High-frequency cable assembly and assembling method thereof

Abstract

The invention discloses a high-frequency cable assembly and an assembling method thereof, and relates to the field of cable assembly manufacturing. The high-frequency cable assembly comprises a coaxial cable and a coaxial connector. The coaxial cable comprises a first conductor, a first insulating medium, a shielding layer group and a sheath. The coaxial connector comprises a second conductor, a wire clamp and a main body assembly, the second conductor is arranged at one end in the main body assembly, and the wire clamp is arranged at the other end in the main body assembly. The assembling method comprises the following steps: welding the shielding layer group of the coaxial cable with the wire clamp of the coaxial connector; welding the first conductor and the second conductor; and assembling the welded coaxial cable, the second conductor and the wire clamp into the main body assembly of the coaxial connector. The cable assembly is used for solving the problems of large difference loss, unstable phase, weak environmental adaptability and low assembly efficiency, and the transmission performance, the anti-interference capability and the environmental adaptability of the cable assembly as well as the assembly reliability and efficiency are remarkably improved.

Description

Technical Field

[0001] The invention belongs to the field of cable assembly manufacturing, and in particular, relates to a high-frequency cable assembly and an assembly method thereof. Background Art

[0002] With the development of modern science and technology, informatization and intelligence have become two major trends in the development of modern military science and technology, which means that the performance requirements of military communications and radar systems for cable assemblies are also constantly increasing. Traditional cable assemblies can no longer meet the needs of modern warfare in terms of transmission speed, transmission distance, anti-interference, and anti-radiation. Especially in complex and changing battlefield environments, ensuring the stability of communication quality is crucial to the accuracy of command decisions.

[0003] In current military communications and radar systems, high-frequency cable assemblies serve as the "highways" and "neural networks" for information transmission, and their performance directly determines the speed, stability, and security of data transmission.

[0004] However, the existing high-frequency cable assemblies have not been fully optimized in terms of design and material selection, resulting in large signal losses during transmission, and the phase is prone to fluctuations. This unstable transmission characteristic not only affects the speed and accuracy of data transmission, but may also cause information distortion or loss during transmission, which seriously restricts the performance of military communications and radar systems. In addition, the modern warfare environment places higher demands on the environmental adaptability of cable assemblies. For example, under extreme climatic conditions, cable assemblies need to have good resistance to solar radiation, salt spray, mildew and waterproof properties to ensure stable operation in harsh environments. However, the performance of existing cable assemblies in these aspects is not ideal and it is difficult to meet actual needs.

[0005] Therefore, in order to meet the needs of modern military technology, it is very necessary to develop high-frequency cable assembly products to match related products. Summary of the invention

[0006] The present invention provides a high-frequency cable assembly and an assembly method thereof, which solves the problems of large differential loss, unstable phase, weak environmental adaptability and low assembly efficiency, and significantly improves the transmission performance, anti-interference ability and environmental adaptability of the cable assembly, as well as the reliability and efficiency of assembly.

[0007] The technical solutions used in the present invention are as follows:

[0008] A high frequency cable assembly, comprising a coaxial cable and a coaxial connector,

[0009] The coaxial cable comprises a first conductor, a first insulating medium surrounding the first conductor, a shielding layer group covering the first insulating medium, and a sheath covering the shielding layer group;

[0010] The coaxial connector comprises a second conductor, a wire clamp and a main body component, wherein the second conductor is placed at one end inside the main body component, and the wire clamp is placed at the other end inside the main body component;

[0011] The first conductor is connected to the second conductor, and the shielding layer group is connected to the wire clamp.

[0012] Furthermore, the first conductor is a single-core silver-plated soft round copper wire, the first insulating medium is made of low-density polytetrafluoroethylene, and the sheath is made of polytetrafluoroethylene.

[0013] Furthermore, the shielding layer group includes a first shielding layer and a second shielding layer, the first shielding layer is a silver-plated copper tape, and the second shielding layer is a silver-plated copper wire.

