Flat data cable and preparation method thereof

Abstract

The invention provides a flat data cable and a preparation method thereof, and the flat data cable comprises a plurality of insulating single wires and a plurality of paired wire groups which are formed by twisting two insulating single wires at different pitches; the sheath is arranged on the outer side of the paired wire group; the framework and the sheath are integrally formed, and the framework is formed by a hollow structure formed in the sheath and is used for isolating the paired wire group and supporting the sheath; according to the flat data cable structure, the supporting performance is enhanced, crosstalk interference between wire pairs is effectively suppressed, the pressure resistance is improved, the signal transmission quality of the flat data cable is ensured, and the maintenance and replacement cost is reduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of data cable, in particular to a flat data cable and a preparation method thereof. BACKGROUND

[0002] In today's highly developed information age, data transmission plays a crucial role in various fields, whether it is the communication industry, computer networks or smart home systems, all of which cannot do without efficient, stable and reliable data transmission cables. Flat data cables, with their unique structural advantages such as ease of wiring and space saving, have been widely used in many application scenarios.

[0003] However, there are still some problems to be solved in the actual use of traditional flat data cables. Among them, the problems of insufficient voltage resistance and crosstalk interference between wire pairs are particularly prominent. In a complex electromagnetic environment, data cables need to withstand high voltage fluctuations. Due to the limitations of structural design, the voltage resistance of traditional flat data cables often fails to meet the increasingly stringent requirements, which may lead to problems such as insulation layer breakdown and signal transmission interruption in high-voltage environments, seriously affecting the stability and reliability of data transmission.

[0004] At the same time, crosstalk interference between wire pairs is also a problem that cannot be ignored during data transmission. When multiple wire pairs transmit signals in parallel, due to electromagnetic induction and capacitive coupling, crosstalk interference will occur between adjacent wire pairs. This interference can cause signal distortion and increase the error rate, thereby reducing the quality and efficiency of data transmission. Especially in high-frequency data transmission scenarios, the problem of crosstalk interference is more serious, which seriously restricts the application of flat data cables in the field of high-performance data transmission.

[0005] In addition, existing flat data cables usually lack effective support mechanisms in structure, and the sheath is prone to collapse under external force, further exacerbating the crosstalk interference between wire pairs, while also limiting the improvement of the overall voltage resistance of the data cable. This structural deficiency not only limits the application of the cable in high-density wiring environments, but also increases the cost of maintenance and replacement.

[0006] The disclosure of the above background art content is only used to assist in understanding the inventive concept and technical solutions of the present application, and it does not necessarily belong to the prior art of the present patent application, nor does it necessarily provide technical teaching; there is no clear evidence that the above-mentioned novelty and inventiveness of the present application. SUMMARY

[0007] In order to solve the above technical problems, the application provides a flat data cable and a preparation method thereof, so as to enhance the support, effectively inhibit the crosstalk interference between the wire pairs, improve the voltage resistance performance, ensure the signal transmission quality of the flat data cable, and reduce the maintenance and replacement costs.

[0008] In order to achieve the above purpose, the technical scheme of the application is as follows: In one aspect, the application provides a flat data cable, comprising: a plurality of insulated single wires, a plurality of wire pair groups formed by twisting two insulated single wires at different pitches; a sheath arranged outside the wire pair groups; a framework integrally formed with the sheath, the framework being composed of a hollow structure formed in the sheath, for isolating the wire pair groups and supporting the sheath.

[0009] The application provides a flat data cable and a preparation method thereof, so as to enhance the support, effectively inhibit the crosstalk interference between the wire pairs, improve the voltage resistance performance, ensure the signal transmission quality of the flat data cable, and reduce the maintenance and replacement costs.

[0010] As a preferred technical scheme, the twisting pitches of the wire pair groups are different, the difference between the twisting pitches is 2mm-4mm, and the twisting direction is left or right.

[0011] As a preferred technical scheme, the thickness of the spacer for isolating the wire pair groups in the framework is 0.35㎜-0.6㎜.

[0012] As a preferred technical scheme, a plurality of hollow structures are arranged, and the height of the inner cavity of the hollow structure is 1.8㎜-2.2㎜.

[0013] As a preferred technical scheme, the interface bonding force between the framework and the sheath is enhanced through a co-extrusion process.

[0014] As a preferred technical scheme, the insulated single wire comprises a copper conductor and a polyethylene insulation layer wrapped outside the copper conductor.

[0015] As a preferred technical scheme, the sheath is a flat sheath, and the material of the sheath is nylon.

