A process for preparing wire cores and a cable

Abstract

This invention proposes a core fabrication process and a cable. The core fabrication process involves softening annealing to ensure uniform distribution of the various components of the internal material, preventing breakage during drawing. Stress-relief annealing then restores the core's toughness, maintaining good mechanical properties and a stable shape, thus achieving a high compression ratio core. The cable made from the core processed using this process includes a core with an inner insulation layer. An outer insulation layer, comprising an inner layer and an outer layer, is provided outside the inner insulation layer. The inner layer is bonded to the inner insulation layer, and the outer layer is located outside the inner layer. A protective layer is provided on the outer side of the outer layer.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a process for preparing wire cores and a cable. Background Technology

[0002] Coaxial cable is a widely used cable in radio frequency communication, video transmission, and high-frequency signal transmission. Its basic structure includes a center conductor, insulation layer, shielding layer, and outer sheath. The center conductor is a crucial part of signal transmission; its materials, structure, and manufacturing process directly affect the cable's conductivity, signal attenuation, and mechanical characteristics. A typical center conductor is composed of a single conductor or multiple strands twisted together. The cross-sectional area of ​​the center conductor includes the cross-sectional area of ​​the conductors and the area of ​​the gaps between them. In a given cross-section of the center conductor, the proportion of each conductor's cross-section affects the overall communication efficiency and signal attenuation.

[0003] In existing technologies, to increase the proportion of the conductor cross-section in the central conductor's cross-section, the central conductor is typically reduced in diameter. This allows the individual conductors within the central conductor to bond more tightly through deformation, thereby increasing the compression ratio. When processing central conductors with smaller diameters, conventional methods involve directly drawing and reducing the diameter at room temperature. This process is effective for lower compression ratios. However, under these conditions, when the standard compression ratio of the central conductor is high, the large degree of deformation during drawing leads to the accumulation of numerous dislocations and the formation of cracks within the central conductor, making wire breakage a common problem. Maintaining a high compression ratio during the drawing process becomes difficult. Summary of the Invention

[0004] The main objective of this invention is to propose a process for preparing wire cores, which aims to solve the technical problem of difficulty in improving the compression ratio of small-diameter wire cores.

[0005] To achieve the above objectives, the present invention proposes a process for preparing wire cores, comprising:

[0006] Step 1: Softening and annealing:

[0007] The first ends of multiple side wires are spot-welded to the first end of the core wire. The first ends of the multiple side wires and the first end of the core wire are then introduced into a first online annealing furnace. The first online annealing furnace is equipped with multiple different temperature gradient zones. As the wire core passes through the first online annealing furnace, it sequentially passes through the 400℃ zone, the 500℃ zone, the 600℃ zone, the 500℃ zone, and the 400℃ zone. The speed at which the wire core passes through the first online annealing furnace is 3.2m / min to 5.2m / min, and the softening annealing time is 5min to 10min.

[0008] Step 2: Diameter Reduction Drawing

[0009] The first end of the softened and annealed wire core is passed through the die on the drawing machine at a speed of 3.5m / min to 5.5m / min; the wire core is subjected to initial ultrasonic treatment before entering the die.

[0010] Step 3: Stress-relief annealing:

[0011] The wire core after the diameter reduction drawing is introduced into the second online annealing furnace. The wire core passes through the second online annealing furnace at a speed of 3.2m / min~5.2m / min. The annealing temperature is 200℃~300℃. The stress-relief annealing process lasts for 3min~5min. The wire core in the stress-relief annealing process is subjected to secondary ultrasonic treatment.

[0012] Step 4: Cooling and winding:

[0013] Air cooling is performed under wind speeds of 20m / s to 25m / s, and the winding speed of the winding machine is 4m / min to 6m / min.

[0014] Furthermore, each of steps one through three includes a tension detection mechanism. The tension detection mechanism is electrically connected to the traction equipment via the control system. The traction equipment adjusts the speed of the traction core based on the core tension value fed back by the tension detection mechanism.

