A high-rated power radio frequency coaxial cable insulation pad structure and preparation method

Abstract

This invention belongs to the field of cable application technology, specifically relating to a high-rated-power radio frequency coaxial cable insulation gasket structure and preparation method. This high-rated-power radio frequency coaxial cable insulation gasket includes: a plurality of gasket bodies sleeved on the inner conductor of the radio frequency coaxial cable, wherein the gaskets have a staggered annular structure; the gaskets are provided with a plurality of support portions and a plurality of connecting portions, wherein the support portions are spaced apart and evenly distributed on the circumference of the gaskets, and a connecting portion is provided between every two support portions; this high-rated-power radio frequency coaxial cable insulation gasket has the effects of improving the heat resistance of the radio frequency coaxial cable insulation layer, reducing the dielectric loss of the cable insulation layer, and improving the mechanical strength of the radio frequency coaxial cable insulation layer.

Description

Technical Field

[0001] This invention belongs to the field of cable application technology, specifically relating to a high-rated power radio frequency coaxial cable insulation pad structure and preparation method. Background Technology

[0002] Mobile communication base station antenna systems use radio frequency coaxial cables, which serve two main functions: signal transmission and power delivery. To improve the signal coverage radius of the base station, common techniques require both reducing cable attenuation and increasing the cable's power delivery. This necessitates a higher rated power for the cable, thus increasing the current in the cable conductor. However, excessive current can lead to severe overheating of the cable conductor. Current base station cables use foamed polyethylene insulation as the insulation layer. However, low-density polyethylene softens above 70°C, causing the air bubbles in the insulation layer to collapse. This leads to a deterioration in the cable's characteristic impedance and attenuation performance, potentially causing communication interruptions. Therefore, to achieve stable signal transmission under high power conditions, a technique using high-temperature resistant insulating pads as the insulation layer can be used as an improvement.

[0003] Existing radio frequency coaxial cables use a structure of polyethylene and polytetrafluoroethylene (PTFE) insulating pads, which is a semi-air insulation, meaning that most of the space between the inner and outer conductors of the cable is air. While this reduces cable attenuation, it also helps dissipate heat inside the cable. However, due to the poor heat resistance of polyethylene, the effect of using polyethylene pads to insulate cables on increasing the rated power of the cable is limited. If PTFE insulating pads are used, although good heat resistance can be maintained, PTFE cannot be melt-processed. It is usually produced by special processes such as extruding PTFE rods and then machining them into rings, resulting in low processing efficiency and high cost. Existing radio frequency coaxial cables also use polytetrafluoroethylene (PTFE) to make the insulating support. For example, in the prior art, a radio frequency coaxial cable with publication number CN202013932U has the following insulating gasket structure: the insulating gasket is a ring-shaped component, which is tightly fitted onto the inner conductor. The ring-shaped component is composed of a circular ring body and at least three supporting feet superimposed on it. The supporting feet are centrally symmetrically arranged on the circular ring body. However, the structure of the insulating gasket in this radio frequency coaxial cable is relatively complex, inconvenient to assemble, and not suitable for mass production.

[0004] The existing technical solutions mentioned above have the following drawbacks: the existing insulating pads cannot simultaneously possess the characteristics of heat resistance and high power transmission. The manufacturing process of insulating pads with good heat resistance is complex and costly. The insulating pads with low cost and simple structure do not have good heat resistance to support high power transmission. Furthermore, the mechanical strength of the insulation layer in the existing technology is insufficient. Long-term operation in high-temperature environments can easily lead to the collapse of the cable insulation structure, resulting in communication interruption. Summary of the Invention

[0005] The purpose of this invention is to provide a high-rated-power radio frequency (RF) coaxial cable insulation gasket structure and preparation method to solve the technical problem that RF coaxial cables are prone to experience a decrease in the mechanical strength of the insulation layer due to insufficient heat resistance during long-term operation in high-power environments, and even the collapse of the pore structure in the insulation layer, thus affecting or interrupting communication. This invention can effectively improve the heat resistance of the RF coaxial cable insulation layer, and the insulation gasket structure and materials can effectively reduce dielectric loss, which seriously affects the high-frequency performance of communication, as well as improve the mechanical strength of the cable insulation layer.