[0016] In another aspect, the application provides a preparation method of a flat data cable, which prepares the flat data cable according to any one of the above aspects, and comprises the following steps: S1 twisting a plurality of insulated single wires at different pitches to form a plurality of wire pair groups; S2 parallelly arranging the plurality of wire pair groups and penetrating them into an extrusion mold core with a plurality of holes; S3 extruding a sheath outside the four alignment groups through the extrusion mold core, the sheath forming a framework with multiple hollow structures between adjacent alignment groups, the framework being integrally formed with the nylon sheath.

[0017] As a preferred technical solution, the step S1 of preparing the insulated single wire comprises the following steps: A plurality of copper conductors are coated with different color polyethylene insulation layers on the outside to form a plurality of insulated single wires.

[0018] As a preferred technical solution, the step S3 of extruding the sheath has an extrusion molding temperature of 200-250 DEG C and an extrusion molding pressure of 10-15 MPa.

[0019] The flat data cable and the preparation method thereof have the following beneficial effects: 1) The flat data cable and the preparation method thereof can enhance the support, effectively suppress crosstalk interference between the wire pairs, and improve the voltage resistance performance, thereby ensuring the signal transmission quality of the flat data cable and reducing the maintenance and replacement costs.

[0020] 2) The flat data cable and the preparation method thereof are referred to the communication industry standard YD / T 1019-2023 "Polyolefin Insulated Horizontal Pair Cable for Digital Communication"; a test voltage (for example, 1500V AC or 3000V DC) much higher than the rated working voltage is applied between the copper conductor and the sheath, and maintained for a specified time (for example, 1 minute), mainly to investigate whether the insulation layer and the sheath are broken down. The framework integrally formed with the sheath can effectively increase the creepage distance and provide stable support for the insulation material, thereby expectedly significantly improving the voltage resistance level. After testing, the flat data cable with the framework structure successfully passes the specified voltage resistance test without breakdown phenomenon. The breakdown voltage value is expected to be increased by more than 20% compared with the traditional flat cable without the framework structure, thereby improving the voltage resistance performance. The framework and the sheath are integrally formed, and the framework is composed of the hollow structure formed in the sheath, and forms a rigid support system with the sheath. When external pressure acts on the cable body, the framework disperses the stress through the following mechanisms: the hollow design of the framework can absorb part of the impact energy for buffering, avoiding the direct conduction of pressure to the internal wire pair group; the close fit of the framework and the sheath forms a distributed stress surface, preventing local collapse. Experiments show that this structure can reduce the deformation amount of the cable under the same pressure by more than 40%; the framework separates multiple alignment groups into independent chambers, avoiding physical contact between the wire pairs due to extrusion. Traditional flat cables are prone to cause wire pair displacement when under pressure, which in turn causes insulation layer wear or conductor short circuit. The physical isolation of the framework reduces the risk of contact between the wire pairs to less than 1 / 5 of the traditional design, thereby reducing the maintenance and replacement costs. Near-end crosstalk is one of the key parameters to measure crosstalk interference. The skeleton of the present application plays a role in physically isolating each pair of wire groups, and this structure can effectively reduce the electromagnetic coupling between wire pairs. In addition, the wire groups are twisted with different pitches, which can also disrupt the periodic superposition of interference signals and further suppress crosstalk. Under the same test conditions, the near-end crosstalk attenuation value of the flat data cable provided by the present application should be better than that of the same product without a skeleton. Specifically, at a frequency of 100MHz, the near-end crosstalk margin is expected to be increased by more than 3dB compared to conventional products, thereby ensuring that it meets the strict requirements of relevant Cat5e (enhanced version of five categories) and / or Cat6 (six categories of wire) standards in high-speed data transmission, effectively suppressing crosstalk interference between wire pairs; by improving the voltage withstand performance and suppressing crosstalk interference between wire pairs, more stable and reliable signal transmission can be achieved, and the signal transmission quality of the flat data cable is improved. BRIEF DESCRIPTION OF DRAWINGS

[0021] Figure 1 A structural schematic diagram of a flat data cable provided by the present application is shown in the figure. Wherein, 1-copper conductor; 2-polyethylene insulation layer; 3-skeleton; 4-sheath; 5-isolator. DETAILED DESCRIPTION

[0022] The preferred embodiments of the present application will be described in detail below with reference to the accompanying drawings.

