Flexible anti-electromagnetic pulse cable assembly

Abstract

The utility model discloses a flexible anti-electromagnetic pulse cable assembly which comprises a cable lead, a copper net sleeve, a PTFE film, a flexible anti-wave sleeve, a braided sheath and an electric connector. The cable conductor is fixedly connected with the electric connector, the cable conductor is sleeved with a copper net sleeve in a penetrating mode, the copper net sleeve is wrapped with a PTFE film, the PTFE film is sleeved with a soft wave-proof sleeve in a penetrating mode, and the soft wave-proof sleeve is sleeved with a woven sheath in a penetrating mode; according to the technical scheme, the copper net sleeve and the soft wave-proof sleeve which have the advantages of being light in weight, small in hole, good in shielding performance, good in weldability and the like, and the PTFE film and the woven sheath which have the advantages of being large in expansibility, high in strength, resistant to abrasion, soft, light in weight and the like are adopted for shielding protection, and therefore the assembly is light in weight, good in signal shielding effect and high in strength.

Description

Technical Field

[0001] The utility model relates to the technical field of cable assembly assembly, in particular to a flexible electromagnetic pulse protection cable assembly. Background Art

[0002] At present, the cable assemblies supporting electrical equipment are constantly developing in the direction of miniaturization, light weight, modularization, high reliability, long life and anti-electromagnetic interference. Cable assemblies are composed of electrical connectors, wires, shielding layers, sheaths, etc. to realize signal transmission, control and electrical connection between electrical equipment. The manufacturing process of cable assemblies mainly includes production preparation, blank cutting and production, welding crimping assembly, shielding treatment, plugging and pouring, tail cover packaging and other processes. At present, there are many wires used to transmit signals in cable assemblies, and some cable assemblies even have more than 200 internal wires. If a molded cable with a multi-layer shielding structure is selected, the cable assembly will be too thick and hard as a whole, the turning radius is too large, and it is difficult to install in a small space. On the other hand, since electrical equipment has many external interfaces and is distributed in different parts, it needs to be transferred multiple times through cable assemblies. Once threatened by electromagnetic pulses, it is very easy to generate coupling current and voltage to interfere with or even destroy the cable transmission signal, and even cause serious damage to the electronic components in the electrical equipment. On the other hand, due to the poor matching between the cable and the electrical connector, the shielding continuity at the connection between the cable and the electrical connector is poor, which easily generates electromagnetic leakage at the gap, and greatly reduces the overall electromagnetic shielding performance of the cable assembly. Therefore, it is necessary to comprehensively consider various factors to improve the electromagnetic pulse protection structure of the cable assembly, so that the electromagnetic shielding performance of the cable assembly can be improved and the signal transmission stability can be guaranteed in the electromagnetic pulse environment. Utility Model Content

[0003] The utility model aims to solve the above technical problems and provide a flexible electromagnetic pulse protection cable assembly.

[0004] In order to achieve the above purpose, the utility model adopts the following technical solutions:

[0005] The utility model provides a flexible electromagnetic pulse protection cable assembly, comprising a cable conductor, a copper mesh sleeve, a PTFE film, a soft wave-proof sleeve, a braided sheath and an electric connector; the cable conductor is fixedly connected to the electric connector, the cable conductor is sheathed with a copper mesh sleeve, the copper mesh sleeve is wrapped with a PTFE film, the PTFE membrane is sheathed with a soft wave-proof sleeve, and the soft wave-proof sleeve is sheathed with a braided sheath.

[0006] Preferably, the ends of the copper mesh sleeve, the soft wave-proof sleeve and the braided sheath extend and are sleeved onto the tail cover of the electrical connector.

[0007] Preferably, a conductive cloth tape is wound around the outside of the soft wave-proof sleeve, and the conductive cloth tape is wound in at least 2 to 3 layers.

[0008] Preferably, the braided sheath is connected to the rear cover of the electrical connector by binding, and an insulating tape is wound around the outside of the braided sheath.