[0006] To address the aforementioned technical problems, this invention provides a high-rated-power radio frequency coaxial cable insulation pad, comprising:

[0007] A number of spacers are fitted onto the inner conductor of the radio frequency coaxial cable, wherein the spacers are annular structures with misaligned ends.

[0008] The gasket is provided with a plurality of support portions and a plurality of connecting portions. The support portions are spaced apart and evenly distributed on the circumference of the gasket, and a connecting portion is provided between every two support portions.

[0009] The above technical solution has the following effects: By forming a ring structure with staggered ends, the gasket can ensure that it can be mounted on the inner conductor during installation. This installation method can enhance the installation stability of the gasket on the inner conductor. The support part is supported between the inner conductor and the outer conductor, and a transmission channel is formed between the inner conductor and the outer conductor through the connecting part, reducing the volume of the entire insulating gasket and further enhancing the mechanical strength of the cable insulation layer.

[0010] Furthermore, the gasket has mounting holes for fitting the gasket onto the inner conductor of the radio frequency coaxial cable;

[0011] The gasket has an installation opening, and the installation opening and the installation hole are connected through each other.

[0012] The above technical solution achieves the following effects: the spaced and uniformly distributed support portions on the circumference of the gasket reduce interference with the transmitted signal and avoid voltage standing wave performance degradation caused by non-uniform distribution of the support portions. The insulating gasket has a ring-shaped structure with staggered ends. Through the mounting opening that communicates with the mounting hole, the insulating gasket is mounted on the inner conductor, completing the gasket installation. Because the inner diameter of the mounting hole is approximately equal to the outer diameter of the inner conductor, and the mounting opening for mounting maintains close contact with the inner conductor, a stable and secure installation of the gasket is achieved.

[0013] Furthermore, the support portion is a sheet-shaped support foot, which, when the pad is fitted inside the radio frequency coaxial cable, supports the formation of a transmission channel between the inner and outer conductors of the radio frequency coaxial cable.

[0014] The outer side of the sheet-like support foot protrudes, forming an arc-shaped protrusion that matches the inner wall of the outer conductor of the radio frequency coaxial cable.

[0015] The effect of the above technical solution is that the support part is provided for the support between the inner conductor and the outer conductor, and the outer side of the support part forms a protrusion that is adapted to the inner wall of the outer conductor, thereby increasing the contact area between the support part and the inner wall of the outer conductor, which can increase the support stability of the support part between the inner and outer conductors.

[0016] Furthermore, the connecting portion is a notch.

[0017] The advantages of the above technical solution are as follows: the concave connection reduces the volume of the insulating gasket, thereby reducing the impact of the gasket on the medium of high-frequency electromagnetic waves transmitted between the inner and outer conductors of the communication cable. It also creates a channel for internal hot air circulation, which is beneficial for cooling the cable's interior, ensuring its continuous operation under high-power conditions, and to some extent reducing material usage and production costs.

[0018] Furthermore, the distance from the outermost edge of the sheet-like support foot to the outer wall of the mounting hole is 2 to 4 times the distance from the bottom of the notch to the outer wall of the mounting hole.

[0019] The effect of the above technical solution is to ensure the high-frequency communication performance of the cable while also ensuring that the gasket has a certain supporting strength to prevent short circuits between the inner and outer conductors.

[0020] Furthermore, this includes the preparation steps of the gasket body.

[0021] S1. Take 75wt% to 95wt% electronic-grade PEEK resin powder and 5wt% to 25wt% nano-SiO2 powder in the total mass of the insulating material to be prepared. Dry the PEEK resin powder at a temperature of 140℃ to 160℃ for 1h to 3h; dry the nano-SiO2 powder at a temperature of 60℃ to 80℃ for 1h to 3h.

[0022] S2. Mix the dried PEEK resin powder and nano SiO2 powder.

[0023] S3. Inject the prepared insulating material into a high-temperature injection molding machine in which the flow channels have been hardened, and maintain the injection temperature at 350°C to 385°C to perform injection molding to form the gasket body as shown in any one of claims 1 to 5.

[0024] S4. The RF coaxial cable insulation pad, after injection molding, is allowed to cool naturally in the air.

[0025] S5. After the RF coaxial cable insulation pad changes from a transparent state to a non-transparent state, the RF coaxial cable insulation pad is cooled to room temperature by spraying or immersing with room temperature water.