[0023] As shown in the figure, the flat data cable provided by the present application comprises: Figure 1 a plurality of insulated single wires, a plurality of pairs of wire groups twisted with different pitches from two insulated single wires; a sheath 4 arranged outside the pair of wire groups; a skeleton 3 integrally formed with the sheath 4, the skeleton 3 being composed of a hollow structure formed inside the sheath 4, for isolating the pair of wire groups and supporting the sheath 4. The present application provides a flat data cable to enhance support, effectively suppress crosstalk interference between wire pairs, and improve voltage withstand performance, thereby ensuring the signal transmission quality of the flat data cable and reducing maintenance and replacement costs.

[0024]

[0025] ​Referring to the communication industry standard YD / T1019-2023 "Polyolefin Insulated Horizontal Pair Cable for Digital Communication"; a test voltage (e.g. 1500V AC or 3000V DC) much higher than the rated working voltage is applied between the cable conductor 1 and the sheath 4 and maintained for a specified time (e.g. 1 minute), mainly to investigate whether the insulation layer 2 and the sheath 4 are punctured. The skeleton 3 integrally formed with the sheath 4 has a hollow structure inside, which can effectively increase the creepage distance and provide stable support for the insulation material, thereby expected to significantly improve the withstand voltage level; after testing, the flat data cable with the skeleton 3 structure successfully passes the specified withstand voltage test without puncture phenomenon. The breakdown voltage value is expected to be increased by more than 20% compared with the traditional flat cable without such a skeleton structure, improving the withstand voltage performance; The skeleton 3 and the sheath 4 are integrally formed, and the skeleton 3 is formed by the hollow structure inside the sheath 4, forming a rigid support system with the sheath 4. When external pressure acts on the cable body, the skeleton 3 disperses the stress through the following mechanism: the hollow design of the skeleton 3 can absorb part of the impact energy for buffering, avoiding the direct transmission of pressure to the internal wire pair group; the close fit of the skeleton 3 and the sheath 4 forms a distributed stress surface, preventing local collapse. Experiments show that this structure can reduce the deformation of the cable under the same pressure by more than 40%; the skeleton 3 separates multiple wire pairs into independent chambers, avoiding physical contact between wire pairs due to extrusion. Traditional flat cables are prone to wire pair displacement when under pressure, which can cause insulation layer wear or conductor short circuit, while the present application reduces the risk of contact between wire pairs to less than 1 / 5 of the traditional design through physical isolation of the skeleton, reducing maintenance and replacement costs; Near-end crosstalk is one of the key parameters for measuring crosstalk interference. The skeleton 3 of the present application plays a role in physically isolating each wire pair group, which can effectively reduce the electromagnetic coupling between wire pairs. In addition, the wire pairs are twisted with different pitches, which can also disrupt the periodic superposition of interference signals, further suppressing crosstalk. Under the same test conditions, the flat data cable provided by the present application has a near-end crosstalk attenuation value superior to similar products without a skeleton design. Specifically, at a frequency of 100MHz, the near-end crosstalk margin is expected to be improved by more than 3dB compared to conventional products, thereby ensuring that it meets the strict requirements of relevant Cat5e (Enhanced Category 5) and / or Cat6 (Category 6) standards in high-speed data transmission, effectively suppressing crosstalk interference between wire pairs; by improving the withstand voltage performance and suppressing crosstalk interference between wire pairs, more stable and reliable signal transmission can be achieved, improving the signal transmission quality of the flat data cable.

[0026] Preferably, the twisting pitch of each pair of wires in the group is different, the difference between the twisting pitches is 2-4 mm, and the twisting direction is left or right; the difference between the twisting pitches is preferably 2 mm, 3 mm or 4 mm, and the specific point values included in the protection scope are not listed again in the present application for the sake of brevity and conciseness; when adjacent wire pairs have the same or similar twisting pitch, the interference signals are likely to be superimposed at the same position during transmission, thereby enhancing crosstalk. By making the twisting pitch of each wire pair different, the synchronization can be destroyed, the interference signals can be generated at different positions, and the crosstalk can be significantly reduced by mutual cancellation; the combination of left and right twisting can further destroy the symmetry of the interference signals and enhance the anti-interference ability; when the difference between the twisting pitches is 3.0 mm, the NEXT attenuation at a frequency of 100 MHz is greater than or equal to 60 dB, which is better than that of a conventional cable (50 dB).

[0027] Preferably, the thickness of the isolation member 5 separating the wire pairs in the skeleton 3 is 0.35-0.6 mm; the thickness of the isolation member 5 separating the wire pairs in the skeleton 3 is preferably 0.35 mm, 0.4 mm, 0.45 mm, 0.5 mm, 0.55 mm or 0.6 mm, and the specific point values included in the protection scope are not listed again in the present application for the sake of brevity and conciseness; by accurately controlling the thickness (0.35-0.6 mm), the isolation member 5 can effectively prevent the adjacent wire groups from being in physical contact when being bent or pressed, thereby reducing the risk of short circuit; this thickness range can balance the mechanical strength and signal isolation requirements, suppress electromagnetic interference, reduce crosstalk between wire groups, and provide sufficient rigidity without excessively increasing the overall hardness of the cable, which is suitable for high-density wiring requirements and plays an important role in physical support and isolation.