[0009] Preferably, the cable conductor includes a trunk cable conductor and a branch cable conductor, and the trunk cable conductor and the branch cable conductor are both covered with a copper mesh sleeve, a PTFE membrane, a soft wave-proof sleeve and a braided sheath. An electromagnetic shielding tape is wrapped around the copper mesh sleeve at the joint of the trunk cable conductor and the branch cable conductor, and a conductive cloth tape is wrapped around the connection between the branch cable conductor and the soft wave-proof sleeve on the trunk cable conductor.

[0010] The utility model provides a flexible electromagnetic pulse protection cable assembly, which has the following beneficial effects:

[0011] 1. The cable assembly adopts a shielding protection structure of copper mesh, PTFE film, soft wave-proof sleeve and braided sheath, and uses multi-layer shielding materials for signal shielding. This structure uses copper mesh and soft wave-proof sleeve with the advantages of light weight, small pores, good shielding performance and good weldability, as well as PTFE membrane and braided sheath with the advantages of large expansibility, high strength, wear resistance, softness and lightness for shielding protection, so that the component is light in weight, good in signal shielding effect and high in strength.

[0012] 2. This technical solution, by wrapping the PTFE film around the copper mesh, not only ensures the tightness and continuity of the copper mesh sleeve, but also increases the reflection loss of electromagnetic waves in the shielding layer and the non-shielding layer, thereby improving the electromagnetic shielding effectiveness of the cable assembly. Since the electromagnetic shielding performance of high-permeability materials is better than that of high-conductivity materials in low-frequency environments, and the opposite is true in high-frequency environments, the combination of high-conductivity and high-permeability materials can broaden the shielding range of cable assemblies. In addition, electromagnetic shielding shields radiation sources through the reflection and absorption of electromagnetic waves by metal shielding materials. Therefore, this cable assembly uses multi-layer shielding in the shielding structure to increase the reflection of electromagnetic waves between layers and improve the shielding effect.

[0013] 3. Due to the requirement of interconnection of electrical systems, cable assemblies will have branch cable conductors, and the continuity of the shielding material will be broken at the connection between the main cable conductor and the branch cable conductor, thus causing a weak link in the shielding. The branch shielding enhanced protection method in this application uses a combination of welding and binding to shield the copper mesh sleeve and soft wave-proof sleeve at the main cable conductor and the branch cable conductor, and at the same time uses lightweight tinned copper braided electromagnetic shielding tape, conductive cloth tape and other protective materials to enhance protection, thereby enhancing the reliability and continuity of the shielding connection between the main cable conductor and the branch cable conductor of the cable assembly; and the shielding materials wrapped between the main cable conductor and the branch cable conductor of the cable conductor are superimposed on each other, thereby greatly enhancing the reliability and continuity of the shielding connection between the main cable conductor and the branch cable conductor of the cable assembly, and improving the shielding performance.

[0014] 5. This technical solution has the advantages of good operational consistency, high shielding integrity, strong product assembly adaptability, and long product service life. It can be adapted to the electrical assembly of various electrical equipment and used in complex and diverse electromagnetic environments. BRIEF DESCRIPTION OF THE DRAWINGS

[0015] The specific implementation of the utility model is further described in detail below with reference to the accompanying drawings:

[0016] Figure 1 It is a structural schematic diagram of the cable assembly in the utility model;

[0017] Figure 2 A schematic diagram of a manufacturing process of a flexible electromagnetic pulse protection cable assembly;

[0018] Figure 3 It is a schematic diagram of the structure of the cable in the cable assembly of the utility model;

[0019] Figure 4 Schematic diagram of the connection between the cable and the electrical connector in the utility model Figure 1 ;

[0020] Figure 5 Schematic diagram of the connection between the cable and the electrical connector in the utility model Figure 2 ;

[0021] Figure 6 Schematic diagram of the connection between the cable and the electrical connector in the utility model Figure 3 ;

[0022] Figure 7 This is a schematic diagram of the connection between the main cable conductor and the branch cable conductor in the utility model. Figure 1 ;

[0023] Figure 8 This is a schematic diagram of the connection between the main cable conductor and the branch cable conductor in the utility model. Figure 2.

