Cable with power collection and signal transmission integrated and manufacturing method thereof

Abstract

The application discloses a cable integrating power transmission and signal transmission and a manufacturing method thereof. The cable comprises a network line, a control line, a power transmission line and an insulating sheath. The network line, the control line and the power transmission line are arranged in the insulating sheath. The network line and the control line are arranged in a first insulating fixed layer. The first insulating fixed layer is coated with an armored shielding layer outside to form a signal transmission cable. The power transmission line and the signal transmission cable are arranged in a second insulating fixed layer. The second insulating fixed layer is provided with a heat dissipation hose and a capacity reduction line. The heat dissipation hose is provided with a heat dissipation medium. The heat dissipation hose and the capacity reduction line are arranged between the power transmission line and the signal transmission cable. The second insulating fixed layer is coated with an oil-resistant waterproof layer and an insulating sheath outside. The cable integrates cables with multiple purposes in one cable, which is convenient for installation and laying, occupies less space and is beneficial to maintenance. The cable has heat dissipation and electric leakage warning functions and can greatly improve the safety performance of the cable.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of cable manufacturing, and particularly relates to a cable integrating power supply and signal transmission and a manufacturing method thereof. BACKGROUND

[0002] With the development of society, more and more types of cables are used in a device, for example, in a vehicle-mounted system, power lines are needed to provide power support, data buses are needed to transmit data in a CPU to other components or receive data information from other components, and network lines are needed to realize network connection. The general electric wires and cables in the prior art are single-purpose cables, that is, power lines are used for transmitting current, network lines are used for transmitting signals, and control lines are used for controlling a system, which are all single use. Therefore, multiple connection lines in a device are often placed together in disorder, which not only occupies space but also is difficult to maintain. SUMMARY

[0003] A first object of the present application is to provide a cable integrating power supply and signal transmission, and a second object of the present application is to provide a manufacturing method of the cable integrating power supply and signal transmission.

[0004] The first object of the present application is achieved by the following technical scheme: a cable integrating power supply and signal transmission, comprising a network line, a control line, a power transmission line and an insulating sheath, the network line, the control line and the power transmission line are integrally arranged in the insulating sheath, the network line and the control line are arranged in a first insulating fixed layer, and a shielded layer is coated outside the first insulating fixed layer to form a signal transmission cable, the power transmission line and the signal transmission cable are arranged in a second insulating fixed layer, a heat dissipation hose and a capacity reduction line are arranged in the second insulating fixed layer, a heat dissipation medium is arranged in the heat dissipation hose, and the heat dissipation hose and the capacity reduction line are between the power transmission line and the signal transmission cable, an electroluminescent coating layer is arranged on an outer wall of the second insulating fixed layer, a light guide line is arranged on the oil-resistant waterproof layer in an axial direction, the thickness of the light guide line is consistent with the thickness of the oil-resistant waterproof layer, the inner side of the light guide line contacts the electroluminescent coating layer, a micro light transmission hole is arranged on the insulating sheath corresponding to the light guide line, and an insulating light guide material is filled in the micro light transmission hole, the material of the second insulating fixed layer is heat-conducting silicone rubber, and metal powder is mixed in the heat-conducting silicone rubber, the heat dissipation hose has two, one is a mother pipe and the other is a child pipe, and the second insulating fixed layer is coated with an oil-resistant waterproof layer and an insulating sheath outside.

[0005] Further, the network line and the control line are respectively coated with an inner insulating layer, a shielding layer and a tape in sequence outside, the power transmission line is coated with an inner insulating layer and an outer insulating layer in sequence outside, and the capacity reduction line is a full-bare metal wire.

[0006] Further, the armored shielding layer is combined by a metal composite film and a metal wire mesh, the thickness of the metal composite film is 0.01-0.02mm, the winding and overlapping covering rate of the armored shielding layer is not less than 50% respectively, and the armored shielding layer is wound at least one layer.

[0007] Further, the heat dissipation medium is liquid or gas.