[0014] Furthermore, the main body component includes a tail cover, a shell and a connecting device, the tail cover, the shell and the connecting device are connected in sequence, the wire clamp is placed in the tail cover, and the second conductor is placed in the shell and the connecting device.

[0015] Furthermore, the coaxial connector further includes a second insulating medium, and the second insulating medium is disposed between the second conductor and the main body component.

[0016] Furthermore, a plurality of first waterproof grooves are provided on the second conductor, and a first sealing ring is arranged in the first waterproof groove; a second waterproof groove is provided on a side of the shell close to the tail cover, and a second sealing ring is arranged in the second waterproof groove; a third waterproof groove is provided on a side of the tail cover close to the wire clamp, and a third sealing ring is arranged in the third waterproof groove; a fourth waterproof groove is provided on the outer circumference of the second insulating medium, and a fourth sealing ring is arranged in the fourth waterproof groove.

[0017] Furthermore, the coaxial connector also includes a heat shrink sleeve, and the heat shrink sleeve is arranged at the connection between the main body component and the coaxial cable.

[0018] Furthermore, the wire clamp is a step-free structure, and the relative position of the first conductor and the shielding layer group is adjusted by heating and moving the wire clamp.

[0019] A method for assembling a high-frequency cable assembly is applied to the assembly of the above-mentioned high-frequency cable assembly, comprising the following steps:

[0020] Step 1: Weld the shielding layer group of the coaxial cable to the wire clamp of the coaxial connector;

[0021] Step 2, welding the first conductor and the second conductor;

[0022] Step 3: Assemble the welded coaxial cable, the second conductor and the wire clamp into the main assembly of the coaxial connector.

[0023] Furthermore, the welding method in step one is a handheld heating method.

[0024] The beneficial effects of the present invention are:

[0025] 1. The structural design optimization and material selection of the coaxial cable in the present invention effectively improve the high-frequency transmission performance. The coaxial cable uses a single-core silver-plated soft round copper wire as the first conductor, combined with the skin effect, to ensure the excellent conductivity of the cable under high-frequency conditions. In addition, the first insulating medium uses low-density polytetrafluoroethylene, which has a low dielectric constant and excellent insulation properties, providing excellent high-frequency insulation effect for the cable. The shielding layer group includes a double-layer shielding structure composed of silver-plated copper tape and silver-plated copper wire, which can effectively resist external electromagnetic interference and ensure the stability of signal transmission inside the cable.

[0026] 2. The design of the coaxial connector in the present invention enhances the connection reliability. The design of the step-free wire clamp allows the relative position to be adjusted by heating and moving the wire clamp during the matching process to achieve matching. It has the advantages of good connection insertion loss, stable performance, and small conductor state deformation. The multi-level waterproof design and the setting of the heat shrink tubing improve the waterproof performance and durability of the high-frequency cable assembly.

[0027] 3. The assembly method of the present invention adopts a combination of welding and assembly. The shielding layer group and the wire clamp, the first conductor and the second conductor are firmly connected by welding, and then the welded parts are assembled into the main assembly by assembly. This combination method not only ensures the reliability of the connection, but also improves the production efficiency. In addition, the handheld heating method is used to replace the traditional soldering station welding, which can more accurately control the welding temperature and the amount of tin, avoid welding failure caused by temperature reasons, and ensure the density and consistency of the welding. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] Figure 1 A schematic diagram of the coaxial cable structure provided by the present invention;

[0029] Figure 2 A schematic diagram of the structure of a coaxial connector provided by the present invention;

[0030] Figure 3 A partial cross-sectional view of the coaxial connector provided by the present invention.

