A high strength stable phase cable assembly and method of making the same

Abstract

The application relates to the technical field of cable assembly, and discloses a high-strength stable-phase cable assembly which comprises a cable and a connector, the cable is fixedly connected with the connector at both ends, the cable comprises seven inner conductors, the outer side of each inner conductor is provided with a flame-retardant filling layer, the outer side of the flame-retardant filling layer is provided with a flame-retardant non-woven fabric layer, the outer side of the flame-retardant non-woven fabric layer is provided with an inner semiconductor electric shielding layer, and the outer side of the inner semiconductor electric shielding layer is provided with a cross-linked polyethylene insulation layer. The seven inner conductors are combined, and the inner conductors are wrapped by the inner semiconductor electric shielding layer, so that the inner conductors eliminate the air gap on the surface of the conductive wire core, effectively weaken the electric field intensity near burrs, reduce field emission, and thus the characteristics of branch discharge resistance are improved; finally, the heat resistance of the inner conductors is improved through the cross-linked polyethylene insulation layer, the protection performance and the strength of the inner conductors are improved, and the practical strength of the stable-phase cable is enhanced.

Description

Technical Field

[0001] This invention relates to the field of cable assembly technology, specifically to a high-strength stable phase cable assembly and its preparation method. Background Technology

[0002] Phase-stable cable assemblies are one of the more important cable assemblies in radio frequency systems. They are commonly used in electronic equipment such as phased array radars and vector network analyzers. In equipment in high-altitude areas, the extreme temperature difference between day and night can cause the temperature variation range to exceed the range that ordinary cables can withstand, resulting in a large phase change. This will cause a certain time delay in the received signal. Therefore, compared with other types of cables, phase-stable cable assemblies have superior performance indicators and flexibility.

[0003] Most existing phase-stabilized cable assemblies mainly consist of an outer conductor and an inner conductor with a double-layer structure, consisting of silver-plated copper flat tape wrapping and silver-plated soft round copper wire braiding. An insulation layer and an electrical shielding layer are placed between the inner and outer conductors, and then an insulating sheath is used to wrap them to form a phase-stabilized cable assembly. This method, which only wraps the outer and inner conductors with the insulating sheath, insulation layer, and electrical shielding layer, results in a relatively weak phase-stabilized cable. Under external forces, it will be damaged to varying degrees, easily leading to the breakage of the insulating sheath, insulation layer, and electrical shielding layer, exposing and damaging the inner and outer conductors. This affects the normal operation of equipment in high-altitude environments. Furthermore, with prolonged use, the insulating sheath, insulation layer, and electrical shielding layer are prone to aging, reducing the safety of the phase-stabilized cable during use. Therefore, a high-strength phase-stabilized cable assembly and its manufacturing method are needed to solve the above-mentioned problems. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a high-strength stable phase cable assembly and its manufacturing method, which solves the problem that stable phase cables in the prior art suffer varying degrees of damage under external forces, resulting in low strength.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a high-strength phase-stable cable assembly, comprising a cable and connectors, wherein connectors are fixedly connected to both ends of the cable, the cable comprises 7 inner conductors, each inner conductor having a flame-retardant filling layer on its outer side, a flame-retardant non-woven fabric layer on its outer side, an inner semiconductor electrical shielding layer on its outer side, a cross-linked polyethylene insulation layer on its outer side, an outer semiconductor electrical shielding layer on its outer side, a water-blocking layer on its outer side, a copper wire shielding layer on its outer side, a plurality of outer conductors equidistantly arranged on its outer side, a buffer layer on its outer side, an aluminum sheath layer on its outer side, a corrugated aluminum sheath layer on its outer side, and an insulating sheath on its outer side.

[0006] Preferably, the inner conductor is composed of 7 regular hexagonal copper wires with a side length of 2mm, and the 7 inner conductors are evenly distributed.

[0007] Preferably, the insulating sleeve may be made of polyvinyl chloride, polyethylene or perfluoroethylene, and the outer side of the insulating sleeve is provided with a waterproof coating.

[0008] Preferably, the outer conductor is made of a double-layer material consisting of silver-plated soft round copper wire and silver-plated copper flat strip wrapped together, and the diameter of the outer conductor is 0.5 mm.