[0008] The second object of the application is achieved by the following technical scheme: a manufacturing method of a cable integrating power collection and signal transmission, comprising the following steps

[0009] A, sub-wire preparation, the conductor is stretched through a mold to form a network wire core, a control wire core, a power transmission wire core and a capacity reduction wire, the conductor is any one or more of copper, aluminum, copper alloy and aluminum alloy; an inner insulation layer, a shielding layer and a wrapping tape are wrapped outside the network wire and the control wire core to obtain the network wire and the control wire; an inner insulation layer and an outer insulation layer are wrapped outside the power transmission wire core to obtain the power transmission wire;

[0010] B, signal transmission cable preparation, the network wire and the control wire prepared in step A are placed side by side in an extruder to form a first insulation fixing layer, so that the network wire and the control wire are fixed in the first insulation fixing layer, and then a armored shielding layer is wrapped outside the first insulation fixing layer to form a signal transmission cable;

[0011] C, integrated wire preparation, the power transmission wire and the capacity reduction wire prepared in step A and the signal transmission cable prepared in step B are arranged in sequence and a heat dissipation hose is added, and then the integrated wire is placed in an extruder to form a second insulation fixing layer, so that the power transmission wire, the capacity reduction wire, the heat dissipation hose and the signal transmission cable are fixed in the second insulation fixing layer to obtain a cable rough material;

[0012] D, light guide material setting, an electroluminescent coating layer is uniformly brushed on the outer wall of the cable rough material prepared in step C, and then the cable rough material is passed through an extruder to form an oil-resistant waterproof layer, and a light guide wire is added in the mold during the extrusion process, the thickness of the light guide wire is consistent with the thickness of the oil-resistant waterproof layer, so that the light guide wire and the oil-resistant waterproof layer are integrally formed; then, the oil-resistant waterproof layer is passed through the extruder again to form an insulation sheath outside the oil-resistant waterproof layer;

[0013] E, cabling, a light guide hole is punched on the insulation sheath prepared in step D corresponding to the light guide wire, and a light guide material is injected into the light guide hole, and then the cable product is obtained after natural cooling and electrical detection.

[0014] The beneficial effects of the application are as follows:

[0015] 1), the cable of multiple purposes is integrated in one cable, the overall cable has higher tensile strength, the cable is more reliable, the space occupied by the cable is reduced as much as possible, the cable structure ensures no interference between each other, has good flexibility and strength, can be used in the internal bending laying of the equipment while protecting the internal structure of the cable from damage by external force; the hardware equipment system is suitable for intelligent field control and information collection processing feedback, not only provides power supply, but also considers signal control and broadband system transmission;

[0016] 2), the work that needs multiple cables to complete is completed by one integrated cable, which is convenient for installation and laying and is beneficial to maintenance; the integrated cable occupies smaller space, the site is simpler, and has heat dissipation and electric leakage warning functions, which can greatly improve the safety performance of the cable. BRIEF DESCRIPTION OF DRAWINGS

[0017] Figure 1 is a structural schematic diagram of the application;

[0018] Figure 2 is Figure 1 the enlarged structural schematic diagram of A in the figure;

[0019] The figure mark: 1~network line, 2~control line, 3~power transmission line, 4~inner insulation layer, 5~outer insulation layer, 6~shielding layer, 7~first insulation fixed layer, 8~armored shielding layer, 9~second insulation fixed layer, 10~heat dissipation hose, 11~reduced capacity line, 12~oil and water resistant layer, 13~insulation sheath, 14~electroluminescent coating layer, 15~light guide line, 16~light guide material. DETAILED DESCRIPTION

[0020] In order for those skilled in the art to better understand the technical solutions of the present application, the specific embodiments thereof will be described in detail below with reference to the accompanying drawings.