[0026] The above technical solution has the following effects: 75wt% to 95wt% electronic-grade PEEK resin powder and 5wt% to 25wt% nano-SiO2 powder can ensure that the insulating gasket has a dielectric constant and dielectric loss suitable for use as a cable insulation layer. The low dielectric constant ensures that the insulating gasket maintains optimal insulation performance; the low dielectric loss results in less heat loss of the insulating sheet in the electric field, thereby ensuring the durability and longevity of the insulating gasket.

[0027] The beneficial effects of this invention are:

[0028] 1. Significantly improves the heat resistance of the RF coaxial cable insulation layer and effectively reduces the dielectric loss of the cable insulation layer during power transmission.

[0029] 2. Effectively improves the mechanical strength of the insulation layer of the radio frequency coaxial cable, preventing the insulation layer from collapsing and causing communication obstruction during communication.

[0030] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described below in detail with reference to the accompanying drawings. Attached Figure Description

[0031] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0032] Figure 1 This is a front view of the first embodiment of an insulating pad structure for a high-rated power radio frequency coaxial cable according to the present invention;

[0033] Figure 2 This is a front view of a second embodiment of an insulating pad structure for a high-rated-power radio frequency coaxial cable according to the present invention;

[0034] Figure 3 This is a schematic diagram of the first embodiment of an insulating gasket structure for a high-rated power radio frequency coaxial cable according to the present invention.

[0035] Figure 4 This is a schematic diagram of the first embodiment of the insulating pad structure of the high rated power radio frequency coaxial cable of the present invention, installed into the coaxial cable;

[0036] Figure 5 This is a side view of the preferred embodiment of the high-rated-power radio frequency coaxial cable insulation pad structure of the present invention, installed into a coaxial cable.

[0037] In the picture:

[0038] 1. Gasket body; 2. Mounting hole; 3. Mounting port; 4. Support part; 5. Connecting part; 6. Transmission channel; 7. Inner conductor; 8. Outer conductor; 9. Sheath. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions 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, 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.

[0040] Example:

[0041] like Figures 1 to 5As shown, a high-rated power radio frequency coaxial cable insulating gasket includes: a plurality of gasket bodies 1 sleeved on the inner conductor 7 of the radio frequency coaxial cable. The gaskets have annular structures with staggered ends. The width of the gaskets is preferably 1mm to 4mm, and the overall width of the gaskets is preferably 5mm to 10mm. The gaskets are provided with a plurality of support parts 4 and a plurality of connecting parts 5. The number of support parts 4 is three to four, preferably three. The support parts 4 are sheet-like support feet. When the gasket is sleeved and installed inside the radio frequency coaxial cable, it supports the inner conductor 7 and the outer conductor 8 of the radio frequency coaxial cable. A transmission channel is formed; the outer side of the sheet-like support foot protrudes, forming an arc-shaped protrusion that matches the inner wall of the outer conductor 8 of the RF coaxial cable. The support parts 4 are spaced apart and evenly distributed on the circumference of the pad. The spaced apart and evenly distributed support parts 4 on the circumference of the pad can reduce interference to the transmitted signal and avoid the deterioration of voltage standing wave performance caused by the non-uniform distribution of the support parts. A connecting part 5 is provided between every two support parts 4. The connecting part 5 is a notch. When the pad is fitted inside the RF coaxial cable, it can ensure that the insulating pad stably supports the signal transmission channel between the inner and outer conductors while further reducing the volume of the insulating pad.

[0042] It should be noted that: the gasket, by forming a ring structure with staggered ends, ensures that it can be mounted on the inner conductor 7 during installation. This installation method enhances the stability of the gasket on the inner conductor 7 and prevents it from collapsing. The support part 4 is provided for support between the inner conductor 7 and the outer conductor 8. The outer side of the support part 4 forms a protrusion that matches the inner wall of the outer conductor 8, thereby increasing the contact area between the support part 4 and the inner wall of the outer conductor 8. This increases the support stability of the support part 4 between the inner and outer conductors 8 and further enhances the mechanical strength of the cable insulation layer. The connecting part 5 is a notch. The notch reduces the volume of the insulating gasket, thereby reducing the impact of the gasket on the medium of high-frequency electromagnetic waves transmitted between the inner and outer conductors of the communication cable. It also forms a channel for internal hot air circulation, which is beneficial for internal cooling of the cable, ensuring that the cable can continue to work in high-power environments, and to a certain extent reducing material usage and production costs.

