description in this specification, those skilled in the art will also understand that the following terms, such as "upper," "lower," "front," "rear," "left," "right," "width," "horizontal," "top," "bottom," "inner," and "outer," which indicate orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings of this specification. They are only for the purpose of facilitating the explanation of the present invention and simplifying the description, and do not explicitly or implicitly suggest that the device or element involved must have the specific orientation, or be constructed and operated in a specific orientation. Therefore, the above-mentioned orientation or positional relationship terms should not be understood or interpreted as limitations on the present invention.

[0045] In addition, in the description of this specification, "multiple" means at least two, such as two, three or more, etc., unless otherwise expressly and specifically defined.

Claims

1. A flat high-speed data cable with an irregularly shaped core, comprising a first core, a second core, a sheathing layer, a shielding layer, and a protective layer, wherein the sheathing layer, the shielding layer, and the protective layer sequentially cover the outer sides of the first core and the second core from the inside out, characterized in that, Both the first and second cores include an inner conductor and an insulating layer. The insulating layer of the first core has a first plane, and the insulating layer of the second core has a second plane. The first and second planes are aligned and fused together.

2. The flat high-speed data cable with irregularly shaped core according to claim 1, characterized in that, The inner conductor is any one of single or multiple stranded copper wires, copper alloy wires, graphene copper-based composite wires, plated copper wires, plated alloy copper wires, or plated graphene copper-based composite wires.

3. A flat high-speed data cable with an irregularly shaped core according to any one of claims 1-2, characterized in that, The insulating layer is made of any one of polyethylene, polypropylene, or Teflon, and its structure is a foamed structure, a solid structure, or a core structure. The longitudinal holes of the core structure are any one of circular, fan-shaped, or triangular. The dielectric constant of the insulating layer is 1.2 to 2.

8. The cross-section of the insulating layer is arc-shaped or D-shaped.

4. A flat high-speed data cable with an irregularly shaped core according to any one of claims 1-2, characterized in that, The inner side of the covering layer or the outer side of the shielding layer has a ground wire, the ground wire being made of the same material as the inner conductor, and its cross-sectional shape being circular or flat.

5. A flat high-speed data cable with an irregularly shaped core according to claim 4, characterized in that, The insulating layer has a groove for placing the ground wire, and the shape of the groove matches the shape of the ground wire.

6. A flat high-speed data cable with an irregularly shaped core according to claim 5, characterized in that, The covering layer is made of wrapping tape made of PTFE, PE, PP or Teflon material. The covering process is wrapping or drag wrapping. When using the wrapping process, the overlap ratio of adjacent wrapping tapes is 50%-52%. The cross-sectional shape of the wrapping tape is rhomboid, trapezoidal or crescent-shaped.

7. A flat high-speed data cable with an irregularly shaped core according to claim 6, characterized in that, The shielding layer is made of any one of aluminum foil, copper foil, or graphene copper-based composite material; the protective layer is made of any one of polyethylene terephthalate, polyvinyl chloride, polyethylene, Teflon, or polyimide film.

8. A method for manufacturing a flat high-speed data cable with an irregularly shaped core, characterized in that, The specific steps include: S1. An insulating layer is made by using an extrusion die with an arc or D-shaped cross section to wrap the inner conductor, thereby making the first core and the second core respectively. The inner conductor is in the form of a single or multiple stranded strands, and the insulating layer is a foamed structure, a solid structure, or a core structure. S2. The first plane of the insulation layer of the first wire core and the second plane of the insulation layer of the second wire core are fused together in a high-temperature heat treatment furnace to form an elliptical whole between the first wire core and the second wire core. S3. A cladding layer is jointly applied to the outside of the first and second cores; S4. Use a pressing die to press the first core, the second core and the covering layer to eliminate the air gap between the first core, the second core and the covering layer; S5. Cover the outside of the covering layer with a shielding layer, and then add a ground wire to the outside of the shielding layer. The arrangement of the ground wire is as follows: a single ground wire is arranged on the upper or lower side between the first wire core and the second wire core, or two ground wires are arranged on the left and right sides of the first wire core and the second wire core respectively. S6. Cover the outside of the shielding layer and the ground wire with a protective layer.

9. A method for manufacturing a flat high-speed data cable with an irregularly shaped core according to claim 8, characterized in that, The specific steps for fusion bonding of the first plane and the second plane are as follows: A1. Clean the surfaces of the first and second core wires; A2. Use a high-temperature heat treatment furnace to melt the surfaces of the insulation layers where the first and second planes are located, and then perform fusion bonding. For the insulation layers of the core structure and the foam structure, a vertical sintering process is used for fusion bonding. A3. Cool the first and second cores that have been fused together.

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