[0021] As Figures 1-2The power collection and signal transmission integrated cable shown includes a network line 1, a control line 2, a power transmission line 3 and an insulating sheath 13, the network line 1, the control line 2 and the power transmission line 3 are integrally arranged in the insulating sheath 13, characterized in that: the network line 1 and the control line 2 are arranged in a first insulating fixed layer 7, and a shielded layer 8 is arranged outside the first insulating fixed layer to form a signal transmission cable, which can eliminate the electromagnetic interference of the power transmission line 3 on the network line 1 and the control line 2, and make the signal transmission more stable, the power transmission line 3 and the signal transmission cable are arranged in a second insulating fixed layer 9, the second insulating fixed layer 9 is provided with a heat dissipation hose 10 and a capacity reduction line 11, the heat dissipation medium is arranged in the heat dissipation hose 10, and the heat dissipation hose 10 and the capacity reduction line 11 are arranged between the power transmission line 3 and the signal transmission cable, an electroluminescent coating layer 14 is arranged on the outer wall of the second insulating fixed layer 9, and a light guide line 15 is arranged axially on an oil-resistant waterproof layer 12, the thickness of the light guide line 15 is consistent with the thickness of the oil-resistant waterproof layer 12, and the light guide line 15 and the oil-resistant waterproof layer 12 are integrally formed, the inner side of the light guide line 15 contacts the electroluminescent coating layer 14, a micro light transmission hole is arranged on the insulating sheath 13 corresponding to the light guide line 15, the micro light transmission hole is filled with an insulating light guide material 16, and the insulating sheath 13 and the light guide material 16 are integrally formed, the electroluminescent coating layer 14 can emit light when the power transmission line 3 leaks, and the light is dissipated through the light guide line 15 and the light guide material 16, which facilitates the rapid positioning and troubleshooting of maintenance personnel, improves the maintenance speed, and also warns personnel to stay away from the leakage position through light,

[0022] The material of the second insulating fixed layer 9 is heat-conducting silicone rubber, and metal powder is mixed in the heat-conducting silicone rubber, which improves the transmission of capacitance and static electricity in the second insulating fixed layer 9, so that the capacitance and static electricity can be more quickly conducted to the capacity reduction line 11 to avoid accumulation; on the other hand, when the power transmission line 3 leaks, the electric energy can also be transmitted to the electroluminescent coating layer 14 to emit light for warning.

[0023] The heat dissipation hose 10 has two pipes, one of which is a mother pipe and the other of which is a child pipe, and the heat dissipation medium is introduced into the mother pipe and the child pipe in use, and the flow directions of the mother pipe and the child pipe are opposite, so that the heat generated in the cable can be quickly dissipated, the working stability is improved, and the network line 1, the control line 2 and the power transmission line 3 in the cable are not unstable due to temperature interference during work

[0024] The second insulating fixed layer 9 is coated with an oil-resistant waterproof layer 12 and an insulating sheath 13.

[0025] The outer part of the network line 1 and the control line 2 is covered with an inner insulation layer 4, a shielding layer 6 and a wrapping tape in sequence, respectively, so as to eliminate the signal interference between the network line 1 and the control line 2, and the outer part of the power transmission line 3 is covered with an inner insulation layer 4 and an outer insulation layer 5 in sequence, so that the network line 1, the control line 2 and the power transmission line 3 operate independently and do not interfere with each other; the capacity reduction line 11 is a full-bare metal line, which can better guide and transport away the capacity and static electricity in the second insulation fixing layer 9, so as to reduce or eliminate the capacity and static electricity in the cable.

[0026] Further, the light guide line 15 is at least two, which are symmetrically arranged on the oil-resistant waterproof layer 12, so as to facilitate seeing the light emitting part from the front and back sides and improving the warning effect.

[0027] The armored shielding layer 8 is composed of a metal composite film and a metal wire mesh, the thickness of the metal composite film is 0.01-0.02 mm, the winding and overlapping coverage rate of the armored shielding layer 8 is not less than 50%, and the armored shielding layer 8 is wound at least one layer, the metal composite film has the function of signal shielding and has excellent flexibility, which can solve the problem of low flexibility of the cable caused by the high rigidity of the metal wrapping tape, and better meet the demand of the cable in flexibility.

[0028] The heat dissipation medium is a liquid or a gas, and according to the demand of the use environment, the heat dissipation medium in the heat dissipation hose 10 can be selected as a liquid or a gas.