[0043] The distance from the outermost edge of the sheet support foot to the outer wall of the mounting hole 2 is 2 to 4 times the distance from the bottom of the notch to the outer wall of the mounting hole 2, with 3 times being preferred in this embodiment.

[0044] It should be noted that in order to ensure the high-frequency communication performance of the cable, the gasket must also have a certain support strength to prevent short circuits between the inner and outer conductors. Furthermore, the outer conductor 8 needs to be corrugated after welding. Therefore, the volume of the insulating gasket must be as small as possible. At the same time, the gasket must be able to withstand greater pressure. When the distance from the outermost edge of the sheet support foot to the outer wall of the mounting hole 2 is three times the distance from the bottom of the notch to the outer wall of the mounting hole 2, it can be ensured that the gasket can withstand greater pressure.

[0045] The gasket has mounting holes 2 for fitting the gasket onto the inner conductor 7 of the RF coaxial cable; the gasket also has mounting openings 3, which are connected to the mounting holes 2. When the gasket is installed on the outside of the inner conductor 7, the insulating gasket has a ring structure with staggered ends. Through the mounting opening 3, which communicates with the mounting holes 2, the insulating gasket is secured to the inner conductor 7, completing the installation of the gasket. Because the inner diameter of the mounting holes 2 is approximately the same as the outer diameter of the inner conductor 7, and because the opening of the mounting opening 3 for securing the gasket is in close contact with the inner conductor 7, a stable and secure installation of the gasket is achieved.

[0046] The following is a detailed description of how the gasket 1 in this embodiment is prepared:

[0047] S1. Take 75wt% to 95wt% electronic-grade PEEK resin powder and 5wt% to 25wt% nano-SiO2 powder in the total mass of the insulation material to be prepared. Dry the PEEK resin powder at 140℃ to 160℃ for 1h to 3h; dry the nano-SiO2 powder at 60℃ to 80℃ for 1h to 3h.

[0048] S2. Mix the dried PEEK resin powder and nano SiO2 powder.

[0049] S3. Inject the prepared insulating material into a high-temperature injection molding machine in which the flow channels have been hardened, and maintain the injection temperature at 350°C to 385°C for injection molding to form the gasket body 1 as shown in any one of claims 1 to 5.

[0050] S4. The injection-molded RF coaxial cable insulation pads are allowed to cool naturally in the air.

[0051] S5. After the RF coaxial cable insulation pad changes from a transparent state to a non-transparent state, cool the RF coaxial cable insulation pad to room temperature by spraying or immersing it with room temperature water.

[0052] It should be noted that the PEEK resin powder is a polyether ketone copolymer that can maintain a long-term working temperature above 260℃. The addition of nano-SiO2 powder to the PEEK resin powder is to reduce the dielectric loss and dielectric constant of the PEEK insulation gasket, thereby reducing the loss of the cable insulation gasket. The PEEK resin powder and nano-SiO2 powder need to be dried separately before mixing, and the drying of the two materials should be synchronized as much as possible. After drying, the two insulation materials should be mixed evenly in proportion immediately to prevent the two insulation materials from becoming damp and causing difficulties in subsequent injection molding.

[0053] Regarding the specific mixing ratio of the insulating materials, this invention provides a set of experimental data, as shown in the table below, revealing the influence of different ratios of PEEK powder and SiO2 powder on the parameters of the prepared insulating gaskets:

[0054]

[0055] Therefore, when the proportion of PEEK powder is 75wt% to 95wt% and the proportion of SiO2 powder is 5wt% to 25wt%, the dielectric loss and dielectric constant of the mixed material can be maintained at a low level. Preferably, the proportion of PEEK powder is 90wt% and the proportion of SiO2 powder is 10wt%. At this point, the dielectric loss and dielectric constant of the mixed material are the lowest values ​​in the tested data, which is the optimal ratio for insulating gasket material.