[0028] Preferably, a plurality of hollow structures are provided, and the height of the inner cavity of the hollow structure is 1.8-2.2 mm; the height of the inner cavity of the hollow structure is preferably 1.8 mm, 1.9 mm, 2.0 mm, 2.1 mm or 2.2 mm, and the specific point values included in the protection scope are not listed again in the present application for the sake of brevity and conciseness; by the multi-cavity design, the electromagnetic interference (EMI) between adjacent wire groups can be effectively isolated, and signal crosstalk (such as near-end crosstalk NEXT) can be reduced; the accurate inner cavity height (1.8-2.2 mm) can control the distance between the wire groups, maintain the consistency of the characteristic impedance, and improve the stability of high-speed data transmission; the multi-cavity structure can disperse external pressure while maintaining the overall flexibility of the cable, which is suitable for high-density wiring scenarios; the inner cavity height design can reduce the friction between the wire groups when bending and prolong the service life.

[0029] Preferably, the interface bonding force between the skeleton 3 and the sheath 4 is enhanced by a co-extrusion process; the enhanced interface bonding force can effectively prevent the relative displacement or delamination of the skeleton and the sheath when the cable is bent, stretched or subjected to external force, ensuring the stability and mechanical strength of the overall structure of the cable; the tightly bonded interface can reduce signal reflection and loss caused by micro-motion or gap between materials, helping to maintain the integrity of signal transmission.

[0030] Preferably, the insulated single wire comprises a copper conductor 1 and a polyethylene insulation layer 2 wrapped outside the copper conductor 1; the polyethylene insulation layer 2 reduces signal interference and loss by maintaining electrical isolation between copper conductors 1, ensuring the accuracy of high-frequency data transmission.

[0031] Preferably, the sheath 4 is a flat sheath, and the material of the sheath 4 is nylon; nylon material has high strength and wear resistance, which can effectively resist external force pulling, friction and extrusion of the cable during laying, installation and daily use, and prevent damage to the cable insulation layer; nylon has a lower density (such as nylon 6 density is only 83% of polyvinyl chloride), using nylon sheath can reduce the weight of the cable, reduce the outer diameter of the finished product, thereby reducing the storage and transportation cost, and accommodating more wires or larger section wires in limited space; nylon has no obvious thermal shrinkage, and when combined with the polyvinyl chloride insulation layer, it can significantly reduce the overall thermal shrinkage of the cable, reduce the risk of conductor exposure at the connection, and improve the safety of the line.

[0032] In another aspect, the present application provides a preparation method of a flat data cable, which is prepared according to any one of the above embodiments, comprising the following steps: S1 twisting a plurality of insulated single wires at different pitches to form a plurality of wire pairs; S2 parallelly arranging the plurality of wire pairs and inserting them into an extrusion mold core with a plurality of holes; S3 forming a sheath 4 around the four wire pairs by the extrusion mold core, the sheath 4 forms a skeleton 3 with a plurality of hollow structures between adjacent wire pairs, and the skeleton 3 is integrally formed with the nylon sheath 4.

[0033] The present application provides a preparation method of a flat data cable to enhance the supportability, effectively suppress crosstalk interference between wire pairs, and improve the voltage resistance performance, thereby ensuring the signal transmission quality of the flat data cable and reducing the maintenance and replacement cost.

[0034] Preferably, the preparation of the insulated single wire in step S1 comprises the following steps: A plurality of copper conductors 1 are coated with polyethylene insulation layers 2 of different colors on the outer side to form a plurality of insulated single wires; after the polyethylene insulation layer 2 is coated on the copper conductor 1, short circuit between the copper conductors 1 or with the external environment can be effectively prevented, and stable current transmission is ensured; the polyethylene (PE) insulation layer 2 is particularly suitable for high-frequency signal transmission due to its low dielectric constant (≈2.3) and low loss characteristics, and signal attenuation can be reduced; the insulation layers of different colors facilitate the differentiation of the plurality of insulated single wires, the wire pairs in complex structures such as twisted pairs can be quickly identified, and the installation and maintenance efficiency is improved.

