STP cable for vehicle-mounted multimedia and preparation method thereof

Abstract

The invention discloses a vehicle-mounted multimedia STP cable and a preparation method thereof. The cable comprises two wire cores, two filling ropes, aluminum foil, a drainage wire, a braided shielding layer, a thin film belt and a sheath layer from inside to outside, wherein the two wire cores and the two filling ropes are twisted with each other; each wire core comprises a conductor and an insulating layer wrapping the conductor; each filling rope is formed by twisting a PP rope in a fine net shape; and the drainage wire is formed by twisting a plurality of aluminum coating basalt fibers. And the conductor is formed by twisting seven strands of fine copper-tin alloy wires with the diameter of 0.15-0.16 mm, the twisting direction is S, and the pitch diameter ratio is controlled to be 13-15. The insulation layer is made of PP materials, the structure of the insulation layer is skin-foam-skin, the inner layer of the insulation layer is foamed PP, the thickness of the insulation layer is controlled to be 0.17-0.20 mm, the insulation outer diameter is 1.8-1.9 mm, and the insulation concentricity is larger than 95%. The invention provides a high-speed, high-reliability and low-loss STP cable for vehicle-mounted multimedia and a preparation method of the STP cable.

Description

Technical Field

[0001] The present invention belongs to the technical field of cables, and specifically refers to an STP cable for in-vehicle multimedia and a preparation method thereof. Background Art

[0002] With the rapid development of automotive electronics technology, the communication requirements between various systems inside the vehicle are increasing day by day, the wire usage environment is more complex, and traditional automotive communication cables can no longer meet the communication requirements of high performance, high speed, and high reliability. The intelligent cockpit needs to support multi-screen linkage and high-definition audio and video transmission, and has strict requirements for signal integrity.

[0003] Traditional cables have the following defects: 1. They are prone to breakage during frequent bending (bending life < 30,000 times); 2. The traditional shielding structure cannot meet the requirements of strong electromagnetic interference (EMC) protection inside the vehicle (shielding effectiveness < 50 dB); 3. The temperature resistance of the sheath material is insufficient (the working temperature of conventional PVC sheaths ≤ 85°C).

[0004] And the current market demand is that the vehicle has a great demand for STP cables with flexibility (resistance to bending > 100,000 times), high reliability (working temperature -40°C to 125°C), and high anti-interference ability (EMC > 50 dB).

[0005] Therefore, developing a new high-composite STP cable for vehicles is of great significance for improving the performance and stability of the in-vehicle communication system. Summary of the Invention

[0006] One of the technical problems to be solved by the present invention is to provide an STP cable for in-vehicle multimedia with high speed, high reliability, and low loss.

[0007] Another technical problem to be solved by the present invention is to provide a preparation method for an STP cable for in-vehicle multimedia with high speed, high reliability, and low loss.

[0008] The present invention is implemented as follows:

[0009] Technical Solution One:

[0010] An STP cable for in-vehicle multimedia, from the inside to the outside, includes: two mutually twisted wire cores, two filling ropes, aluminum foil, a drainage wire, a braided shielding layer, a film tape, and a sheath layer;

[0011] Each of the wire cores includes: a conductor and an insulating layer wrapped around the conductor;

[0012] Each of the filling ropes is a fine mesh of PP ropes twisted together;

[0013] The drainage wire is composed of multiple aluminum-coated basalt fibers twisted together.

[0014] Further, the drain wire is formed by stranding 2964 single filaments of 10 μm aluminized basalt fiber, and the outer diameter of the stranded wire bundle is 0.65 mm after stranding.

[0015] Further, the conductor is formed by stranding 7 fine copper-tin alloy wires with a diameter of 0.15 - 0.16 mm, the stranding direction is S, and the pitch diameter ratio is controlled at 13 - 15.

[0016] Further, the insulating layer is made of PP material, and its structure is skin-foam-skin, with the inner layer being foamed PP. The thickness of the insulating layer is controlled at 0.17 - 0.20 mm, the outer diameter of the insulation is 1.8 - 1.9 mm, and the insulation concentricity > 95%.

[0017] Further, the braided shielding layer is made of tinned copper metal.

[0018] Further, the sheath layer is made of polyurethane TPU material, the thickness is controlled at 0.6 - 0.8 mm, the outer diameter is 5.6 - 6.0 mm, and the concentricity > 85%.