[0015] Furthermore, the compression rate of the wire core is 5% to 40%;

[0016] ;

[0017] ;

[0018] ;

[0019] S1 is the cross-sectional area of ​​the side wire and the core wire; S2 is the sum of the cross-sectional areas of the core wire; W is the total compression ratio of the core wire; d is the diameter of the side wire or the core wire; n is the number of side wires and the core wire; D is the diameter of the circumscribed circle, which is tangent to multiple side wires at the same time.

[0020] This invention also proposes a cable comprising a wire core manufactured using the wire core manufacturing process described in the above embodiments. The wire core has an inner insulation layer on its exterior, and multiple first copper cores are arranged circumferentially within the inner insulation layer, with the multiple first copper cores being evenly spaced. An outer insulation layer is provided outside the inner insulation layer, comprising an inner layer and an outer layer, with the inner layer bonded to the inner insulation layer and the outer layer disposed outside the inner layer. Multiple second copper cores are arranged circumferentially within the inner layer, with the multiple second copper cores being evenly spaced, and a protective layer is provided on the outer surface of the outer layer.

[0021] Furthermore, both the first and second copper cores are made of multiple copper wires connected end to end through terminals; both sides of the terminals are provided with rubber sleeves to match the ends of the copper wires.

[0022] Furthermore, the terminal includes a connecting cylinder and an isolation cylinder. Both ends of the isolation cylinder are provided with an integrated isolation cylinder. The inner wall of the isolation cylinder is provided with a rubber sleeve that fits into the end of the first copper core or the second copper core. The isolation cylinder contains an isolation gel.

[0023] Furthermore, the second copper core is located at the interface between the inner layer and the outer layer, and the outer sidewall of the inner layer and the inner sidewall of the outer layer are both provided with grooves to match the second copper core.

[0024] Furthermore, the second copper core is spirally wound inside the groove.

[0025] Furthermore, a fully shielding layer is provided between the outer layer and the protective layer. The outer side of the fully shielding layer is attached to the protective layer, and the inner side of the fully shielding layer is attached to the outer layer.

[0026] Furthermore, the complete shielding layer includes a corrugated copper tube, an inner protective layer, and an outer protective layer, with the corrugated copper tube located between the inner and outer protective layers; the inner protective layer is attached to the outer side wall of the outer layer, and the outer protective layer is attached to the inner side wall of the protective layer. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the structures shown in these drawings without creative effort.

[0028] Figure 1 This is a cross-sectional schematic diagram of the conductor of the present invention;

[0029] Figure 2 This is a schematic diagram of the cable structure of the present invention;

[0030] Figure 3 This is a cross-sectional schematic diagram of the present invention;

[0031] Figure 4 This is a schematic diagram of the core structure of the present invention;

[0032] Figure 5 This is a schematic diagram of the structure of the inner insulating layer of the present invention;

[0033] Figure 6 This is a schematic diagram of the structure of the outer insulating layer of the present invention;

[0034] Figure 7 This is a cross-sectional schematic diagram of the shielding layer of the present invention;

[0035] Figure 8 for Figure 6A magnified view of a section at point A in the middle;

[0036] Figure 9 This is a schematic diagram of the assembly of the first copper core and the terminal;

[0037] Figure 10 This is a cross-sectional schematic diagram of the terminal of the present invention.

[0038] Explanation of icon numbers:

[0039] 1. Core wire; 2. Inner insulation layer; 3. Outer insulation layer; 4. Shielding layer; 5. Protective layer; 6. Terminal; 11. Core wire; 12. Side wire; 21. First copper core; 22. Raised ridge; 31. Outer layer; 32. Inner layer; 33. Second copper core; 321. Positioning groove; 41. Corrugated copper tube; 42. Inner protective layer; 43. Outer protective layer; 211. Copper wire; 61. Isolation cylinder; 62. Connecting cylinder; 63. Isolation gel; 621. Rubber sleeve; 622. Limiting ring; 631. Cavity.