[0009] Preferably, the flame-retardant filling layer is made of aluminum foam, and both the inner and outer semiconductor electrical shielding layers are made of multi-strand ultra-fine twisted oxygen-free copper wire and high-quality high-density polyethylene.

[0010] Preferably, the water-blocking layer is made of water-absorbing and water-blocking rope material, and the buffer layer is composed of polyester fiber nonwoven fabric and conductive carbon powder.

[0011] Preferably, a method for preparing a high-strength, phase-stable cable assembly includes the following preparation steps: S1: First, a regular hexagonal copper wire with a side length of 2mm is made by a copper wire extruder, and its surface is plated with 1μm of silver. Then, the edges of 7 regular hexagonal copper wires are aligned and combined, and wrapped with a flame-retardant filling layer of aluminum foam. A flame-retardant non-woven fabric layer is then wrapped around the outer layer of the flame-retardant filling layer to form an inner conductor. S2: Then, the 7 prepared inner conductors are arranged at equal intervals, and an inner semiconductor electrical shielding layer made of multi-strand ultra-fine twisted oxygen-free copper wire and high-quality high-density polyethylene is filled between the inner conductors, and a cross-linked polyethylene insulation layer is wrapped on the outside of the inner semiconductor electrical shielding layer. S3: Secondly, an outer semiconductor electric shielding layer made of multi-strand ultra-fine twisted oxygen-free copper wire and high-quality high-density polyethylene is wrapped around the outside of the cross-linked polyethylene insulation layer, and a water-blocking layer made of water-blocking rope material is wrapped around the outside of the outer semiconductor electric shielding layer. S4: Finally, on the outside of the water-blocking layer made of water-blocking rope material, a copper wire shielding layer, a double-layered conductor made of silver-plated soft round copper wire and silver-plated copper flat strip, a buffer layer composed of polyester fiber non-woven fabric and conductive carbon powder, an aluminum sheath layer, a wrinkled aluminum sheath layer, and an insulating sheath with a waterproof coating are wrapped in sequence.

[0012] Preferably, in step S4, the copper wire shielding layer is formed by winding oxygen-free copper wire with a diameter of 0.5 mm around the outside of the water-blocking layer.

[0013] Preferably, in steps S1-S4, the wrapping process is used to sequentially wrap the different material layers, and the aluminum sleeve layer and the wrinkled aluminum sheath layer are manufactured using a high-temperature extrusion molding process.

[0014] Preferably, in step S2, the cross-linked polyethylene insulation layer is made of polyethylene insulation material with added peroxide cross-linking agent. After the conductor shield layer-insulation layer-insulation shield layer are extruded through three-layer co-extrusion, the cross-linking process is completed by continuously and uniformly passing through a sealed cross-linking tube filled with high temperature and high pressure nitrogen gas.

[0015] This invention provides a high-strength phase-stable cable assembly and its manufacturing method. It has the following beneficial effects: 1. This invention combines seven regular hexagonal inner conductors, then wraps the inner conductors with a flame-retardant filling layer, and then wraps the flame-retardant filling layer with a flame-retardant non-woven fabric layer. This increases the stability and conductivity of the inner conductors, making them less prone to damage under external forces. Secondly, by combining the seven inner conductors and wrapping them with an inner semiconductor electric shielding layer, the air gaps on the surface of the conductive cores are eliminated, effectively reducing the electric field strength near the burrs and decreasing field emission, thereby improving the resistance to tree discharge. Finally, the heat resistance of the inner conductors is improved by using a cross-linked polyethylene insulation layer, enhancing the protective performance and strength of the inner conductors.

[0016] 2. This invention eliminates air gaps on the surface of the conductive core of the inner conductor again through an outer semiconductor electrical shielding layer, then uses a water-blocking layer for water blocking, a copper wire shielding layer to prevent electromagnetic interference and shield the inner conductor, an outer conductor to achieve low loss and phase stability in the cable, a buffer layer to buffer the cable when subjected to external forces, an aluminum sheath layer and a corrugated aluminum sheath layer to increase the cable's impact resistance, and finally an insulating sheath with a waterproof coating to provide overall protection and waterproofing for the outside of the cable, increasing the overall structural strength of the phase-stable cable and improving its impact and pressure resistance during use. Attached Figure Description

[0017] Figure 1 This is a perspective view of the present invention; Figure 2 This is a cross-sectional schematic diagram of the present invention; Figure 3 This is a cross-sectional schematic diagram of the cable structure of the present invention.