[0019] Technical solution two:

[0020] A preparation method of an STP cable for in-vehicle multimedia includes the following steps:

[0021] Strand 7 fine copper-tin alloy wires with a diameter of 0.15 - 0.16 mm to form a conductor, with the stranding direction being S and the pitch diameter ratio controlled at 13 - 15;

[0022] Extrude an insulating layer outside the conductor to form a wire core;

[0023] Strand two wire cores and two PP filling ropes. The PP filling ropes are fine meshed and twisted, with an outer diameter controlled at 1.5 mm, the stranding direction is S, and the stranding pitch diameter ratio is 7 - 10;

[0024] Process a double-layer aluminum foil by the winding method. The width of the aluminum foil is 14 mm and the thickness is 0.04 mm;

[0025] Weave with a 16 / 9 / 0.1 mm structure and a pitch of 20 ± 0.5 to form a braided shielding layer. During the weaving process, add a drain wire with a multi-strand structure of aluminized basalt fiber. The drain wire is a stranded wire of 2964 single filaments of 10 μm, and the outer diameter of the stranded wire bundle is 0.65 mm. The drain wire is added using an external wire pay-off stand of the weaving machine to ensure that the drain layer is located between the braided shielding layer and the aluminum foil;

[0026] Cover the outside of the braided shielding layer with a single-sided adhesive film tape made of PP material, with the adhesive side facing outwards;

[0027] Extrude the sheath layer with a thickness controlled at 0.6 - 0.8 mm, an outer diameter of 5.6 - 6.0 mm, and a concentricity > 85%.

[0028] Furthermore, the braided shielding layer is made of tinned copper metal.

[0029] The advantages of the present invention are as follows:

[0030] 1. Compared with traditional STP 100BASE-T1 cables, it has better transmission performance and still has excellent transmission performance after high-intensity combined torsion and bending tests (> 100,000 times).

[0031] 2. Using the AluCoat aluminum-coated basalt fiber multi-strand twisted structure as the drain wire improves the transmission stability and flexibility of the cable. Compared with traditional copper wires with the same cross-sectional area, the weight is reduced by about 45% and the cost is saved by 90%.

[0032] 3. The double-layer aluminum foil + tinned copper metal braiding + AluCoat aluminum-coated basalt fiber multi-strand twisted structure as the drain wire enhances the anti-electromagnetic wave interference ability of the cable.

[0033] 4. By adopting the PP tape isolation layer structure, the integrity and stability of the cable structure are effectively guaranteed, thus ensuring the communication transmission ability of the cable and the stable operation of the vehicle.

[0034] 5. By using the flame-retardant and weather-resistant TPU material as the sheath layer, it can work normally in an environment with a high temperature of 125 degrees, protects the cable from the external environment, improves the service life and safety of the cable, and enhances the safety and reliability of the vehicle. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] The present invention will be further described below with reference to the accompanying drawings in conjunction with embodiments.

[0036] Figure 1 is a cross-sectional view of the cable of the present invention.

[0037] Figure 2 is a cross-sectional view of the die in the braiding process of the present invention.

[0038] Figure 3 is a comparison diagram of EMC between a conventional STP cable and the STP cable of the present invention (the left is the conventional STP cable, and the right is the STP cable of the present invention).

[0039] Figure 4 is a comparison diagram of the attenuation performance of the STP cable of the present invention before and after the bending test (the left is the attenuation performance before bending, and the right is the attenuation performance after bending).

[0040] Figure 5It is a comparison chart of the EMC performance of the STP cable of the present invention before and after the bending test (the left side is the EMC performance before bending, and the right side is the EMC performance after bending).

[0041] Explanation of reference numerals:

[0042] 1 - Core, 11 - Conductor, 12 - Insulation layer, 3 - Aluminum foil, 4 - Drain wire, 5 - Braided shielding layer, 6 - Sheath layer, 100 - Braiding die, 101 - Cylindrical channel. Detailed implementation manners

[0043] As Figure 1 shown, an STP cable for in - vehicle multimedia includes, from the inside to the outside: two mutually twisted cores 1 and two filling ropes 2, aluminum foil 3, drain wire 4, braided shielding layer 5, a film tape (not shown in the figure), and sheath layer 6;

[0044] Each core 1 includes: a conductor 11 and an insulation layer 12 wrapped outside the conductor 11; the conductor 11 is formed by stranding 7 fine copper - tin alloy wires with a diameter of 0.15 - 0.16 mm, the insulation layer 12 is made of PP material, and the structure is skin - foam - skin, with the inner layer being foamed PP. The thickness of the insulation layer is controlled within 0.17 - 0.20 mm, the insulation outer diameter is 1.8 - 1.9 mm, and the insulation concentricity > 95%;

[0045] Each filling rope 2 is a fine - meshed and twisted PP rope;

[0046] The aluminum foil 3 is processed into a double - layer aluminum foil by a winding method, with the aluminum foil width being 14 mm and the thickness being 0.04 mm;