[0031] In the accompanying drawings, the components represented by the reference numerals are listed as follows:

[0032] 1. First conductor; 2. First insulating medium; 3. First shielding layer; 4. Second shielding layer; 5. Sheath; 6. Second conductor; 7. Wire clamp; 8. Shell; 9. Tail cover; 10. Second insulating medium; 11. Connector; 12. Heat shrink tubing; 61. First waterproof groove; 62. First sealing ring; 81. Second waterproof groove; 82. Second sealing ring; 91. Third waterproof groove; 92. Third sealing ring; 101. Fourth waterproof groove; 102. Fourth sealing ring. DETAILED DESCRIPTION

[0033] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on 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.

[0034] The technical solutions in the embodiments of the present application will be described clearly and completely below in conjunction with the accompanying drawings.

[0035] Example 1

[0036] like Figure 1-Figure 3 As shown, this embodiment provides a high-frequency cable assembly, including a coaxial cable and a coaxial connector. The coaxial cable includes a first conductor 1, a first insulating medium 2 surrounding the first conductor 1, a shielding layer group covering the first insulating medium 2, and a sheath 5 covering the shielding layer group; the coaxial connector includes a second conductor 6, a wire clamp 7 and a main body component, the second conductor 6 is placed at one end inside the main body component, the wire clamp 7 is placed at the other end inside the main body component, the wire clamp 7 is a step-free structure, the second conductor 6 and the wire clamp 7 are made of copper-plated gold material, so that the second conductor 6 is welded to the first conductor 1, and the wire clamp 7 is welded to the shielding layer group, so as to realize the assembly of the coaxial cable and the coaxial connector.

[0037] Specifically, Figure 1As shown in the figure, as the core transmission part of the high-frequency cable assembly, the first conductor 1 adopts a single-core silver-plated soft round copper wire. This silver material has good conductivity. According to the skin effect, the current can be concentrated on the surface of the conductor during high-frequency transmission, which improves the transmission efficiency and ensures low loss and high efficiency of the signal during transmission. The first insulating medium 2 is made of low-density polytetrafluoroethylene, which plays a key insulating role. It has the characteristics of low density, light weight, small relative dielectric constant, good dielectric constant consistency in a wide range, etc., which provides excellent insulation effect for the cable, and also has good mechanical properties, high temperature resistance and The corrosion resistance ensures the stable operation of the cable in harsh environments; the shielding layer group includes a first shielding layer 3 and a second shielding layer 4, the first shielding layer 3 is a silver-plated copper tape, and the second shielding layer 4 is a silver-plated copper wire. The double-layer shielding structure can effectively resist external electromagnetic interference and ensure the stability of the signal transmission inside the cable; the sheath 5 is the outermost protective structure of the coaxial cable, and is made of polytetrafluoroethylene propylene material, which has the characteristics of resistance to solar radiation, mold, and waterproof, further enhancing the durability and reliability of the cable. At the same time, the sheath 5 also has a certain degree of flexibility, making the cable more convenient to bend and install. Therefore, the coaxial cable provided in this embodiment has excellent high-frequency transmission performance, excellent conductivity, insulation effect, anti-interference ability and durability, and provides a stable and reliable solution for application scenarios such as microwave signal transmission.

[0038] Specifically, Figure 2 and Figure 3 As shown, the main component includes a tail cover 9, a shell 8 and a connector 11, which are connected in sequence. The wire clamp 7 is placed in the tail cover 9, and the second conductor 6 is placed in the shell 8 and the connector 11. The shell 8, the tail cover 9 and the connector 11 are all made of stainless steel and passivated to further enhance their corrosion resistance and mildew resistance. The shell 8 is the external protection structure of the coaxial connector, which is used to protect the electrical components inside the connector from interference and damage from the external environment. The tail cover 9 is mainly used to fix the wire clamp 7 and protect the end portion of the coaxial cable. The connector 11 is usually connected to the interface of the next-level device or system.

[0039] In order to prevent short circuit or leakage between the second conductor 6 and the housing 8, Figure 2 As shown, a second insulating medium 10 is also provided. The second insulating medium 10 is placed between the second conductor 6 and the housing 8 to provide insulation and support, thereby ensuring that the electrical performance of the connector is stable and reliable.