[0018] Among them, 1. Cable; 101. Inner conductor; 102. Flame-retardant filling layer; 103. Flame-retardant non-woven fabric layer; 104. Inner semiconductor electrical shielding layer; 105. Cross-linked polyethylene insulation layer; 106. Outer semiconductor electrical shielding layer; 107. Water-blocking layer; 108. Copper wire shielding layer; 109. Outer conductor; 110. Buffer layer; 111. Aluminum sheath layer; 112. Corrugated aluminum sheath layer; 113. Insulating sheath; 114. Waterproof coating; 2. Connector. Detailed Implementation

[0019] The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0020] Example 1: Please see the appendix Figure 1 - Appendix Figure 3This invention provides a high-strength phase-stable cable assembly, including a cable 1 and connectors 2. Connectors 2 are fixedly connected to both ends of the cable 1. The cable 1 includes seven inner conductors 101. A flame-retardant filling layer 102 is provided on the outer side of each inner conductor 101. A flame-retardant non-woven fabric layer 103 is provided on the outer side of the flame-retardant non-woven fabric layer 103. An inner semiconductor electrical shielding layer 104 is provided on the outer side of the inner semiconductor electrical shielding layer 104. A cross-linked polyethylene insulation layer 105 is provided on the outer side of the inner semiconductor electrical shielding layer 104. An outer semiconductor electrical shielding layer 106 is provided on the outer side of the cross-linked polyethylene insulation layer 105. A water-blocking layer 107 is provided on the outer side of the outer semiconductor electrical shielding layer 106. A copper wire shielding layer 108 is provided on the outer side of the water-blocking layer 107. The copper wire shielding layer 108 is equidistantly spaced on the outer side. The inner conductor is provided with several outer conductors 109, a buffer layer 110 is provided on the outside of the outer conductors 109, an aluminum sheath layer 111 is provided on the outside of the buffer layer 110, a corrugated aluminum sheath layer 112 is provided on the outside of the aluminum sheath layer 111, and an insulating sheath 113 is provided on the outside of the corrugated aluminum sheath layer 112. The stability and conductivity of the inner conductor are increased, and the inner conductor is not easily damaged under external force. Secondly, by combining the seven inner conductors and wrapping them with an inner semiconductor electric shielding layer, the air gap on the surface of the conductive core of the inner conductor is eliminated, effectively weakening the electric field strength near the burrs and reducing field emission, thereby improving the resistance to tree discharge. Finally, the heat resistance of the inner conductor is improved by the cross-linked polyethylene insulation layer, which enhances the protection performance and strength of the inner conductor.

[0021] The inner conductor 101 is composed of 7 regular hexagonal copper wires with a side length of 2mm. The 7 inner conductors 101 are equidistantly distributed and are combined to form an inner conductor layer of the phase-stable cable. This enhances the stability between them and makes them less susceptible to deformation and damage caused by external pressure.

[0022] The insulating sleeve 113 can be made of polyvinyl chloride, polyethylene or perfluoroethylene. The outer side of the insulating sleeve 113 is provided with a waterproof coating 114. The insulating sleeve 113 made of polyvinyl chloride, polyethylene or perfluoroethylene not only has good insulation performance, but is also not easy to be damaged and has a low manufacturing cost. At the same time, the waterproof coating 114 can provide external protection against rainwater.

[0023] The outer conductor 109 is made of a double-layer material consisting of silver-plated soft round copper wire and silver-plated copper flat strip wrapped together. The outer conductor 109 has a diameter of 0.5 mm, which enables the outer conductor 109 to achieve low loss and phase stability.

[0024] The flame-retardant filler layer 102 is made of aluminum foam. The inner semiconductor electric shielding layer 104 and the outer semiconductor electric shielding layer 106 are both made of multi-strand ultra-fine twisted oxygen-free copper wire and high-quality high-density polyethylene. The flame-retardant filler layer 102 not only increases the conductivity of the inner conductor 101, but also achieves the flame-retardant effect. The inner semiconductor electric shielding layer 104 and the outer semiconductor electric shielding layer 106 eliminate the air gap on the surface of the conductive core. When the metal burrs on the conductor surface directly penetrate the insulation layer, the field emission of the high field strength of the burrs will induce electric trees, which will effectively weaken the electric field strength near the burrs, reduce field emission, and thus improve the resistance to tree discharge.

