Discontinuous aluminum foil, cable having the same, and cable manufacturing method

Abstract

The present application discloses a non-continuous aluminum foil and a non-shielded cable and a cable manufacturing method having the same, and relates to the technical field of data transmission cables. The non-continuous aluminum foil comprises a metal layer, on which a plurality of truncation grooves are arranged; a first insulating layer; a second insulating layer, wherein blank edges without the metal layer are formed on both sides of the first insulating layer and the second insulating layer; wherein, at the blank edges and the truncation grooves, the first insulating layer and the second insulating layer are bonded together by melting. The present application forms a closed accommodation cavity by bonding the first insulating layer and the second insulating layer at the blank edges and the truncation grooves together by melting, thereby better sealing the metal layer and further preventing the metal layer from generating electromagnetic interference to the cable core.

Description

Technical Field

[0001] The present application relates to the technical field of data transmission cables, and in particular to a discontinuous aluminum foil, a cable having the same, and a cable manufacturing method. Background Art

[0002] The existing CAT.6A unshielded twisted paired (UTP) cables generally do not have a shielding function, so some well-known technical means need to be used to improve their anti-interference ability to prevent adjacent cables from crosstalking with each other in common installation structures. For example, when installing the cables into bundles, use cables with different cabling pitches, or use a cross skeleton to isolate the wire pairs inside the cable and increase the gap between the wire pairs and the outer sheath. The contact area of ​​adjacent cables can also be reduced as much as possible, thereby reducing the mutual crosstalk interference between cables and wire pairs. Despite the adoption of the above-mentioned anti-interference measures, the existing UTP CAT.6A cables cannot completely eliminate external crosstalk interference, and additional protection measures are needed to prevent crosstalk and increase anti-interference capabilities.

[0003] At present, a non-continuous shielding tape has been proposed in the prior art, such as the Chinese invention patent with publication number CN108257728A. This solution sets a non-conductive gap on the shielding layer, which can prevent the signal in the shielding layer from being transmitted from one end of the cable to the other end to cause interference, and can avoid the use of drain wires in the cable, reducing the production cost and installation cost of the cable. However, the gap will also cause electromagnetic leakage, which greatly reduces the shielding effect of the metal shielding layer. Summary of the invention

[0004] The purpose of the present application is to provide a discontinuous aluminum foil and a non-shielded cable having the aluminum foil, which can avoid electromagnetic leakage in the gaps of the aluminum foil and improve the anti-interference ability of the non-shielded cable.

[0005] To achieve the above-mentioned purpose, the embodiment of the present application adopts the following technical scheme: a discontinuous aluminum foil, comprising: a metal layer, the metal layer is made of aluminum foil, and a plurality of truncation grooves are arranged on the metal layer, and the truncation grooves divide the metal layer into a plurality of discontinuous modules; a first insulating layer, the first insulating layer is arranged on one side of the metal layer, and the width of the first insulating layer is greater than that of the metal layer; a second insulating layer, the second insulating layer is arranged on the other side of the metal layer, and the width of the second insulating layer is equal to the width of the first insulating layer, so that blank edges without the metal layer are formed on both sides of the first insulating layer and the second insulating layer; wherein, at the blank edges and the truncation grooves, the first insulating layer and the second insulating layer are bonded together by melting.

[0006] In the above technical solution, the embodiment of the present application sets the first insulating layer and the second insulating layer on both sides of the metal layer. When it is wound on the cable core, the electromagnetic interference generated by the metal layer is blocked by the first insulating layer and the second insulating layer, and will not interfere with the cable core, avoiding the use of drain wires in the cable core, so that the cable can be better bent (that is, the minimum bending radius can be reduced), and thus winding can be performed without using a winding reel. Furthermore, the present application forms a closed accommodating cavity by fusing the first insulating layer and the second insulating layer at the blank edge and the truncation groove together to better seal the metal layer, further preventing the metal layer from generating electromagnetic interference to the cable core.

[0007] Further, according to an embodiment of the present application, the blank edges and the truncation grooves on both sides together form a accommodating cavity, and the accommodating cavity seals the metal layer.

[0008] Further, according to an embodiment of the present application, the first insulating layer and the second insulating layer are made of plastic film.

[0009] Further, according to an embodiment of the present application, the shape of the truncation groove is linear or wavy.