[0035] Preferably, the temperature for extrusion molding of the sheath 4 in step S3 is 200-250℃, and the extrusion molding pressure is 10-15MPa; 200-250℃ is the typical melting temperature range of thermoplastics such as nylon, which ensures that the plastic is fully plasticized to form a uniform melt, avoiding surface defects of the sheath caused by unmelted particles; the pressure of 10-15MPa makes the melt tightly fill the gap between the mold cores, eliminates pores inside the sheath, and improves the density and compressive strength; the combination of temperature and pressure can optimize the crystallinity of the nylon sheath, enhance its environmental stress cracking resistance, and at the same time reduce the shrinkage rate during extrusion, ensuring the dimensional stability of the flat cable.

[0036] As shown in Figure 1 The present application provides a flat data cable, which comprises: 8 copper conductors 1 and polyethylene insulation layers 2 of 8 colors of blue, white blue, orange, white orange, green, white green, brown, and white brown respectively coated on the outer side of the copper conductors 1 to form insulated single wires of different colors; two insulated single wires of blue and white blue, two insulated single wires of orange and white orange, two insulated single wires of green and white green, and two insulated single wires of brown and white brown are twisted at different pitches to form four wire pair groups, wherein the twisting pitch difference is 2mm-4mm, the twisting direction is left or right, and a sheath 4 is arranged on the outer side of the wire pair groups; a framework 3 is integrally formed with the sheath 4, the framework 3 is composed of a hollow structure formed in the sheath 4, and is used for isolating the wire pair groups and supporting the sheath 4; the thickness of the spacer for isolating the wire pair groups in the framework 3 is 0.35㎜-0.6㎜, the hollow structure is provided with 3, the inner cavity height of the hollow structure is 1.8㎜-2.2㎜, the sheath 4 is a flat sheath, and the material of the sheath 4 is nylon; the structure of the flat data cable enhances the supportability, effectively suppresses crosstalk interference between the wire pairs, and improves the voltage resistance performance, thereby ensuring the signal transmission quality of the flat data cable and reducing the maintenance and replacement cost.

[0037] It is to be understood that the present application is described by way of example only, and that modifications or alterations can be made to the features and embodiments described without departing from the spirit and scope of the application. In addition, modifications can be made to the features and embodiments described to adapt them to particular situations and materials without departing from the spirit and scope of the application. Accordingly, the present application is not limited to the specific embodiments described herein, but rather only by the claims which follow, all variations and equivalents which fall within the ranges of the claims being intended to be embraced herein.

Claims

1. A flat data cable, characterized in that, The utility model relates to a flat type data cable, comprising: a plurality of insulated single wires, a plurality of pairs of wires formed by twisting two insulated single wires at different pitches; a sheath arranged outside the pairs of wires; a skeleton integrally formed with the sheath, the skeleton being formed by a hollow structure formed inside the sheath, for isolating the pairs of wires and supporting the sheath.

2. The flat data cable of claim 1, wherein, The twisting pitches of the pairs of wires are different, the difference between the twisting pitches being 2-4 mm, and the twisting direction being leftward or rightward.

3. The flat data cable of claim 1, wherein, The thickness of the isolating member inside the skeleton for isolating the pairs of wires is 0.35-0.6 mm.

4. The flat data cable of claim 1, wherein, The hollow structure is provided in multiple, and the height of the inner cavity of the hollow structure is 1.8-2.2 mm.

5. The flat data cable of claim 1, wherein, The interface bonding force between the skeleton and the sheath is enhanced by a co-extrusion process.

6. The flat data cable of claim 1, wherein, The insulated single wire comprises a copper conductor and a polyethylene insulation layer wrapped outside the copper conductor.

7. The flat data cable of claim 1, wherein, The sheath is a flat type sheath, and the material of the sheath is nylon.

8. A method of manufacturing a flat data cable, characterized by The utility model relates to a flat type data cable, comprising: S1 twisting a plurality of insulated single wires at different pitches to form a plurality of pairs of wires; S2 parallelly arranging the plurality of pairs of wires and passing them through an extrusion die core with a plurality of holes; S3 extruding the sheath outside the four pairs of wires by the extrusion die core, the sheath forming a skeleton with a plurality of hollow structures between adjacent pairs of wires, the skeleton being integrally formed with the nylon sheath.

9. The method of claim 8, wherein the flat data cable is prepared by the steps of: In step S1, the insulated single wire is prepared by: wrapping a polyethylene insulation layer of different colors outside a plurality of copper conductors to form a plurality of insulated single wires.

10. The method of claim 8, wherein the flat data cable is prepared by the steps of: In step S3, the extrusion molding temperature of the sheath is 200-250 ℃, and the extrusion molding pressure is 10-15 MPa.

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