[0040] The realization of the objective, functional features and advantages of the present invention will be further explained in conjunction with the embodiments and with reference to the accompanying drawings. Detailed Implementation

[0041] The technical solutions of 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 a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0042] It should be noted that if the embodiments of the present invention involve directional indicators (such as up, down, left, right, front, back, etc.), the directional indicators are only used to explain the relative positional relationship and movement of the components in a certain specific posture (as shown in the figure). If the specific posture changes, the directional indicators will also change accordingly.

[0043] Furthermore, the use of terms such as "first" and "second" in this invention is for descriptive purposes only and should not be construed as indicating or implying their relative importance or implicitly specifying the number of technical features indicated. Therefore, a feature defined with "first" or "second" may explicitly or implicitly include at least one of those features. Additionally, the term "and / or" throughout the text includes three solutions; taking A and / or B as an example, it includes technical solution A, technical solution B, and a technical solution that simultaneously satisfies A and B. Furthermore, the technical solutions of various embodiments can be combined with each other, provided that they are feasible for those skilled in the art. When the combination of technical solutions is contradictory or impossible to implement, it should be considered that such a combination of technical solutions does not exist and is not within the scope of protection claimed by this invention.

[0044] To address the technical problem of difficulty in increasing the compression ratio of small-diameter wire cores, this invention proposes a process for preparing wire cores, comprising:

[0045] Step 1: Softening and annealing:

[0046] The first ends of multiple side wires 12 are spot-welded to the first end of the core wire 11, and the other ends of the side wires 12 are also spot-welded to the core wire 11. The first ends of the multiple side wires 12 and the first ends of the core wire 11 are introduced into a first online annealing furnace. The first online annealing furnace is equipped with multiple different temperature gradient zones. During the process of the wire core 1 passing through the first online annealing furnace, it passes through the 400℃ zone, the 500℃ zone, the 600℃ zone, the 500℃ zone, and the 400℃ zone in sequence. The speed at which the wire core 1 passes through the first online annealing furnace is 3.2m / min to 5.2m / min, and the softening annealing time is 5min to 10min.

[0047] The main purpose of softening annealing is to change the microstructure of the core material itself, reduce hardness, improve plasticity and toughness, homogenize chemical composition, and release internal stress, thus preparing it for subsequent processing and treatment. During the process of core 1 entering and leaving the first online annealing furnace, uneven internal stress occurs due to sudden temperature changes. By setting multiple temperature gradient ranges, core 1 undergoes a cycle from low temperature to high temperature and back to low temperature during annealing, which reduces the impact of stress, allowing core 1 to maintain a stable shape during softening annealing, while effectively utilizing heat energy and reducing energy consumption.

[0048] Before introducing the core wire 1 into the first online annealing furnace, the surfaces of the core wire 11 and side wires 12 generally need to be cleaned to prevent impurities from adversely affecting subsequent steps. The side wires 12 and core wire 11 sequentially pass through an acid pickling tank and a drying section. The acid pickling solution is a mixture of 8%~10% sulfuric acid and hydrochloric acid. After acid pickling for 10~15 minutes, the wire is rinsed with clean water, followed by air drying at a wind speed of 15m / s~20m / s. This ensures the outer surfaces of the side wires 12 and core wire 11 remain clean. The acid pickling tank is equipped with a pH meter and a temperature sensor, which monitor the acid pickling conditions in real time to ensure the final acid pickling effect.

[0049] After pickling, the core wire 11 and side wires 12 are fed to a stranding machine for stranding. The stranding speed is 1025 r / min to 25 r / min. The stranding machine strands the side wires 12 onto the core wire 11 in a clockwise or counterclockwise direction to form the wire core 1. The output speed of the stranding machine is 3 m / min to 5 m / min.