[0010] In order to achieve the above-mentioned purpose, the embodiment of the present application further discloses a cable, the cable comprising: a cable core, the cable core comprising a conductor; a shielding layer, the shielding layer is made of the aluminum foil as described above, the shielding layer is arranged on the outside of the cable core; a sheath layer, the sheath layer is arranged on the outside of the shielding layer

[0011] Further, according to an embodiment of the present application, the cable core includes: a cross frame, the cross frame and the inner side of the shielding layer form a accommodating cavity, and the accommodating cavity provides an accommodating space for the conductor.

[0012] Further, according to an embodiment of the present application, there are at least two conductors, and the conductors are spirally twisted to form at least one set of twisted pairs.

[0013] Further, according to an embodiment of the present application, the outside of the conductor is wrapped with an insulating layer.

[0014] Further, according to an embodiment of the present application, the shielding layer is wrapped around the outside of the cable core by coating or winding, and the shielding layers overlap at overlapping locations.

[0015] In order to achieve the above object, the embodiment of the present application further discloses a cable manufacturing method, which is used to manufacture the cable as described above, comprising the following steps:

[0016] Making twisted pair cables: prepare the raw material copper rod of the conductor, draw the copper rod, and then coat the copper wire with insulating material PE so that the outer side of the copper wire conductor is wrapped with an insulating layer; then, twist the two conductors with insulating layers into a twisted pair cable;

[0017] Making a cable core: installing the four twisted pair cables in the accommodating cavity of the cross frame by a cabling machine to make a cable core;

[0018] Add shielding layer and sheath layer: Wrap the shielding tape on the outside of the cable core by coating to form a shielding layer; finally, set the sheath layer on the outside of the shielding layer.

[0019] Compared with the prior art, this application has the following beneficial effects:. BRIEF DESCRIPTION OF THE DRAWINGS

[0020] The present application is further described below in conjunction with the accompanying drawings and embodiments.

[0021] Figure 1 It is a schematic diagram of the structure of an aluminum foil in this application.

[0022] Figure 2 yes Figure 1 Schematic diagram of the top view structure.

[0023] Figure 3 yes Figure 1 Schematic diagram of the side structure.

[0024] Figure 4 It is a structural schematic diagram of an unshielded cable in this application.

[0025] In the attached figure

[0026] 1. First insulating layer 2. Metal layer 3. Second insulating layer

[0027] 4. Blank edge 5. Cut-off groove

[0028] 10. Cable core 101, cross frame 102, accommodating cavity

[0029] 103, twisted pair 104, conductor 105, insulation layer

[0030] 20. Shielding layer

[0031] 30. Sheath layer DETAILED DESCRIPTION

[0032] In order to make the purpose and technical solution of the present invention clearly and completely described, and the advantages more clearly understood, the embodiments of the present invention are further described in detail with reference to the accompanying drawings. It should be understood that the specific embodiments described herein are part of the embodiments of the present invention, rather than all of the embodiments, and are only used to explain the embodiments of the present invention, and are not used to limit the embodiments of the present invention. All other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0033] In the description of the present invention, it should be noted that the terms "center", "middle", "upper", "lower", "left", "right", "inner", "outer", "top", "bottom", "side", "vertical", "horizontal" and the like indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, and are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operate in a specific orientation, and therefore cannot be understood as limiting the present invention. In addition, the terms "one", "first", "second", "third", "fourth", "fifth", "sixth" are used for descriptive purposes only, and cannot be understood as indicating or implying relative importance.

[0034] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "connected", and "connected" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0035] For the purpose of simplicity and illustration, the principles of the embodiments are mainly described by reference to examples. In the following description, many specific details are proposed to provide a thorough understanding of the embodiments. However, it is obvious that for those of ordinary skill in the art, these embodiments may not be limited to these specific details in practice. In some instances, known methods and structures are not described in detail to avoid making these embodiments unnecessarily difficult to understand. In addition, all embodiments can be used in combination with each other.

[0036] [Example 1]

[0037] Figure 1 A schematic diagram of the structure of an aluminum foil in this application is shown. Figure 2 yes Figure 1 A top view of Figure 3 yes Figure 1 Side view of the Figure 1-3As shown, the aluminum foil comprises a first insulating layer 1, a metal layer 2 and a second insulating layer 3, wherein the first insulating layer 1 and the second insulating layer 3 respectively cover both sides of the metal layer 2. The width of the first insulating layer 1 and the second insulating layer 3 is greater than that of the metal layer 2, so that blank edges 4 without the metal layer 2 are formed on both sides between the first insulating layer 1 and the second insulating layer 3. At the blank edges 4, the first insulating layer 1 and the second insulating layer 3 are bonded together by melting, so that a receiving cavity is formed between the blank edges 4 on both sides, and the metal layer 2 is sealed in the receiving cavity.

