STP cable for high-flexibility vehicle and preparation method of STP cable

Abstract

The invention provides a high-flexibility STP cable for a vehicle and a preparation method of the high-flexibility STP cable. The cable sequentially comprises a wire core, a metal shielding layer, a shielding braid layer and a sheath from inside to outside, the shielding braid layer is formed by weaving an Alu Coat aluminum coating basalt fiber shielding braid layer on the surface of the metal shielding layer, and an Alu Coat aluminum coating basalt fiber conductor with 24 ingots and 10 single wires with the diameter of 0.23 [mu] m is adopted to be evenly attached to the surface of the metal shielding layer. The wire core is composed of seven tinned copper conductors and a foamed PP insulating layer, wherein the maximum diameter of each tinned copper conductor is 0.16 mm, and the outer diameter of each tinned copper conductor is 1.3-2.6 mm. And the sheath is made of a TPU (Thermoplastic Polyurethane) material. The invention provides the high-flexibility STP cable for the vehicle, which is light in weight, low in cost and stable in structure, and the preparation method of the high-flexibility STP cable.

Description

Technical Field

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

[0002] With the development of automotive intelligence and networking, the requirements for the data volume and transmission rate of in-vehicle networks are continuously increasing. With the increasing popularity of self-driving functions for in-vehicle STP shielded Ethernet, the demand for STP shielded Ethernet has been rapidly developing in the direction of higher bandwidth and higher transmission rate.

[0003] The vehicle-use STP shielded cable has a metal shielding layer, which can effectively block external electromagnetic interference from entering the cable, and at the same time prevent the signals transmitted inside from generating electromagnetic radiation outside, ensuring the stability and reliability of data transmission. It is particularly suitable for scenarios with a complex electromagnetic environment inside the vehicle. It supports a relatively high data transmission rate. For example, under the 10GBase-T1 standard, symmetric rate transmissions of 2.5Gbit / s, 5Gbit / s, and 10Gbit / s can be achieved, meeting the application requirements with high bandwidth requirements such as intelligent driving and high-definition video transmission. The STP shielded cable can achieve low-latency data transmission, which is crucial for control systems that require real-time response such as autonomous driving systems and advanced driver assistance systems (ADAS), and can ensure that the vehicle responds quickly and accurately to environmental changes. It is applied in multiple scenarios such as autonomous driving systems, advanced driver assistance systems (ADAS), multimedia entertainment systems, vehicle networks, and information systems.

[0004] The structure of the vehicle-use STP shielded cable generally uses stranded copper as the inner conductor, with an insulating medium wrapped around the inner conductor. First, a metal tape is wrapped around the insulating medium, and a non-magnetic metal wire braid layer is wrapped around the outer layer of the metal tape to serve as the outer conductor and shielding, and finally, a sheath material is covered on the outer braided shielding structure.

[0005] Traditional STP shielded cables have problems such as low overall cable flexibility and hard wire materials. In some special application scenarios, when frequently bent and in the case of reciprocating cyclic bending and combined bending and torsion, conductor breakage is likely to occur; at the same time, when it is not easy to bend and route in a complex laying environment inside the vehicle or when the bending angle is too small, communication failures and other problems occur. For such situations, a great challenge is posed to the reliability of communication. At the same time, in today's situation, in the era of rapidly rising copper prices, the high copper price has hindered the installation volume of STP shielded cables used by vehicle manufacturers, bringing great cost pressure to vehicle manufacturers. Summary of the Invention

[0006] One of the technical problems to be solved by the present invention is to provide a lightweight and high-flexibility vehicle-use STP cable.

[0007] The second technical problem to be solved by the present invention is to provide a preparation method for a lightweight and highly flexible vehicle STP cable.

[0008] The present invention is implemented as follows:

[0009] Technical solution one:

[0010] A highly flexible vehicle STP cable includes, from inside to outside in sequence: a pair-stranded core, a metal shielding layer, a shielding braid layer, and a sheath;

[0011] The shielding braid layer is an aluminum-coated basalt fiber shielding braid layer braided on the surface of the metal shielding layer.

[0012] Further, the aluminum-coated basalt fiber shielding braid layer is formed by uniformly attaching 24-spindle 10 aluminum-coated basalt fiber conductors with a single wire diameter of 0.23 μm to the surface of the metal shielding layer.

[0013] Further, each core is composed of a tinned copper conductor and an insulating layer wrapped around it.

[0014] Further, each core is a core with an outer diameter of 1.3 - 2.6 mm composed of 7 tinned copper conductors with a maximum single wire diameter of 0.16 mm and a foamed PP insulating layer.

[0015] Further, the sheath is made of TPU material.