[0050] Step 2: Diameter Reduction Drawing

[0051] The first end of the softened and annealed wire core 1 is passed through the die on the wire drawing machine at a speed of 3.5m / min to 5.5m / min; the wire core 1 is subjected to initial ultrasonic treatment before entering the die.

[0052] As core 1 passes through the die, its diameter decreases. Due to pre-softening annealing, the crystal structure and composition of core 1 are uniform during drawing, making it less prone to dislocation formation and reducing the probability of crack formation. Therefore, at processing speeds of 3.5 m / min to 5.5 m / min, core 1 can maintain a stable shape without breaking after diameter reduction drawing. Ultrasonic treatment of core 1 before entering the die is performed using an ultrasonic generator to eliminate the stress between the core wire 11 and the side wire 12 during processing. This allows core 1 to pass through the die smoothly and prevents breakage during drawing.

[0053] Step 3: Stress-relief annealing:

[0054] The wire core 1 after the diameter reduction drawing is introduced into the second online annealing furnace. The wire core 1 passes through the second online annealing furnace at a speed of 3.2m / min~5.2m / min. The annealing temperature is 200℃~300℃. The stress-relief annealing process lasts for 3min~5min. The wire core 1 in the stress-relief annealing process is subjected to secondary ultrasonic treatment.

[0055] After the diameter reduction drawing, core 1 experiences work hardening, resulting in significant internal stress accumulation. Low-temperature annealing at 200℃~300℃ effectively eliminates the residual stress generated during the diameter reduction drawing process, preventing deformation or cracking due to stress release during subsequent processing or use. This also stabilizes the crystal structure of core 1, reduces internal defects, and improves the material's dimensional stability and mechanical properties. Secondary ultrasonic treatment further refines the grains during annealing, improving the material's microstructure and thus enhancing the strength, toughness, and fatigue life of core 1.

[0056] Step 4: Cooling and winding. Air cooling is performed at a wind speed of 20m / s to 25m / s. The winding speed of the winding machine is 4m / min to 6m / min. The stress-relieved annealed wire core 1 is then stored in roll form.

[0057] The entire process of preparing wire core 1 includes pickling, stranding, softening annealing, drawing, and stress-relief annealing, with the moving speed of wire core 1 gradually increasing. This ensures that wire core 1 maintains a certain tension during processing, preventing it from loosening and falling off the equipment. However, the speed difference between different steps cannot be too large; otherwise, excessive tension may cause wire core 1 to break. Tension detection mechanisms are installed in steps one through three. These mechanisms are electrically connected to the traction equipment via a control system. The traction equipment adjusts the speed of traction of wire core 1 based on the tension value fed back by the tension detection mechanism.

[0058] The tension of core 1 is monitored in real time by a tension detection mechanism, and the detected tension data is transmitted to the control system to ensure that core 1 will not break due to excessive tension or slack due to insufficient tension during processing. The control system receives the tension data transmitted by the tension detection mechanism, analyzes the tension data and compares it with the preset tension range, and sends adjustment commands to the traction equipment based on the comparison results. The traction equipment dynamically adjusts the traction speed of core 1 according to the commands sent by the control system. If excessive tension is detected, the traction equipment will reduce the traction speed to reduce the tension on core 1. If insufficient tension is detected, the traction equipment will increase the traction speed to increase the tension on core 1. This forms a closed-loop automatic control process, ensuring that core 1 will not have defects due to uneven stress during processing, thus guaranteeing product quality. It avoids material waste caused by core 1 breaking due to excessive tension or slack falling off the equipment due to insufficient tension. It reduces manual intervention and improves the continuity and stability of the production line.

[0059] The compression rate of core 1 during its movement is detected in real time by a tension detection mechanism, ranging from 5% to 40%.

[0060] ;

[0061] ;

[0062] ;

[0063] S1 is the sum of the cross-sectional areas of the side wire 12 and the core wire 11; S2 is the cross-sectional area of ​​the core 1; W is the total compression ratio of the core 1; d is the diameter of the side wire 12 or the core wire 11; n is the number of side wires 12 and core wires 11; D is the diameter of the circumscribed circle, which is tangent to multiple side wires 12 at the same time.