[0025] The water-blocking layer 107 is made of water-absorbing and water-blocking rope material, and the buffer layer 110 is composed of polyester fiber nonwoven fabric and conductive carbon powder. The water-blocking layer 107 provides a water-blocking effect on the inside of the phase-stable cable, increasing the stability of the phase-stable cable during use. The buffer layer 110 can increase the structural strength of the phase-stable cable and protect the inner conductor 101 inside the phase-stable cable under external force.

[0026] Example 2: Please see the appendix Figure 1 - Appendix Figure 3 A method for preparing a high-strength, phase-stable cable assembly includes the following preparation steps: S1: First, a regular hexagonal copper wire with a side length of 2mm is made by a copper wire extruder, and silver is plated on its surface by 1μm. Then, the edges of 7 regular hexagonal copper wires are aligned and combined, and wrapped with a flame-retardant filling layer 102 made of aluminum foam material. A flame-retardant non-woven fabric layer 103 is wrapped around the outer layer of the flame-retardant filling layer 102 to form an inner conductor 101. S2: Then, the 7 prepared inner conductors 101 are arranged at equal intervals, and an inner semiconductor electrical shielding layer 104 made of multi-strand ultra-fine twisted oxygen-free copper wire and high-quality high-density polyethylene is filled between the inner conductors 101, and a cross-linked polyethylene insulation layer 105 is wrapped around the outside of the inner semiconductor electrical shielding layer 104. S3: Next, an outer semiconductor electric shielding layer 106 made of multi-strand ultra-fine twisted oxygen-free copper wire and high-quality high-density polyethylene is wrapped around the outside of the cross-linked polyethylene insulation layer 105, and a water-blocking layer 107 made of water-blocking rope material is wrapped around the outside of the outer semiconductor electric shielding layer 106. S4: Finally, on the outside of the water-blocking layer 107 made of water-blocking rope material, a copper wire shielding layer 108, an outer conductor 109 made of double-layer material wrapped with silver-plated soft round copper wire and silver-plated copper flat strip, a buffer layer 110 composed of polyester fiber non-woven fabric and conductive carbon powder, an aluminum sheath layer 111, a wrinkled aluminum sheath layer 112, and an insulating sheath 113 with a waterproof coating 114 on the outer layer are wrapped in sequence.

[0027] In step S4, the copper wire shielding layer 108 is formed by wrapping oxygen-free copper wire with a diameter of 0.5 mm around the outside of the water-blocking layer 107.

[0028] In steps S1-S4, different material wrapping layers are wrapped sequentially using a wrapping process. The aluminum sheath 111 and the wrinkled aluminum sheath 112 are manufactured using a high-temperature extrusion molding process.

[0029] In step S2, the cross-linked polyethylene insulation layer 105 is made of polyethylene insulation material with added peroxide cross-linking agent. After the inner semiconductor shielding layer 104, cross-linked polyethylene insulation layer 105, and outer semiconductor electrical shielding layer 106 are extruded through three layers of co-extrusion, the cross-linking process is completed by continuously and uniformly passing through a sealed cross-linking tube filled with high temperature and high pressure nitrogen gas.

[0030] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A high-strength phase-stable cable assembly, comprising a cable (1) and a connector (2), characterized in that, Both ends of the cable (1) are fixedly connected to connectors (2). The cable (1) includes 7 inner conductors (101). A flame-retardant filling layer (102) is provided on the outside of each inner conductor (101). A flame-retardant non-woven fabric layer (103) is provided on the outside of the flame-retardant filling layer (102). An inner semiconductor electrical shielding layer (104) is provided on the outside of the flame-retardant non-woven fabric layer (103). A cross-linked polyethylene insulation layer (105) is provided on the outside of the inner semiconductor electrical shielding layer (104). An outer semiconductor electrical shielding layer (105) is provided on the outside of the cross-linked polyethylene insulation layer (105). 06), a water-blocking layer (107) is provided on the outside of the outer semiconductor electrical shielding layer (106), a copper wire shielding layer (108) is provided on the outside of the water-blocking layer (107), a plurality of outer conductors (109) are provided at equal intervals on the outside of the copper wire shielding layer (108), a buffer layer (110) is provided on the outside of the outer conductors (109), an aluminum sheath layer (111) is provided on the outside of the buffer layer (110), a wrinkled aluminum sheath layer (112) is provided on the outside of the aluminum sheath layer (111), and an insulating sheath (113) is provided on the outside of the wrinkled aluminum sheath layer (112).