[0040] In order to improve the waterproof capability of the coaxial connector and the coaxial cable after being assembled, a multi-level waterproof design is provided in the structure of the coaxial connector. Figure 3As shown, a plurality of first waterproof grooves 61 are provided on the second conductor 6, two of which are provided in the present embodiment, and a first sealing ring 62 is provided in the first waterproof groove 61 to prevent moisture penetration between the second conductor 6 and the second insulating medium 10; a second waterproof groove 81 is provided on the side of the shell 8 close to the tail cover 9, and a second sealing ring 82 is provided in the second waterproof groove 81 to achieve waterproofing between the shell 8 and the tail cover 9; a third waterproof groove 91 is provided on the side of the tail cover 9 close to the wire clamp 7, and a third sealing ring 92 is provided in the third waterproof groove 91 to achieve waterproofing between the tail cover 9 and the wire clamp 7; a fourth waterproof groove 101 is provided on the outer circumference of the second insulating medium 10, and a fourth sealing ring 102 is provided in the fourth waterproof groove 101 to achieve waterproofing between the coaxial connector shell 8 and the second insulating medium 10. By providing these multiple waterproof grooves and sealing ring structures, the waterproof level of the coaxial connector can reach IP68.

[0041] In order to enhance the protection performance of the product, a heat shrink tube 12 is provided at the connection between the main component and the coaxial cable. The waterproof function of the joint is achieved through heat shrinkage hardening treatment, which not only improves the waterproof level and protection performance of the coaxial connector, but also enhances the reliability and stability of the connection. In harsh environments, the heat shrink tube 12 can effectively protect the electrical components inside the connector from erosion by water and moisture.

[0042] A high-frequency cable assembly provided in this embodiment is mainly used for microwave signal transmission, and has the characteristics of small loss, good flexibility, wide temperature adaptability, protection against sun damage, strong resistance to salt spray, good resistance to mildew, and excellent waterproof performance. The main technical indicators are shown in Table 1.

[0043] Table 1: Main technical indicators of a high-frequency cable assembly

[0044] property Performance Indicators Connection Type NJ / N-KF、NJ / N-JW Characteristic impedance 50Ω Working frequency band DC~18GHz VSWR Vswr≤1.35 Insertion loss ≤1.8dB@18GHz Phase Deviation ±3° Temperature phase stability ≤750PPM-45℃~+85℃ Amplitude stability ±0.1dB@18GHz Dynamic bending radius ≤70mm Operating temperature -50℃～100℃ Salt spray test 96 hours

[0045] Example 2

[0046] This embodiment provides a method for assembling a high-frequency cable assembly, using the high-frequency cable assembly in Embodiment 1, and adopting a method combining welding and assembly, including:

[0047] Step 1: Weld the shielding layer group of the coaxial cable to the wire clamp 7 of the coaxial connector;

[0048] Step 2: welding the first conductor 1 and the second conductor 6;

[0049] Step 3: Assemble the welded coaxial cable, the second conductor 6 and the wire clamp 7 into the main assembly of the coaxial connector.

[0050] Specifically, in step 1, a handheld heating method is used for welding. The traditional welding method is welding with a soldering station, which has the disadvantage of being difficult to control the welding time and the amount of tin fed during the welding process. The handheld heating method can improve the ability of temperature control and tin feeding control, and ensure that the temperature is constant between 300±10℃, thereby avoiding welding failures caused by temperature reasons; the handheld heating method not only ensures the constant welding temperature, but also can evenly heat the wire clamp 7, so that the solder can be fully infiltrated to achieve the density and consistency of welding; in step 2, the connection between the first conductor 1 and the second conductor 6 is selected by material welding, and the amount of solder required for assembly is achieved by controlling the power and then the feeding speed of the solder; in addition, the step-free design of the wire clamp 7 enables the relative position of the first conductor 1 and the shielding layer group to be adjusted by heating and moving the wire clamp 7 during the phase matching process, so as to achieve accurate phase matching. This design not only improves the reliability of the connection, but also simplifies the assembly process. This assembly method has the advantages of good connection insertion loss, stable performance, and small conductor state deformation, ensuring the reliability and attenuation performance of signal transmission of high-frequency cable assemblies.