[0064] like Figures 1-7As shown, the present invention proposes a cable including a core 1, with an inner insulation layer 2 on the outside of the core 1. Multiple first copper cores 21 are arranged circumferentially inside the inner insulation layer 2, with the multiple first copper cores 21 evenly spaced. An outer insulation layer 3 is provided outside the inner insulation layer 2, comprising an inner layer 32 and an outer layer 31. The inner layer 32 is bonded to the inner insulation layer 2, and the outer layer 31 is located outside the inner layer 32. Multiple second copper cores 33 are arranged circumferentially in the inner layer 32, with the multiple second copper cores 33 evenly spaced. A protective layer 5 is provided on the outer surface of the outer layer 31. The protective layer 5, as the outermost physical protection of the cable, is typically made of PE or PU material, possessing good insulation properties, protecting the cable from external mechanical damage such as pulling, compression, and impact, and preventing damage to the cable due to external forces.

[0065] As the core component for signal transmission, conductor 1 is responsible for transmitting current or signals. Conductor 1 includes core wire 11 and side wires 12. Multiple side wires 12 are wound around the outer surface of conductor 1, which helps reduce interference from external electromagnetic fields, lower crosstalk, and improve signal transmission quality. Multiple side wires 12 are evenly wound on the same core wire 11, which can evenly distribute the electric and magnetic fields between the conductors, thereby reducing signal loss and distortion and maintaining signal stability. Simultaneously, the twisted structure allows for a more even distribution of stress when the cable is under tension, thus improving the cable's tensile strength and durability. The twisted structure of the side wires 12 and core wire 11 makes the cable more flexible, easier to bend and install, suitable for use in various complex environments, and facilitates cable wiring. The cross-section of conductor 1 is circular, the cross-section of core wire 11 is polygonal, and the cross-section of side wire 12 is fan-shaped. The side wires 12 are closely fitted to the core wire 11. The polygonal cross-section core wire 11 and the fan-shaped cross-section side wire 12 work together to increase the contact area between the side wire 12 and the core wire 11, thereby improving the overall compression ratio of the cable cross-section. Without affecting the cable's transmission capacity, this helps to reduce the cable diameter, making the cable more compact and easier to lay and install. The tight fit between the side wire 12 and the core wire 11 improves the stability and strength of the overall structure, reducing relative displacement and friction. Through this tight fit, the wire can better withstand external forces, improving its tensile strength and durability.

[0066] The inner insulation layer 2 wraps around the wire core 1, serving as insulation and protecting the wire core 1 from the influence of the external environment. The inner insulation layer 2 can typically be made of rubber, epoxy resin, polytetrafluoroethylene, or other mixed insulating materials. Multiple evenly spaced first copper cores 21 form the first shielding mesh, reducing signal attenuation. At the same time, the first copper cores 21 can increase the tensile strength of the inner insulation layer 2, preventing localized damage to the inner insulation layer 2 and ensuring the effective wrapping of the wire core 1 by the inner insulation layer 2.