[0029] A manufacturing method of a cable integrating power and signal transmission, the specific steps are as follows:

[0030] A, sub-line preparation, the conductor is stretched through a mold or stretched and then twisted into a network line core, a control line core, a power transmission line core and a capacity reduction line 11, the conductor is any one or more of copper, aluminum, copper alloy and aluminum alloy; the network line 1 and the control line core are covered with an inner insulation layer 4, a shielding layer 6 and a wrapping tape on the outside, respectively, to obtain the network line 1 and the control line 2, and the power transmission line core is covered with an inner insulation layer 4 and an outer insulation layer 5 on the outside to obtain the power transmission line 3;

[0031] B, signal transmission cable preparation, the network line 1 and the control line 2 prepared in step A are placed side by side in an extruder to be extruded and covered to form a first insulation fixing layer, so as to fix the network line 1 and the control line 2 in the first insulation fixing layer, and then the first insulation fixing layer is covered with an armored shielding layer 8 on the outside to form a signal transmission cable;

[0032] C. Integrated line preparation, the power transmission line 3 prepared in step A, the reduced capacity line 11, the signal transmission cable prepared in step B are arranged in order, and the heat dissipation hose 10 is added, then put into the extruder to form the second insulation fixing layer 9, so as to fix the power transmission line 3, the reduced capacity line 11, the heat dissipation hose 10 and the signal transmission cable in the second insulation fixing layer 9, and obtain the cable rough material; in this step C, the material of the second insulation fixing layer 9 is prepared by mixing heat-conducting silicone rubber and metal powder, and the component ratio of the heat-conducting silicone rubber and the metal powder is 40-60:2-4;

[0033] D. Light guide material 16 is arranged, the electroluminescent paint layer 14 is uniformly brushed on the outer wall of the cable rough material prepared in step C, then the extruder is passed to form the oil-resistant waterproof layer 12, and a light guide wire 15 is added in the mold during the extrusion process. The thickness of the light guide wire 15 is consistent with the thickness of the oil-resistant waterproof layer 12, so that the light guide wire 15 and the oil-resistant waterproof layer 12 are integrally formed; then, the extruder is passed again to form the insulation sheath 13 outside the oil-resistant waterproof layer 12;

[0034] E. Cabling, the light guide hole corresponding to the light guide wire 15 is punched on the insulation sheath 13 prepared in step D, and the light guide material 16 is injected into the light guide hole, and the cable product is obtained after natural cooling and electrical detection.

[0035] In the above-mentioned injection molding machine extrusion process, the surfaces of the inner insulation layer 4, the outer insulation layer 5, the first insulation fixing layer, the second insulation fixing layer 9, the oil-resistant waterproof layer 12 and the insulation sheath 13 should be smooth, uniform in color, and free of visible sand holes and pores; the surface of the insulation sheath 13 should be flat, uniform in color, and free of mechanical damage; the oil-resistant waterproof layer 12 should also not have obvious concave-convex bubbles, holes, and defects such as disconnection; the inner insulation layer 4 and the outer insulation layer 5 must be subjected to spark test, the extrusion temperature can be adjusted appropriately according to the actual situation, and the temperature allowable variation range is ±10℃ of the process specified value; the pulling speed can be adjusted appropriately according to the actual situation in the production process, and the mold size can be adjusted appropriately according to the actual situation.

Claims

1. A cable integrating power and signal transmission, comprising a network cable (1), a control cable (2), a transmission cable (3), and an insulating sheath (13), wherein the network cable (1), the control cable (2), and the transmission cable (3) are integrated within the insulating sheath (13), characterized in that: The network cable (1) and control cable (2) are set in the first insulating fixing layer (7). The first insulating fixing layer is covered with an armored shielding layer (8) to form a signal transmission cable. The power transmission line (3) and signal transmission cable are set in the second insulating fixing layer (9). The second insulating fixing layer (9) is provided with a heat dissipation hose (10) and a derating line (11). The heat dissipation hose (10) is provided with a heat dissipation medium. The heat dissipation hose (10) and the derating line (11) are located between the power transmission line (3) and the signal transmission cable. The outer wall of the second insulating fixing layer (9) is provided with an electroluminescent coating layer (14). A light guide (15) is axially provided on the oil-resistant and waterproof layer (12). The thickness of the light guide (15) is the same as the thickness of the oil-resistant and waterproof layer (12). The inner side of the light guide (15) contacts the electroluminescent coating layer (14). A micro light-transmitting hole is provided on the insulating sheath (13) corresponding to the light guide (15). The micro light-transmitting hole is filled with an insulating light-transmitting material (16). The second insulating fixing layer (9) is made of thermally conductive silicone rubber, and metal powder is mixed into the thermally conductive silicone rubber. The heat dissipation hose (10) has two parts, one of which is the main hose and the other is the daughter hose. The second insulating fixing layer (9) is covered with an oil-resistant and waterproof layer (12) and an insulating sheath (13).