[0056] In summary, by quantitatively mixing PEEK powder and SiO2 powder, the resulting injection-molded insulating gasket has the lowest possible dielectric loss and dielectric constant. The low dielectric constant ensures optimal insulation performance, while the low dielectric loss minimizes heat loss in the electric field, thus guaranteeing the gasket's durability and longevity. The injection-molded insulating gasket forms a ring structure with staggered ends, straddling the inner conductor 7. This mounting method enhances the gasket's stability on the inner conductor 7 and prevents it from collapsing. The support portion 4 provides support between the inner conductor 7 and the outer conductor 8, and its outer side protrudes and connects with the outer conductor 8. The inner wall is adapted to each other, thereby increasing the contact area between the inner wall of the support part 4 and the inner wall of the outer conductor 8, which can increase the support stability of the support part 4 between the inner and outer conductors 8 and further enhance the mechanical strength of the cable insulation layer; the transmission channel 6 formed by the gasket between the inner and outer conductors 8 and the connection part 5 is a notch, by reducing the volume of the insulating gasket, the influence of the gasket on the high-frequency electromagnetic waves transmitted between the inner and outer conductors 8 of the communication cable can be reduced. Furthermore, when the distance from the outermost edge of the sheet support foot to the outer wall of the mounting hole 2 is three times the distance from the bottom of the notch to the outer wall of the mounting hole 2, the volume of the insulating gasket can be kept small, while the gasket can withstand greater pressure, thus enhancing the mechanical strength of the cable insulation layer.

[0057] All the devices selected in this application are general standard parts or components known to those skilled in the art. Their structures and principles can be learned by those skilled in the art through technical manuals or conventional experimental methods.

[0058] In the description of the embodiments of the present invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in the present invention based on the specific circumstances.

[0059] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing the invention and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0060] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A high-rated-power radio frequency coaxial cable insulating pad, characterized in that, include: A number of spacer bodies (1) are sleeved on the inner conductor (7) of the radio frequency coaxial cable, wherein the spacer is a ring structure with the first and last ends misaligned; The gasket is provided with a plurality of support portions (4) and a plurality of connecting portions (5). The support portions (4) are spaced apart and evenly distributed on the circumference of the gasket. A connecting portion (5) is provided between every two support portions (4). The connecting portion (5) is a notch. The support part (4) is a sheet-shaped support foot, and the outer side of the sheet-shaped support foot protrudes to form an arc-shaped protrusion that matches the inner wall of the outer conductor (8) of the radio frequency coaxial cable. The insulating pad is composed of electronic-grade PEEK resin powder accounting for 75wt% to 95wt% of the total mass of the insulating material and nano-SiO2 powder accounting for 5wt% to 25wt%.

2. The high-rated-power radio frequency coaxial cable insulating pad as described in claim 1, characterized in that, The gasket has a mounting hole (2) for fitting the gasket onto the inner conductor (7) of the radio frequency coaxial cable; The gasket has an installation opening (3), and the installation opening (3) and the installation hole (2) are connected through each other.

3. The high-rated-power radio frequency coaxial cable insulating pad as described in claim 2, characterized in that, When the gasket is installed inside the radio frequency coaxial cable, it supports the formation of a transmission channel (6) between the inner conductor (7) and the outer conductor (8) of the radio frequency coaxial cable.

4. The high-rated-power radio frequency coaxial cable insulating pad as described in claim 3, characterized in that, The distance from the outermost edge of the sheet support foot to the outer wall of the mounting hole (2) is 2 to 4 times the distance from the bottom of the notch to the outer wall of the mounting hole (2).

5. A method for preparing an insulating pad for a high-rated power radio frequency coaxial cable as described in any one of claims 1 to 4, characterized in that, The preparation steps include the following: S1. Take 75wt% to 95wt% electronic-grade PEEK resin powder and 5wt% to 25wt% nano-SiO2 powder in the total mass of the insulating material to be prepared. Dry the PEEK resin powder at a temperature of 140℃ to 160℃ for 1h to 3h; dry the nano-SiO2 powder at a temperature of 60℃ to 80℃ for 1h to 3h. S2. Mix the dried PEEK resin powder and nano-SiO2 powder. S3. The prepared insulating material is injected into a high-temperature injection molding machine with hardened flow channels for injection molding to form the gasket body (1) as shown in any one of claims 1 to 4. S4. The RF coaxial cable insulation pad, after injection molding, is allowed to cool naturally in air. S5. After the RF coaxial cable insulation pad changes from a transparent state to a non-transparent state, the RF coaxial cable insulation pad is cooled to room temperature by spraying or immersing with room temperature water.

6. The method for preparing the high-rated-power radio frequency coaxial cable insulating pad as described in claim 5, characterized in that, Injection molding is performed while maintaining a temperature between 350℃ and 385℃.

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