[0024] Explanation of the numbers in the figure: 1. Cable conductor; 2. Copper mesh sleeve; 3. PTFE membrane; 4. Soft wave-proof sleeve; 5. Braided sheath; 6. Electrical connector; 7. Conductive cloth tape; 8. Electromagnetic shielding tape. DETAILED DESCRIPTION

[0025] It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0026] The following will be combined with the drawings in the embodiments of the utility model to clearly and completely describe the technical solutions in the embodiments of the utility model. Obviously, the described embodiments are only part of the embodiments of the utility model, not all of the embodiments. Based on the embodiments of the utility model, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the utility model.

[0027] It should be noted that all directional indications in the embodiments of the present invention (such as up-down-left-right-front-back...) are only used to explain the relative position relationship - movement status, etc. between the components under a certain specific posture (as shown in the accompanying drawings). If the specific posture changes, the directional indication will also change accordingly. The connection can be a direct connection or an indirect connection.

[0028] like Figure 1 As shown, an embodiment of the utility model provides a flexible electromagnetic pulse protection cable assembly, comprising a cable conductor 1, a copper mesh sleeve 2, a PTFE membrane 3, a soft wave-proof sleeve 4, a braided sheath 5 and an electrical connector 6; the cable conductor 1 is fixedly connected to the electrical connector 6, the cable conductor 1 is sheathed with a copper mesh sleeve 2, the copper mesh sleeve 2 is wrapped with a PTFE membrane 3, the PTFE membrane 3 is sheathed with a soft wave-proof sleeve 4, and the soft wave-proof sleeve 4 is sheathed with a braided sheath 5.

[0029] Specifically, the ends of the copper mesh sleeve 2 , the soft wave-proof sleeve 4 and the braided sheath 5 extend and are sleeved onto the tail cover of the electrical connector 6 .

[0030] Specifically, a conductive cloth tape 7 is wound around the outside of the soft wave-proof sleeve 4, and the conductive cloth tape 7 is wound in at least 2 to 3 layers.

[0031] Specifically, the braided sheath 5 is connected to the rear cover of the electrical connector 6 by binding, and an insulating tape is wound around the outside of the braided sheath 5 .

[0032] Specifically, the cable conductor 1 includes a trunk cable conductor and a branch cable conductor, and the trunk cable conductor and the branch cable conductor are both covered with a copper mesh sleeve 2, a PTFE membrane 3, a soft wave-proof sleeve 4 and a braided sheath 5. An electromagnetic shielding tape 8 is wrapped around the copper mesh sleeve 2 at the joint of the trunk cable conductor and the branch cable conductor, and a conductive cloth tape 7 is wrapped around the connection between the branch cable conductor and the soft wave-proof sleeve 4 on the trunk cable conductor.

[0033] The manufacturing process of the flexible electromagnetic pulse protection cable assembly in this technical solution includes the following steps:

[0034] Step S1: cutting and laying the cable conductor 1 according to the connection relationship and length of the cable assembly, and selecting the copper mesh 2, soft wave-proof sleeve 4 and braided sheath 5 of suitable specifications according to the length and diameter of the cable assembly; wherein the length of the copper mesh 2, soft wave-proof sleeve 4 and braided sheath 5 is greater than the length of the cable conductor 1, and the diameter is adapted to the tail cover of the electric connector 6, so that the copper mesh, soft wave-proof sleeve and braided sheath are covered with the tail cover of the electric connector. There is a margin for shielding treatment; the metal wire of the copper mesh 2 is tin bronze after heat treatment; the PTFE film 3 is a semi-oriented film with a thickness of 0.03mm; the soft wave-proof sleeve 4 is a shielding sleeve woven with tinned copper, and the braiding density is ≥95%; the braided sheath 5 is a nylon braided sleeve, a nylon silk braided sleeve or an aramid silk braided sleeve;