[0016] Technical solution two:

[0017] A preparation method for a highly flexible vehicle STP cable includes the following steps:

[0018] Strand 7 bare copper wires with a single wire diameter of 0.16 mm in the S direction, control the lay length within 11 - 13 mm, and control the stranded outer diameter within 0.750 - 0.780 mm to make a conductor;

[0019] Extrude an insulating layer outside the conductor to make a core. The insulating layer uses a foamed PP low-dielectric insulating material, control the outer diameter within 1.20 - 1.30 mm, and the concentricity ≥ 90%;

[0020] Twist and strand two cores in a pair, use a lay length of 15 ± 3 mm for the twist, and control the stranded outer diameter within 2.40 - 2.50 mm;

[0021] Use a 7×27 μm single-sided aluminum foil to wrap around the pair-stranded cores in the S direction to form an aluminum foil shielding layer;

[0022] Use a 24-spindle braiding machine to braid 11 aluminum-coated basalt fibers with a diameter of 23 μm on the semi-finished product after aluminum foil coating to form a shielding braid layer;

[0023] Finally, extrude a TPU material sheath layer outside the shielding braided layer.

[0024] The advantages of the present invention are as follows:

[0025] The high-flexibility vehicle-used STP cable structure provided by the present invention solves the problem of the shielding layer breaking under the use environments of high-strength bending, cyclic bending and compound torsion of traditional vehicle-used STP cables. It overcomes the problems of high cost and heavy copper usage of traditional vehicle-used STP shielding cables; avoids the problems such as difficult bending and laying of traditional vehicle-used STP shielding cables, and realizes the following advantages:

[0026] 1. The wire is more lightweight

[0027] Traditional vehicle-used STP shielding cables use a metal tape + tinned copper braided shielding structure to increase the shielding effectiveness. The single wire of tinned copper wire is 0.10 TD with a density of 8.89 g / cm3, while the density of the AluCoat aluminum-coated basalt fiber shielding is 2.7 g / cm3. Under the same braiding density; the present invention uses the AluCoat aluminum-coated basalt fiber shielding structure to achieve the same shielding effect as the tinned copper shielding, which can reduce the copper weight by 80%, making the wire lighter and conforming to the development route of lightweight new energy vehicles.

[0028] 2. Cost reduction

[0029] The high-flexibility STP shielding cable structure of the present invention uses the AluCoat aluminum-coated basalt fiber shielding, reducing the cost by 87.5% and thus obtaining a more competitive cost.

[0030] 3. Improved structural stability of the cable

[0031] The AluCoat aluminum-coated basalt fiber shielding of the present invention has a higher tensile strength compared to tinned copper braided wires, increasing the tensile strength of the overall cable. At the same time, a TPU sheath is used, which can protect the cable from physical damage and chemical corrosion, increasing the stability and reliability of the cable. It meets more stringent application scenarios, and at the same time can solve the problems such as small bending radius and difficult laying in the narrow space inside the vehicle, improving the application margin of this product.

[0032] In summary, the high-flexibility vehicle-used STP shielding cable structure of the present invention uses the AluCoat aluminum-coated basalt fiber shielding to replace the original tinned copper braided structure, and cooperates with technical means such as a metal shielding layer and an extruded TPU sheath to improve the signal transmission quality and application reliability. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] The following further describes the present invention with reference to the drawings in conjunction with embodiments.

[0034] Figure 1It is a schematic cross - section view of the STP cable of the present invention.

[0035] Figure 2 It is a structural diagram of the braided shielding layer of a traditional STP cable.

[0036] Figure 3 It is a structural diagram of the braided shielding layer of the AluCoat aluminum - coated basalt fiber wire of the present invention.

[0037] Reference numerals:

[0038] 1 - wire core; 11 - conductor; 12 - insulating layer; 2 - aluminum foil shielding layer; 3 - shielding braided layer; 4 - sheath. Detailed implementation mode

[0039] As Figure 1 shown, this embodiment provides a highly flexible vehicle - used STP cable, which successively includes from inside to outside: a pair - stranded wire core 1, an aluminum foil shielding layer 2, a shielding braided layer 3, and a sheath 4;

[0040] Each wire core 1 is a wire core 1 with an outer diameter of 1.3 - 2.6 mm, which is composed of 7 tinned copper conductors 11 with a maximum single - wire diameter of 0.16 mm and a foamed PP insulating layer 12.

[0041] The shielding braided layer 3 is a braided shielding layer 3 of Alu Coat aluminum - coated basalt fiber on the surface of the aluminum foil shielding layer 2. 10 Alu Coat aluminum - coated basalt fiber conductors 11 with a single - wire diameter of 0.23 μm are evenly attached to the surface of the aluminum foil shielding layer 2 by using 24 spindles.

[0042] The sheath 4 is made of TPU material.