2. The cable integrating power and signal transmission according to claim 1, characterized in that: The network line (1) and control line (2) are respectively covered with an inner insulation layer (4), a shielding layer (6) and a wrapping tape. The transmission line (3) is covered with an inner insulation layer (4) and an outer insulation layer (5). The derating line (11) is a completely bare metal wire.

3. The cable integrating power and signal transmission according to claim 1, characterized in that: The armored shielding layer (8) is composed of a metal composite film and a metal wire mesh. The thickness of the metal composite film is 0.01~0.02mm. The winding and overlapping coverage rate of the armored shielding layer (8) is not less than 50%, and at least one layer is wound.

4. The cable integrating power and signal transmission according to claim 1, characterized in that: The heat dissipation medium is a liquid or a gas.

5. A method for manufacturing a cable integrating power and signal transmission as described in any one of claims 1 to 4, comprising A. preparation of sub-wires, B. preparation of signal transmission cables, C. preparation of integrated wires, D. placement of light-guiding material (16), and E. cabling, characterized in that: The specific steps are as follows: A. Sub-wire preparation: The conductor is stretched by a mold or stretched and then stranded to form a network core, control core, transmission core and derating wire (11). The conductor is any one or more of copper, aluminum, copper alloy and aluminum alloy. The network wire (1) and control core are respectively covered with an inner insulation layer (4), a shielding layer (6) and a wrapping tape to obtain the network wire (1) and control wire (2). The transmission wire core is covered with an inner insulation layer (4) and an outer insulation layer (5) to obtain the transmission wire (3). B. Signal transmission cable preparation: The network cable (1) and control cable (2) obtained in step A are placed side by side into an extruder to form a first insulating fixing layer, thereby fixing the network cable (1) and control cable (2) in the first insulating fixing layer. Then, an armored shielding layer (8) is wrapped around the outside of the first insulating fixing layer to form a signal transmission cable. C. Preparation of integrated wire: The power transmission wire (3), the derating wire (11) obtained in step A, and the signal transmission cable obtained in step B are arranged in sequence and heat dissipation hose (10) is added. Then, they are put into an extruder to form a second insulation fixing layer (9), thereby fixing the power transmission wire (3), the derating wire (11), the heat dissipation hose (10) and the signal transmission cable in the second insulation fixing layer (9) to obtain cable coarse material; D. Setting of light guide material (16): The outer wall of the cable coarse material obtained in step C is uniformly coated with an electroluminescent coating layer (14), and then extruded through an extruder to form an oil-resistant and waterproof layer (12). During the extrusion process, a light guide (15) is added to the mold. The thickness of the light guide (15) is the same as the thickness of the oil-resistant and waterproof layer (12), so that the light guide (15) and the oil-resistant and waterproof layer (12) are integrally formed. Subsequently, it is extruded through an extruder again to form an insulating sheath (13) on the outside of the oil-resistant and waterproof layer (12). E. Cable making: Drill light guide holes on the insulating sheath (13) obtained in step D corresponding to the light guide (15), and inject light guide material (16) into the light guide holes. After natural cooling, the finished cable is obtained after passing the electrical test.

6. The method for manufacturing a cable integrating power and signal transmission according to claim 5, characterized in that: In step C, the material of the second insulating fixing layer (9) is a mixture of thermally conductive silicone rubber and metal powder, with a ratio of 40~60:2~4.

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