[0035] Step S2: After the cable conductor 1 is laid, the end of the cable conductor 1 is wrapped with insulating tape for protection to prevent the conductor from piercing the copper mesh sleeve 2 when inserting the copper mesh; the copper mesh sleeve 2 is inserted from one end to the other end of the cable conductor 1;

[0036] Step S3: After the cable conductor 1 is sheathed in the copper mesh 2, a PTFE film 3 is wound around the outside of the copper mesh 2, wherein the PTFE film 3 is spirally wound and the overlapping width of adjacent turns of the PTFE film 3 is not less than 1 / 2 of the width of the PTFE film 3, and the ends and joints are tied securely;

[0037] Step S4: After the PTFE film 3 is wound, a soft wave-proof sleeve 4 is put on the outside of the PTFE film 3 on the cable conductor 1 from one end to the other end;

[0038] Step S5: After the soft wave-proof sleeve 4 is put on, a braided sheath 5 is put on the soft wave-proof sleeve 4 on the cable conductor 1 for protection, and the braided sheath 5 is attached to the soft wave-proof sleeve 4. Figure 3 As shown;

[0039] Step S6: After the copper mesh sleeve 2, PTFE membrane 3, soft wave-proof sleeve 4, and braided sleeve 5 are sequentially sleeved and wound, the cable conductor 1 and the inner conductor plug in the electrical connector 6 are welded and crimped according to the wiring relationship of the cable assembly; after the welding and crimping are completed, the welding and crimping quality is checked;

[0040] Step S7: After the welding and crimping assembly is completed, the gaps between the welding cups and the tail cover cavity of the electrical connector 6 are sealed with potting glue; the potting glue used in the sealing process is an organic silicone gel or organic silicone rubber with good shock resistance, moisture resistance, electrical insulation performance and good fluidity, so that the colloid can cover the dense wires and welding points; during potting, the colloid should be injected evenly without bubbles and leakage; the curing time of the colloid should be sufficient to ensure that the potting glue is completely cured, thereby improving the electrical insulation performance, reliability and service life of the cable assembly;

[0041] Step S8: After the plugging and potting is completed, the tail cover of the electrical connector is encapsulated and protected by an insulating material such as a self-adhesive tape or a soft polyvinyl chloride insulating tape, and the insulating material firmly fixes the wires at the outlet of the tail cover;

[0042] Step S9: After the rear cover packaging is completed, a 360-degree circumferential shielding process is performed on the cable end in layers, and the multi-layer shielding protection material is connected to the rear cover of the electrical connector 6 .

[0043] Specifically, a copper mesh sleeve 2 (such as Figure 4 As shown), a soft wave-proof sleeve 4 is welded in the second groove (as shown Figure 5 As shown), a conductive cloth tape 7 is wound around the soft wave-proof sleeve 4 (as shown Figure 6 As shown), then tie the braided sheath 5 firmly on the tail cover of the electrical connector 6 or at the outlet of the tail cover, and wrap it with 3 to 4 layers of insulating tape for protection. When welding, use the wire core wire or silver-plated copper wire to wrap the copper mesh sleeve 2 and the soft wave-proof sleeve 4 2 to 3 turns respectively and fix them in the groove of the tail cover of the electrical connector 6, and then perform tin-plating welding in the entire groove; after welding, trim the edges of the copper mesh sleeve 2 and the soft wave-proof sleeve 4; wrap the conductive cloth tape 7 with at least 2 to 3 layers, and the adjacent turns of the conductive cloth tape 7 are superimposed and wrapped with not less than 1 / 2 of the width of the conductive cloth tape 7. The winding should be uniform, and the outer surface should be smooth and flat without obvious wrinkles. Among them, the shielding effectiveness of the conductive cloth tape is ≥60dB.