[0047] The drain wire 4 is formed by stranding 2964 single - filaments of 10 - μm aluminum - coated basalt fibers, and the outer diameter of the stranded bundle wire is 0.65 mm;

[0048] For the braided shielding layer 5, during the braiding process, a drain wire 4 with a multi - stranded structure of aluminum - coated basalt fibers is added. The drain wire 4 is added using an external wire pay - off stand of the braiding machine to ensure that the drain wire 4 is located between the aluminum foil 3 and the braided shielding layer 5;

[0049] Outside the braided shielding layer 5, it is coated with a film tape made of PP material with single - sided adhesive, with the adhesive side facing outwards. When the sheath is extruded, the adhesive will melt to make the film tape adhere to the sheath; in this embodiment, the film tape is made of PP polypropylene material, and it can also be a polyester tape;

[0050] The sheath layer 6 is made of polyurethane TPU material, with the thickness controlled within 0.6 - 0.8 mm, the outer diameter being 5.6 - 6.0 mm, and the concentricity > 85%.

[0051] The preparation method of the above - mentioned STP cable for in - vehicle multimedia includes the following steps:

[0052] Strand 7 fine copper-tin alloy wires with a diameter of 0.15 - 0.16 mm to form conductor 11, with the strand direction S and the pitch diameter ratio controlled at 13 - 15;

[0053] Extrude an insulating layer 12 outside conductor 11 to form a wire core 1;

[0054] Strand two wire cores 1 and two PP filling ropes 2, where the PP filling ropes are fine meshed and twisted, with an outer diameter controlled at 1.5 mm, the strand direction S, and the strand pitch diameter ratio 7 - 10;

[0055] Process a double-layer aluminum foil 3 by wrapping, with the width of the aluminum foil 3 being 14 mm and the thickness being 0.04 mm;

[0056] Tinned copper metal braiding: adopt a 16 / 9 / 0.1 mm structure, with a pitch of 20 ± 0.5. During the braiding process, a drainage wire 4 with a stranded structure of multiple aluminum-coated basalt fibers needs to be added. The drainage wire 4 is a stranded wire of 2964 single filaments of 10 μm, with a stranded wire outer diameter of 0.65 mm. The drainage wire is added using an external wire pay-off stand of the braiding machine to ensure that the drainage layer is located between the aluminum foil 3 and the braided shielding layer 5. During the processing, due to the large difference in tensile strength between the wire core and the AluCoat aluminum-coated basalt fiber filaments, it is not easy to process and form with the same wire passing method, and the wire core structure is not easy to be stable. It is necessary to optimize and improve the process die 100, add a cylindrical channel 101 for the drainage wire in the die 100 to ensure the stability and roundness of the wire core, and it can maintain stable performance under bending and environmental electromagnetic interference. During processing, the drainage wire 4 needs to be placed and passed through according to the position of the cylindrical channel 101. The die is as Figure 2 shown;

[0057] Cover the outside of the braided shielding layer 5 with a PP material single-sided adhesive film tape, with the adhesive side facing outwards; the dimensional requirements are thickness: 0.020 - 0.023 mm, width: 20 mm, and the wrapping pitch is 16. This PP tape is too large compared to the wire size and is not easy to process and form. Wrapping can effectively cover the wire core;

[0058] Extrude a sheath layer 6, with the thickness controlled at 0.6 - 0.8 mm, the outer diameter 5.6 - 6.0 mm, and the concentricity > 85%; when the sheath is extruded, the glue will melt and cause the tape to adhere to the sheath together.

[0059] The high composite flexible STP communication cable for automobiles of the present invention realizes high-speed, high-reliability, and low-loss communication performance by optimizing the structures and materials of the conductor, insulating layer, filling layer, shielding layer, drainage layer, isolation layer, and sheath layer. At the same time, the cable also has good flexibility, wear resistance, and high-temperature resistance, and can adapt to the complex working environment and variable installation conditions inside the automobile.

[0060] The technical comparison between the aluminum-coated basalt fiber material (abbreviated as AluCoat in the table) and the traditional copper wire is shown in Table 1 as follows:

[0061] Table 1:

[0062]

[0063]

[0064] The key properties of the aluminum-coated basalt fiber material are shown in Table 2:

[0065] Table 2:

[0066]

[0067] It can be seen that using the aluminum-coated basalt fiber as the drain wire has great advantages compared with using the traditional copper wire as the drain wire.

[0068] As Figure 3 shown, for the traditional STP 100BASE-T1 communication cable: EMC: about 45 dB, and for the high-performance STP100BASE-T1 communication cable of the present invention: EMC: about 60 dB.

[0069] Figure 4 and Figure 5 The test data shown can reflect that the high-performance STP communication cable of the present invention has better transmission performance compared with the traditional STP100BASE-T1 cable, and still has excellent transmission performance after the high-strength composite torsion and bending test (>100000 times).