2. The high-strength phase-stable cable assembly according to claim 1, characterized in that, The inner conductor (101) is composed of 7 regular hexagonal copper wires with a side length of 2mm, and the inner conductor (101) consists of 7 equally spaced wires.

3. A high-strength phase-stable cable assembly according to claim 1, characterized in that, The insulating sleeve (113) may be made of polyvinyl chloride, polyethylene or polytetrafluoroethylene, and the outer side of the insulating sleeve (113) is provided with a waterproof coating (114).

4. A high-strength phase-stable cable assembly according to claim 1, characterized in that, The outer conductor (109) is made of a double-layer material consisting of silver-plated soft round copper wire and silver-plated copper flat strip wrapped together, and the diameter of the outer conductor (109) is 0.5 mm.

5. A high-strength phase-stable cable assembly according to claim 1, characterized in that, The flame-retardant filling layer (102) is made of aluminum foam, and the inner semiconductor electrical shielding layer (104) and the outer semiconductor electrical shielding layer (106) are both made of multi-strand ultra-fine twisted oxygen-free copper wire and high-quality high-density polyethylene.

6. A high-strength phase-stable cable assembly according to claim 1, characterized in that, The water-blocking layer (107) is made of water-absorbing and water-blocking rope material, and the buffer layer (110) is composed of polyester fiber nonwoven fabric and conductive carbon powder.

7. A method for preparing a high-strength, phase-stable cable assembly, characterized in that... A high-strength phase-stable cable assembly according to any one of claims 1-6 comprises the following preparation steps: S1: First, a regular hexagonal copper wire with a side length of 2mm is made by a copper wire extruder and silver-plated on its surface by 1μm. Then, the edges of 7 regular hexagonal copper wires are aligned and combined, and wrapped with a flame-retardant filling layer (102) made of aluminum foam. A flame-retardant non-woven fabric layer (103) is wrapped around the outer layer of the flame-retardant filling layer (102) to form an inner conductor (101). S2: Then, the 7 prepared inner conductors (101) are arranged at equal intervals, and an inner semiconductor electrical shielding layer (104) made of multi-strand ultra-fine twisted oxygen-free copper wire and high-quality high-density polyethylene is filled between the inner conductors (101), and a cross-linked polyethylene insulation layer (105) is wrapped around the outside of the inner semiconductor electrical shielding layer (104). S3: Next, an outer semiconductor electric shielding layer (106) made of multi-strand ultra-fine twisted oxygen-free copper wire and high-quality high-density polyethylene is wrapped around the outside of the cross-linked polyethylene insulation layer (105), and a water-blocking layer (107) made of water-blocking rope material is wrapped around the outside of the outer semiconductor electric shielding layer (106). S4: Finally, on the outside of the water-blocking layer (107) made of water-blocking rope material, a copper wire shielding layer (108), an outer conductor (109) made of double-layer material wrapped with silver-plated soft round copper wire and silver-plated copper flat strip, a buffer layer (110) composed of polyester fiber non-woven fabric and conductive carbon powder, an aluminum sheath layer (111), a wrinkled aluminum sheath layer (112), and an insulating sheath (113) with a waterproof coating (114) on the outer layer are wrapped in sequence.

8. The method for preparing a high-strength phase-stable cable assembly according to claim 7, characterized in that, In step S4, the copper wire shielding layer (108) is formed by wrapping oxygen-free copper wire with a diameter of 0.5 mm around the outside of the water-blocking layer (107).

9. The method for preparing a high-strength phase-stable cable assembly according to claim 7, characterized in that, In steps S1-S4, different material wrapping layers are wrapped sequentially using a wrapping process. The aluminum sheath (111) and the wrinkled aluminum sheath (112) are manufactured using a high-temperature extrusion molding process.

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