[0044] In another embodiment, a manufacturing process of a flexible electromagnetic pulse protection cable assembly also includes a branch shielding enhanced protection method, which is applied to the manufacture of a cable assembly composed of a trunk cable conductor and a branch cable conductor. On the basis of the above manufacturing process, the following enhanced protection treatment is added: the trunk cable conductor and the branch cable conductor are both covered with a copper mesh sleeve 2, a PTFE membrane 3, a soft wave-proof sleeve 4 and a braided sheath 5, and the copper mesh sleeve 2 at the junction of the trunk cable conductor and the branch cable conductor is wrapped with an electromagnetic shielding tape 8, and the branch cable conductor is connected to the soft wave-proof sleeve 4 on the trunk cable conductor. A conductive cloth tape 7 is wrapped. Specifically:

[0045] In step S2, when the electrical connectors 6 connected by the cable conductors 1 in the cable assembly are in a one-to-many or many-to-many relationship, the cable conductors 1 between the main terminal and each branch terminal are respectively covered with a copper mesh sleeve 2, and then a copper mesh sleeve 2 is covered in each main terminal, and the diameters of the copper mesh sleeve 2 covered in the main terminal and the copper mesh sleeve 2 covered in the branch terminal should be respectively adapted to the rear cover of the main terminal electrical connector 6 and the rear cover of the branch terminal electrical connector 6, so that the copper mesh sleeve 2 is covered on the rear cover of the electrical connector for shielding;

[0046] In step S2, the copper mesh sleeve 2 on the main terminal covers the copper mesh sleeve 2 on the branch cable conductor by at least 20 mm, and then the electromagnetic shielding tape 8 is wrapped with 2 to 3 layers at the joint, and 3 to 4 rows of welding points are evenly welded outside the electromagnetic shielding tape 8 (such as Figure 7 The electromagnetic shielding tape 8 presses the joint of the copper mesh sleeve 2, and the electromagnetic shielding tape 8 and the copper mesh sleeve 2 are well welded without relative sliding;

[0047] In step S3, the main cable conductor and the branch cable conductor are wrapped with a PTFE film 3 outside the copper mesh sleeve 2, wherein the overlapping width of the PTFE film 3 wrapped in adjacent circles is not less than 1 / 2 of the PTFE film width, and are firmly tied at the ends and joints;

[0048] In step S4, after the PTFE membrane 3 is wrapped, the main cable conductor and the branch cable conductor are respectively covered with soft wave-proof sleeves 4, and the diameters of the soft wave-proof sleeves 4 covered by the main cable conductor and the soft wave-proof sleeves 4 covered by the branch cable conductor should be respectively adapted to the tail cover of the main cable conductor end electrical connector 6 and the tail cover of the branch cable conductor end electrical connector 6, so that the soft wave-proof sleeve 4 can be shielded on the tail cover of the electrical connector 6; before covering with the soft wave-proof sleeve 4, 2 to 3 layers of high-temperature glass cloth tape are wrapped around the inside of the soft wave-proof sleeve 4 at the connection position between the branch cable conductor and the main cable conductor for heat insulation protection; then the branch cable conductor The soft wave-proof sleeve 4 on the line is tied and fixed, and 2 to 3 layers of conductive cloth tape 7 are wrapped around the branch soft wave-proof sleeve 4; after the soft wave-proof sleeve 4 on the branch cable conductor is processed, the soft wave-proof sleeve 4 on the trunk cable conductor is covered and sleeved onto the outside of the soft wave-proof sleeve 4 on the branch cable conductor, with a covering length of not less than 40 mm. At the same time, 2 to 3 strands of shielding wire are picked from the soft wave-proof sleeve 4 on the branch cable conductor and welded together with the soft wave-proof sleeve 4 on the trunk cable conductor; the soft wave-proof sleeve 4 on the trunk cable conductor is tied and fixed, and 2 to 3 layers of conductive cloth tape 7 are wrapped around the connection between the branch cable conductor and the soft wave-proof sleeve 4 on the trunk cable conductor as a whole (such as Figure 8 As shown), wrapped with insulating tape for protection;