[0043] The preparation method of the above - mentioned highly flexible vehicle - used STP cable includes the following steps:

[0044] Strand 7 bare copper wires with a single - wire diameter of 0.16 mm in the S direction, control the lay length within 11 - 13 mm, and control the stranded outer diameter within 0.750 - 0.780 mm to make the conductor 11;

[0045] Extrude an insulating layer 12 outside the conductor 11 to make the wire core 1. The insulating layer 12 uses a foamed PP low - dielectric insulating material, controls the outer diameter within 1.20 - 1.30 mm, and the concentricity ≥ 90%;

[0046] Twist - pair and strand two wire cores 1, adopt a lay length of 15 ± 3 mm, and control the stranded outer diameter within 2.40 - 2.50 mm;

[0047] Use a 7×27μm wide single - sided aluminum foil to wrap around the twisted - pair wire core 1 in the S direction to form the aluminum foil shielding layer 2.

[0048] A 24-spindle knitting machine is used, with 11 AluCoat basalt fibers with a diameter of 23 μm. They are knitted on the semi-finished product after aluminum foil cladding to form the shielding knitted layer 3.

[0049] The knitting process parameters are shown in Table 1:

[0050] Table 1:

[0051] Strand specification Lower eye die Upper eye die Weaving die Weaving pitch Weaving angle Main machine speed 11×23μm 2.7mm 2.7mm 2.8mm 8.8mm 30～35° 100±rpm

[0052] Finally, an outer sheath layer 4 of TPU material is extruded outside the shielding knitted layer 3. The TPU material is used to cover the outer surface of the cable. The nominal thickness of the sheath is controlled at 0.40 mm, the outer diameter of the sheath is controlled at 3.80 - 4.20 mm, the concentricity is controlled at ≥80%, the die core uses a 3.10 mm sleeve inner die, and the outer die uses a 3.80 mm semi-extrusion die sleeve. It is extruded according to the semi-sleeve process to ensure that the appearance of the sheath is smooth and the peeling is good.

[0053] Traditional automotive STP shielded cables use a metal tape + tinned copper braided shield structure (as Figure 2 shown) to increase the shielding effectiveness. The single wire of tinned copper wire has a density of 8.89 g / cm3 with a diameter of 0.10 TD, while the density of the AluCoat basalt fiber shield is 2.7 g / cm3. At the same knitting density; the present invention uses the AluCoat basalt fiber shield structure (as Figure 3 shown) to achieve the same shielding effect as the tinned copper shield, which can reduce the copper weight by 80%, making the wire lighter and conforming to the development route of lightweight for new energy vehicles.

[0054] The present invention proposes a high-flexibility automotive STP cable structure and its preparation method. The original tinned copper braided wire is replaced with ALucoat basalt fiber material to increase the tensile strength of the overall cable. At the same time, a TPU sheath is adopted, which can protect the cable from physical damage and chemical corrosion, and increase the stability and reliability of the cable. With technical means such as a metal shielding layer and an extruded TPU sheath, the signal transmission quality and the reliability of the application are improved. It has high tensile strength.

[0055] 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. A highly flexible STP cable for automotive use, characterized in that: From inside to outside, it includes: twisted wire core, metal shielding layer, shielding braided layer, and sheath; The shielding braided layer is a shielding braided layer of basalt fiber with aluminum coating woven on the surface of the metal shielding layer.

2. A highly flexible STP cable for vehicle use as claimed in claim 1, characterized in that: The aluminum-coated basalt fiber shielding braided layer adopts 24 spindles and 10 aluminum-coated basalt fiber conductors with a single wire diameter of 0.23 μm, which are evenly attached to the surface of the metal shielding layer.

3. A highly flexible STP cable for vehicle use as claimed in claim 1, characterized in that: Each of the wire cores is composed of a tinned copper conductor and an insulating layer wrapped therearound.

4. A highly flexible STP cable for vehicle use as claimed in claim 3, characterized in that: Each of the wire cores is composed of 7 tinned copper conductors with a maximum single-filament diameter of 0.16 mm and a foamed PP insulation layer, and has an outer diameter of 1.3 to 2.6 mm.

5. A highly flexible STP cable for vehicle use as claimed in claim 1, characterized in that: The sheath is made of TPU material.

6. A method for preparing a highly flexible STP cable for vehicle use, characterized in that: The steps include: Seven bare copper wires with a single wire diameter of 0.16 mm are twisted in the S direction, with the twist length controlled at 11 to 13 mm and the twist outer diameter controlled at 0.750 to 0.780 mm to make a conductor; Extruding an insulating layer outside the conductor to form a wire core, the insulating layer uses foamed PP low-dielectric insulating material, the outer diameter is controlled at 1.20-1.30mm, and the concentricity is ≥90%; Twist the two cores together, with a twisting pitch of 15±3mm and an outer diameter of 2.40-2.50mm; A single-sided aluminum foil with a width of 7×27μm is used outside the twisted wire core to wrap it in the S direction to form an aluminum foil shielding layer; Using a 24-spindle braiding machine, 11 aluminum-coated basalt fibers with a diameter of 23μm are woven on the semi-finished product covered with aluminum foil to form a shielding braided layer; Finally, a TPU material sheath layer is extruded outside the shielding braided layer.

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