[0067] The outer insulation layer 3 is made of foamed rubber-plastic insulation material, polyurethane foam, or EPDM rubber, possessing excellent elasticity and providing both thermal insulation and electrical insulation. The outer surface of the inner layer 32 has multiple raised ribs 22 circumferentially, and the inner surface of the outer layer 31 has positioning grooves 321 that mate with the raised ribs 22. The raised ribs 22 on the inner layer 32 are embedded into the positioning grooves 321 of the outer layer 31, improving the stability between the inner layer 32 and the outer layer 31 and preventing slippage or misalignment. This structure helps ensure the stability of the inner and outer layer 31 components during use, improving the overall durability of the outer insulation layer 3. The cooperation between the raised ribs 22 and the positioning grooves 321 enhances the shock resistance and impact resistance of the outer insulation layer 3. When subjected to external impact, the structure of the raised ribs 22 and the positioning grooves 321 can disperse or absorb some of the impact force, thereby reducing the risk of damage to the outer insulation layer 3. The engagement of the protruding ridge 22 and the positioning groove 321 increases the contact area between the inner layer 32 and the outer layer 31, which helps improve the sealing effect of the inner layer 32 and the outer layer 31, reducing the possibility of air or water leakage. Under the protection of the inner layer 32 and the outer layer 31, the second copper core 33 has its contact area with the outside world minimized, effectively delaying the oxidation of the second copper core 33 and increasing its service life. The second copper core 33 forms a second shielding mesh, further ensuring the efficiency of signal transmission by the wire core 1.

[0068] The second copper core 33 is disposed at the interface between the inner layer 32 and the outer layer 31. Both the outer sidewall of the inner layer 32 and the inner sidewall of the outer layer 31 have grooves for mates with the second copper core 33. This embedded structure of the second copper core 33 and the grooves improves the stability of the assembly between the inner layer 32 and the outer layer 31, preventing relative displacement and loosening. This effectively enhances the overall stability of the outer insulation layer 3. Sealant is applied between the contact surfaces of the grooves and the second copper core 33, and between the contact surfaces of the inner layer 32 and the outer layer 31. The sealant further improves the sealing performance of the assembly between the second copper core 33 and the inner layer 32 or the outer layer 31, effectively delaying the oxidation process of the copper core and increasing the bonding strength between the second copper core 33 and the outer layer 31 and the inner layer 32. The second copper core 33 is spirally wound within the groove. This spiral shape increases the contact area with the inner layer 32 and the outer layer 31, enhancing the overall bonding strength of the outer insulation layer 3. It also increases the shielding density of the second copper core 33, optimizing its shielding effect. Compared to the first copper core 21, the second copper core 33 is located further from the wire core 1. The diameter of the second copper core 33 is larger than that of the first copper core 21, further increasing its shielding area and optimizing its shielding effect.

[0069] Both the first copper core 21 and the second copper core 33 are formed by connecting multiple copper wires 211 end to end through a terminal 6. Both sides of the terminal 6 are provided with rubber sleeves 621 that mate with the ends of the copper wires 211. Different copper wires 211 are connected as a whole through the terminal 6, and indirectly contact the terminal 6 through the rubber sleeves 621. When one copper wire 211 oxidizes and corrodes, the isolation effect of the terminal 6 prevents the corrosion from spreading to another section of copper wire 211, preventing the entire first copper core 21 or second copper core 33 from oxidizing and failing. The terminal 6 body is made of metal, and while connecting the copper wires 211, it also serves to shield the signal of the wire core 1. The terminal 6 includes a connecting cylinder 62 and an isolation cylinder 61. Both ends of the isolation cylinder 61 are provided with integrated isolation cylinders 61. The inner wall of the isolation cylinder 61 is provided with rubber sleeves 621 that fit against the ends of the first copper core 21 or the second copper core 33. An isolation gel 63 is provided inside the isolation cylinder 61. Before installing the copper wire into the connecting cylinder 62, the terminal 6 is heated to cause the connecting cylinder 62 to expand. Then, the end of the copper wire is inserted into the connecting cylinder 62. A limiting ring 622 is provided inside the connecting cylinder 62, which quickly determines the position of the copper wire within the connecting cylinder 62. After the terminal 6 cools and shrinks, the connecting cylinder 62 and the terminal 6 are tightly bonded under the action of radial contraction force. The insulating colloid 63 divides the interior of the terminal 6 into two spaces, and cavities 631 are provided between the two ends of the insulating colloid 63 and the copper wire. Before inserting the copper wire into the terminal 6, desiccant material can be filled into the cavities 631 to keep the internal space of the terminal 6 dry and prevent excessive moisture content from accelerating the rusting of the terminal 6 or the copper core.