[0049] In step S5, after the soft wave-proof sleeve 4 is put on, the braided sleeve 5 is put on the main cable conductor and the branch cable conductor for protection respectively, and the braided sleeve 5 is attached to the soft wave-proof sleeve 4. The braided sleeve (5) on the branch cable conductor is tied and fixed, and the braided sleeve (5) on the main cable conductor is covered and put on the braided sleeve (5) on the branch cable conductor, with a covering length of not less than 40 mm. After the braided sleeve (5) on the main cable conductor is tied and fixed, it is wrapped with an insulating tape for protection.

[0050] The shielding effectiveness test of the cable assembly made by the above embodiment is carried out, and the test results are as follows:

[0051] Table 1: Shielding effectiveness test results of cable assemblies

[0052] frequency External field strength (kV / m) Shielding effectiveness (dB) 1 56.0 54.1 2 56.0 54.1 3 55.6 54.0 4 56.0 54.7 5 56.0 54.1 average value 55.9 54.2

[0053] The test results show that the average shielding effectiveness of the cable assembly produced by the method reaches 54.2dB, and the shielding effectiveness is not less than 30dB. The cable assembly produced by the method has good shielding effect.

[0054] The parts not involved in this technical solution can be implemented by using existing technologies.

[0055] The above shows and describes the basic principle, main features and characteristics of the utility model. Those skilled in the art should understand that the utility model is not limited by the above embodiments. The above embodiments and descriptions are only for explaining the principle of the utility model. Without departing from the spirit and scope of the utility model, the utility model may have various changes and improvements, which fall within the scope of the utility model to be protected. The scope of protection claimed by the utility model includes the attached claims and their equivalents.

Claims

1. A flexible electromagnetic pulse protection cable assembly, characterized in that: The invention comprises a cable conductor (1), a copper mesh sleeve (2), a PTFE film (3), a soft wave-proof sleeve (4), a braided sheath (5) and an electric connector (6); the cable conductor (1) is fixedly connected to the electric connector (6); the cable conductor (1) is sheathed with a copper mesh sleeve (2); the copper mesh sleeve (2) is wrapped with a PTFE film (3); the PTFE film (3) is sheathed with a soft wave-proof sleeve (4); the soft wave-proof sleeve (4) is sheathed with a braided sheath (5).

2. The flexible electromagnetic pulse protection cable assembly according to claim 1, characterized in that: The ends of the copper mesh sleeve (2), the soft wave-proof sleeve (4) and the braided sleeve (5) extend and are sleeved onto the tail cover of the electrical connector (6).

3. The flexible electromagnetic pulse protection cable assembly according to claim 1, characterized in that: A conductive cloth tape (7) is also wound around the outside of the soft wave-proof sleeve (4), and the conductive cloth tape (7) is wound in at least 2 to 3 layers.

4. The flexible electromagnetic pulse protection cable assembly according to claim 2, characterized in that: The braided sheath (5) is connected to the rear cover of the electrical connector (6) by binding, and an insulating tape is wound around the outside of the braided sheath (5).

5. The flexible electromagnetic pulse protection cable assembly according to claim 1, characterized in that: The cable conductor (1) comprises a trunk cable conductor and a branch cable conductor, wherein the trunk cable conductor and the branch cable conductor are both covered with a copper mesh sleeve (2), a PTFE film (3), a soft wave-proof sleeve (4) and a braided sheath (5), an electromagnetic shielding tape (8) is wrapped around the copper mesh sleeve (2) at the junction of the trunk cable conductor and the branch cable conductor, and a conductive cloth tape (7) is wrapped around the connection between the branch cable conductor and the soft wave-proof sleeve (4) on the trunk cable conductor.

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