[0038] Furthermore, a plurality of truncation grooves 5 are provided on the metal layer 2, and the truncation grooves 5 are used to separate the metal layer 2 into a plurality of discontinuous modules, and the shape of the truncation grooves 5 can be linear or wavy. At the truncation grooves 5, the first insulation 1 and the second insulation 3 are bonded together by melting, so that the above-mentioned accommodation cavity is completely closed to prevent electromagnetic leakage from the gap of the aluminum foil.

[0039] In the above technical solution, the present application sets the first insulating layer 1 and the second insulating layer 3 on both sides of the metal layer 2. When it is wound on the cable core, the electromagnetic interference generated by the metal layer 2 is blocked by the first insulating layer 1 and the second insulating layer 3, and will not interfere with the cable core, avoiding the use of drainage wires in the cable core, so that the cable can be better bent (that is, the minimum bending radius can be reduced), and thus winding can be performed without using a winding reel. Furthermore, the present application forms a closed accommodating cavity by bonding the first insulating layer 1 and the second insulating layer 3 at the blank edge 4 and the truncation groove 5 together by melting, thereby better sealing the metal layer 2 and further preventing the metal layer 2 from generating electromagnetic interference to the cable core.

[0040] Specifically, the first insulating layer 1 and the second insulating layer 3 are both made of plastic films with insulating properties, such as polyethylene terephthalate PET, polyethylene naphthalate PEN, polypropylene PP and other film strips. In this embodiment, PET film strips are specifically used. The metal layer 2 is made of aluminum foil. This low-resistivity metal material can generate electromagnetic eddy currents, forming a counteracting effect on external electromagnetic waves, thereby achieving a shielding effect.

[0041] Furthermore, when the first insulating layer 1 and the second insulating layer 3 are both made of PET material, the melting temperature is 70-80°C.

[0042] [Example 2]

[0043] Figure 2 The specific structure of a non-shielded cable in the present application is shown, and the cable has a discontinuous aluminum foil as described in Example 1. Figure 2As shown, the cable includes a cable core 10, a shielding layer 20 and a sheath layer 30 from the inside to the outside, wherein the shielding layer 20 is formed by winding or coating the aluminum foil. To ensure its shielding effect, the overlapped parts of the shielding tape winding or coating overlap, and specifically in this embodiment, the overlap rate is greater than or equal to 25%. Since insulating materials (a first insulating layer 1 and a second insulating layer 3) are provided on both the inside and outside of the shielding layer 20, the metal layer 2 is isolated from the cable core 10 and the sheath layer 30. Therefore, when in use, the charge on the metal layer 2 will not generate electrostatic interference to the inside and outside of the cable. Compared with the existing FTP, there is no need to set up an additional drain line and perform grounding installation. Compared with the existing UTP, it has a better shielding effect.

[0044] In addition, in this embodiment, the cable core 10 includes a cross frame 101, and the cross frame 101 and the inner side of the shielding layer form four relatively closed accommodating cavities 102, and the accommodating cavity 102 is installed with a twisted pair 103, and the twisted pair 103 is formed by spirally twisting two conductors 104, and the outer side of the conductor 104 is wrapped with an insulating layer 105. Among them, the cross frame 101 and the insulating layer 105 are specifically made of high-density PE material in this embodiment. The PE material has a low dielectric constant and can prevent mutual interference between the conductors 104 and the twisted pair 103; the conductor 104 is made of 99.95% oxygen-free copper and has a high conductivity.

[0045] Secondly, the sheath layer 30 is made of plastic material and has the function of protecting the cable core.

[0046] The shielding effect test results of the above unshielded cables all meet the requirements of the key cable test parameters PSANEXT (comprehensive external near-end crosstalk power sum) and PSAACRF (comprehensive external far-end signal-to-noise ratio power sum).