[0070] The high-performance STP communication cable of the present invention improves the transmission stability and flexibility of the cable by using a high-foaming low-dielectric constant PP material as insulation, double PP rope filling, and a multi-strand stranded structure of AluCoat aluminum-coated basalt fiber as the drain wire.

[0071] The multi-strand stranded structure conductor drain wire of AluCoat aluminum-coated basalt fiber has a weight reduction of about 45% and a cost savings of 90% under the same cross-sectional area compared with the traditional copper conductor.

[0072] The double-layer aluminum foil + tin-plated copper metal braiding + multi-strand stranded structure conductor drain wire of AluCoat aluminum-coated basalt fiber improves the anti-electromagnetic wave interference ability of the cable.

[0073] By adopting the PP tape isolation layer structure, the integrity and stability of the cable structure are effectively guaranteed, thereby ensuring the communication transmission ability of the cable and the stable operation of the vehicle.

[0074] By using a flame-retardant and weather-resistant TPU material as the sheath layer, it can work normally in an environment with a high temperature of 125 degrees Celsius, protect the cable from the external environment, improve the service life and safety of the cable, and enhance the safety and reliability of the vehicle.

[0075] The above embodiments and diagrams do not limit the product form and style of the present invention. Any appropriate changes or modifications made by those of ordinary skill in the art shall be regarded as not departing from the patent scope of the present invention.

Claims

1. An STP cable for vehicle-mounted multimedia, characterized in that: From inside to outside, it includes: two twisted cores and two filling ropes, aluminum foil, drainage wire, braided shielding layer, film tape, and sheath layer; Each of the wire cores comprises: a conductor and an insulating layer wrapped outside the conductor; Each of the filling ropes is a PP rope with fine mesh twisting; The drainage wire is formed by twisting together a plurality of aluminum-coated basalt fibers.

2. The STP cable for vehicle-mounted multimedia according to claim 1, characterized in that: The drainage wire is a strand of 2964 10 μm single-filament aluminum-coated basalt fibers twisted together, and the outer diameter of the strand after twisting is 0.65 mm.

3. The STP cable for vehicle-mounted multimedia as claimed in claim 1, characterized in that: The conductor is formed by twisting 7 strands of fine copper-tin alloy wires with a diameter of 0.15-0.16 mm, with a twisting direction of S and a pitch-diameter ratio of 13-15.

4. The STP cable for vehicle-mounted multimedia as claimed in claim 1, characterized in that: The insulating layer is made of PP material, with a skin-foam-skin structure, an inner layer of foamed PP, a thickness of the insulating layer controlled at 0.17-0.20 mm, an insulating outer diameter of 1.8-1.9 mm, and an insulating concentricity of >95%.

5. The STP cable for vehicle-mounted multimedia as claimed in claim 1, characterized in that: The braided shielding layer is made of tinned copper metal.

6. The STP cable for vehicle-mounted multimedia according to claim 1, characterized in that: The sheath layer is made of polyurethane TPU material, with a thickness of 0.6-0.8 mm, an outer diameter of 5.6-6.0 mm, and a concentricity of more than 85%.

7. A method for preparing an STP cable for vehicle-mounted multimedia, characterized in that: The steps include: Seven strands of fine copper-tin alloy wires with a diameter of 0.15-0.16 mm are twisted together to form a conductor, with the twisting direction being S and the pitch-diameter ratio being controlled at 13-15; Extruding an insulating layer outside the conductor to form a wire core; Two wire cores and two PP filling ropes are twisted together. The PP filling rope is finely twisted and has an outer diameter of 1.5 mm. The twisting direction is S, and the twisting pitch-diameter ratio is 7-10. The double-layer aluminum foil is processed by wrapping, with a width of 14mm and a thickness of 0.04mm; The 16 / 9 / 0.1mm structure and the pitch are 20±0.5, and the braided shielding layer is formed by weaving. During the weaving process, a drainage wire with a multi-stranded structure of aluminum-coated basalt fibers is added. The drainage wire is 2964 strands of 10μm single-filament bundles with an outer diameter of 0.65mm. The drainage wire is added by the external pay-off frame of the braiding machine to ensure that the drainage layer is located between the braided shielding layer and the aluminum foil. The braided shielding layer is covered with a PP single-sided adhesive film tape, with the adhesive side facing outwards; Extruded sheath layer, thickness controlled at 0.6-0.8mm, outer diameter 5.6-6.0mm, concentricity > 85%.

8. The method for preparing a STP cable for vehicle-mounted multimedia according to claim 7, characterized in that: The braided shielding layer is made of tinned copper metal.

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