[0070] A fully shielded layer 4 is provided between the outer layer 31 and the protective layer 5. The outer surface of the fully shielded layer 4 is attached to the protective layer 5, and the inner surface of the fully shielded layer 4 is attached to the outer layer 31. Multiple first copper cores 21 and multiple second copper cores 33 form a shielding mesh structure on the inner insulation layer 2 and the outer insulation layer 3, respectively. The fully shielded layer 4 fills the gap between the outer layer 31 and the protective layer 5, further optimizing the mesh shielding structure formed by the first copper cores 21 and the second copper cores 33, and achieving full-area shielding of the wire core 1. The fully shielded layer 4 includes a corrugated copper tube 41, an inner protective layer 42, and an outer protective layer 43. The corrugated copper tube 41 is located between the inner protective layer 42 and the outer protective layer 43. The inner protective layer 42 is attached to the outer side wall of the outer layer 31, and the outer protective layer 43 is attached to the inner side wall of the protective layer 5. As the main component of the shielding layer 4, the corrugated copper tube 41 completely wraps the outer surface of the outer insulation layer 3, achieving a complete shielding effect. The corrugated copper tube 41, due to its corrugated structure, possesses excellent flexibility, making it easy to bend and less prone to fatigue damage. It can adapt to various installation environments, offering greater flexibility in use. The corrugated structure also provides strong pressure resistance, enabling it to withstand significant pressure changes and ensuring the stability of the cable structure. An air gap is formed between the outer insulation layer 3 and the protective layer 5 in the corrugated copper tube 41. Air, as an excellent insulating material, effectively isolates the electrical contact between the center conductor and the outer conductor, preventing short circuits and signal attenuation. Because the air gap has a low dielectric constant, it helps reduce signal propagation delay and distortion, better maintaining signal integrity and ensuring the propagation quality of high-frequency signals. The air gap also reduces crosstalk between different cables, ensuring signal clarity and stability. The inner protective layer 42 and the outer protective layer 43 provide physical protection for the inner and outer walls of the corrugated copper tube 41, preventing moisture or other impurities from adhering to it. When the cable needs to be bent, the inner and outer walls of the corrugated copper tube 41 are prone to relative displacement with the outer insulation layer 3 or protective layer 5. Under the action of the inner protective layer 42 and the outer protective layer 43, the wear of the corrugated copper tube 41 can be reduced, and the service life of the corrugated copper tube 41 can be extended to a certain extent. The inner protective layer 42 and the outer protective layer 43 are both made of nitrile rubber, fluororubber, and acrylic rubber, which are elastic and wear-resistant rubber materials.

[0071] The above description is merely a preferred embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural transformations made using the contents of the present invention's specification and drawings under the inventive concept of the present invention, or direct / indirect applications in other related technical fields, are included within the patent protection scope of the present invention.

Claims

1. A process for manufacturing a wire core, characterized in that, The wire core (1) includes a core wire (11) and multiple side wires (12) disposed on the peripheral wall of the core wire (11). The manufacturing process of the wire core (1) includes: Step 1: Softening and annealing: The first ends of the multiple side wires (12) are spot-welded to the first end of the core wire (11), and the first ends of the multiple side wires (12) and the first end of the core wire (11) are introduced into the first online annealing furnace; the first online annealing furnace is provided with multiple different temperature gradient zones, and the core wire (1) passes through the first online annealing furnace in sequence through the 400°C zone, the 500°C zone, the 600°C zone, the 500°C zone, and the 400°C zone; the speed at which the core wire (1) passes through the first online annealing furnace is 3.2 m / min to 5.2 m / min, and the softening annealing time is 5 min to 10 min; Step 2: Diameter Reduction Drawing The first end of the softened and annealed wire core (1) is passed through the die on the wire drawing machine at a speed of 3.5m / min to 5.5m / min; the wire core (1) before entering the die is subjected to initial ultrasonic treatment. Step 3: Stress-relief annealing: The wire core (1) after diameter reduction and drawing is introduced into the second online annealing furnace. The wire core (1) passes through the second online annealing furnace at a speed of 3.2m / min to 5.2m / min. The annealing temperature is 200℃ to 300℃. The stress-relief annealing process lasts for 3min to 5min. The wire core (1) in the stress-relief annealing process is subjected to secondary ultrasonic treatment. Step 4: Cooling and winding: Air cooling is performed under wind speeds of 20m / s to 25m / s, and the winding speed of the winding machine is 4m / min to 6m / min.