[0051] The embodiments of the present invention are described in detail above, but the contents described are only preferred embodiments of the present invention and cannot be considered to limit the scope of implementation of the present invention. All equivalent changes and improvements made within the scope of the present invention should still fall within the scope of the patent coverage of the present invention.

Claims

1. A high-frequency cable assembly, comprising a coaxial cable and a coaxial connector, characterized in that: The coaxial cable comprises a first conductor (1), a first insulating medium (2) surrounding the first conductor (1), a shielding layer group covering the first insulating medium (2), and a sheath (5) covering the shielding layer group; The coaxial connector comprises a second conductor (6), a wire clamp (7) and a main body component, wherein the second conductor (6) is placed at one end inside the main body component, and the wire clamp (7) is placed at the other end inside the main body component; The first conductor (1) is connected to the second conductor (6), and the shielding layer group is connected to the wire clamp (7).

2. A high frequency cable assembly according to claim 1, characterized in that: The first conductor (1) is made of a single-core silver-plated soft round copper wire, the first insulating medium (2) is made of low-density polytetrafluoroethylene, and the sheath (5) is made of polytetrafluoroethylene.

3. A high-frequency cable assembly according to claim 1 or 2, characterized in that: The shielding layer group comprises a first shielding layer (3) and a second shielding layer (4), the first shielding layer (3) is a silver-plated copper tape, and the second shielding layer (4) is a silver-plated copper wire.

4. A high frequency cable assembly according to claim 1, characterized in that: The main body assembly comprises a tail cover (9), a shell (8) and a connecting device (11); the tail cover (9), the shell (8) and the connecting device (11) are connected in sequence; the wire clamp (7) is placed in the tail cover (9); and the second conductor (6) is placed in the shell (8) and the connecting device (11).

5. A high-frequency cable assembly according to claim 1 or 4, characterized in that: The coaxial connector further comprises a second insulating medium (10), wherein the second insulating medium (10) is disposed between the second conductor (6) and the main body component.

6. A high frequency cable assembly according to claim 5, characterized in that: The second conductor (6) is provided with a plurality of first waterproof grooves (61), and a first sealing ring (62) is arranged in the first waterproof groove (61); a second waterproof groove (81) is provided on a side of the housing (8) close to the tail cover (9), and a second sealing ring (82) is arranged in the second waterproof groove (81); a third waterproof groove (91) is provided on a side of the tail cover (9) close to the wire clamp (7), and a third sealing ring (92) is arranged in the third waterproof groove (91); a fourth waterproof groove (101) is provided on the outer circumference of the second insulating medium (10), and a fourth sealing ring (102) is arranged in the fourth waterproof groove (101).

7. A high frequency cable assembly according to claim 1, characterized in that: The coaxial connector also includes a heat shrink sleeve (12), and the heat shrink sleeve (12) is arranged at the connection between the main body component and the coaxial cable.

8. A high frequency cable assembly according to claim 1, characterized in that: The wire clamp (7) is a step-free structure, and the relative position of the first conductor (1) and the shielding layer group is adjusted by heating and moving the wire clamp (7).

9. A method for assembling a high-frequency cable assembly, characterized in that: The assembly of the high-frequency cable assembly according to any one of claims 1 to 8 comprises the following steps: Step 1, welding the shielding layer group of the coaxial cable to the wire clamp (7) of the coaxial connector; Step 2: welding the first conductor (1) and the second conductor (6); Step 3: Assemble the welded coaxial cable, the second conductor (6) and the wire clamp (7) into the main assembly of the coaxial connector.

10. A method for assembling a high-frequency cable assembly according to claim 9, characterized in that: The welding method in step 1 is a handheld heating method.

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