[0047] In this embodiment, since a shielding layer is provided in the non-shielded cable, the anti-interference capability of the non-shielded cable is greatly improved, and the anti-interference measures in the prior art can be omitted during its manufacture and use. For example, in the prior art, the contact area between adjacent cables is often reduced by increasing the outer diameter of the cable, and the outer diameter is basically 8-9 mm. However, in this embodiment, the outer diameter of the cable can be reduced to 7-7.5 mm, saving the installation space of the cable.

[0048] Furthermore, in this embodiment, the distance between any two truncation grooves 5 on the aluminum foil is 1-1.5 times the cable core pitch, which can prevent the aluminum foil from exploding during practical use of the cable.

[0049] [Example 3]

[0050] The present application also discloses a method for manufacturing an unshielded cable, which is used to manufacture the unshielded cable as described in Example 2, comprising the following steps:

[0051] Making the twisted pair 103: preparing the raw material copper rod of the conductor 104, drawing the copper rod, and then coating the copper wire with the insulating material PE, so that the outer side of the copper wire conductor 104 is wrapped with the insulating layer 105; then, twisting two conductors 104 with the insulating layer 105 into a twisted pair 103;

[0052] Making the cable core 10: installing four twisted pair cables 103 in the receiving cavity 102 of the cross frame 101 by a cabling machine to make the cable core 10;

[0053] Adding the shielding layer 20 and the sheath layer 30 : Wrapping the shielding tape on the outside of the cable core 10 by coating, wherein the coating overlap rate is greater than or equal to 25%, to form the shielding layer 20 ; finally, setting the sheath layer 30 on the outside of the shielding layer 20 .

[0054] Although the above describes the illustrative specific implementation methods of the present application so that technicians in this technical field can understand the present application, the present application is not limited to the scope of the specific implementation methods. For ordinary technicians in this technical field, as long as various changes are within the spirit and scope of the present application defined and determined by the attached claims, all application creations using the concept of the present application are protected.

Claims

1. A discontinuous aluminum foil, characterized in that: It comprises: a metal layer, the metal layer is made of aluminum foil, a plurality of truncation grooves are arranged on the metal layer, and the truncation grooves divide the metal layer into a plurality of discontinuous modules; A first insulating layer, wherein the first insulating layer is arranged on one side of the metal layer, and the width of the first insulating layer is greater than that of the metal layer; a second insulating layer, wherein the second insulating layer is arranged on the other side of the metal layer, and the width of the second insulating layer is equal to that of the first insulating layer, so that blank edges without the metal layer are formed on both sides of the first insulating layer and the second insulating layer; wherein, at the blank edges and the truncation grooves, the first insulating layer and the second insulating layer are bonded together by melting; the blank edges and the truncation grooves on both sides jointly form a receiving cavity, and the receiving cavity seals the metal layer; the shape of the truncation groove is straight or wavy.

2. The discontinuous aluminum foil according to claim 1, characterized in that: The first insulating layer and the second insulating layer are made of plastic films.

3. A non-shielded cable, characterized in that: The unshielded cable comprises: a cable core, the cable core comprising a conductor; a shielding layer, the shielding layer is made of the aluminum foil as claimed in claim 1 and is arranged outside the cable core; and a sheath layer, the sheath layer is arranged outside the shielding layer.

4. The unshielded cable according to claim 3, characterized in that: The cable core comprises: a cross frame, wherein the cross frame and the inner side of the shielding layer form a receiving cavity, and the receiving cavity provides a receiving space for the conductor.

5. The unshielded cable according to claim 3, characterized in that: There are at least two conductors, and the conductors are twisted in a spiral to form at least one set of twisted pairs.

6. The unshielded cable according to claim 3, characterized in that: The conductor is wrapped with an insulating layer outside.

7. The unshielded cable according to claim 3, characterized in that: The shielding layer is wrapped around the outside of the cable core in a covering or winding manner, and the shielding layers overlap at overlapping locations.

8. A method for manufacturing a cable, characterized in that: Used to manufacture an unshielded cable as claimed in claim 3, The method comprises the following steps: making a twisted pair: preparing a raw material copper rod of a conductor, drawing the copper rod, and then coating the copper wire with an insulating material PE so that the outer side of the copper wire conductor is coated with an insulating layer; then twisting two conductors with insulating layers into a twisted pair; making a cable core: installing four twisted pair cables in a receiving cavity of a cross frame by a cabling machine to form a cable core; adding a shielding layer and a sheath layer: wrapping a shielding tape on the outer side of the cable core by coating to form a shielding layer; finally, arranging a sheath layer on the outer side of the shielding layer.

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