2. The wire core preparation process according to claim 1, characterized in that, Tension detection mechanisms are provided in steps one through three. The tension detection mechanism is electrically connected to the traction equipment through the control system. The traction equipment adjusts the speed of the traction core (1) based on the tension value of the core (1) fed back by the tension detection mechanism.

3. The wire core preparation process according to claim 1, characterized in that, In step four, the compression rate of the wire core (1) is 5%~40%; ； ； ； S1 is the sum of the cross-sectional areas of the side wire (12) and the core wire (11); S2 is the cross-sectional area of ​​the wire core (1); W is the total compression ratio of the wire core (1); d is the diameter of the side wire (12) or the core wire (11); n is the number of the side wire (12) and the core wire (11); and D is the diameter of the circumscribed circle.

4. A cable, characterized in that, include: The wire core (1) is prepared by the wire core preparation process according to any one of claims 1 to 3; The outer side of the wire core (1) is provided with an inner insulation layer (2); The inner insulation layer (2) has multiple first copper cores (21) arranged in the circumferential direction inside, and the multiple first copper cores (21) are evenly spaced; the inner insulation layer (2) has an outer insulation layer (3) arranged outside; The outer insulation layer (3) includes an inner layer (32) and an outer layer (31). The inner layer (32) is attached to the inner insulation layer (2), and the outer layer (31) is disposed outside the inner layer (32). The inner layer (32) has multiple second copper cores (33) in the circumferential direction, and the multiple second copper cores (33) are evenly spaced. The outer surface of the outer layer (31) is provided with a protective layer (5).

5. The cable as described in claim 4, characterized in that, The first copper core (21) and the second copper core (33) are both formed by connecting multiple copper wires (211) end to end through a terminal (6); both sides of the terminal (6) are provided with rubber sleeves (621) that match the ends of the copper wires (211).

6. The cable as described in claim 5, characterized in that, The terminal (6) includes a connecting tube (62) and an isolation tube (61). Both ends of the isolation tube (61) are provided with an integrated isolation tube (61). The inner wall of the isolation tube (61) is provided with a rubber sleeve (621) that fits against the end of the first copper core (21) or the second copper core (33). The isolation tube (61) is provided with an isolation gel (63).

7. The cable as described in claim 4, characterized in that, The second copper core (33) is disposed at the interface between the inner layer (32) and the outer layer (31). The outer sidewall of the inner layer (32) and the inner sidewall of the outer layer (31) are provided with grooves that cooperate with the second copper core (33).

8. The cable as described in claim 7, characterized in that, The second copper core (33) is spirally wound inside the groove.

9. The cable as described in any one of claims 4 to 8, characterized in that, A fully shielding layer (4) is provided between the outer layer (31) and the protective layer (5). The outer side of the fully shielding layer (4) is attached to the protective layer (5), and the inner side of the fully shielding layer (4) is attached to the outer layer (31).

10. The cable as described in claim 9, characterized in that, The complete shielding layer (4) includes a corrugated copper tube (41), an inner protective layer (42), and an outer protective layer (43). The corrugated copper tube (41) is located between the inner protective layer (42) and the outer protective layer (43). The inner protective layer (42) is attached to the outer side wall of the outer layer (31), and the outer protective layer (43) is attached to the inner side wall of the protective layer (5).

Images