Cable and cable assembly

Abstract

A cable and a cable assembly are provided. The cable comprises: at least two conductive cores (110) spaced apart from each other and extending in a longitudinal direction of the cable; an internal insulation structure (120), the internal insulation structure (120) circumferentially wrapping and contacting each of the at least two conductive wire cores (110) so as to fix the at least two conductive wire cores (110); an inner insulating layer (130) covering and contacting the inner insulating structure on the outer side; a first conductive shielding layer (140) externally wrapped on the inner insulating layer; and an outer insulating layer (150) wrapped outside the first conductive shielding layer, the inner insulating structure being a foamed insulating structure in which the at least two conductive cores are fixedly held.

Description

TECHNICAL FIELD

[0001] Embodiments of the present disclosure relate generally to cables, and more particularly, to a cable having improved electrical performance stability and a cable assembly including the same. BACKGROUND

[0002] A conventional data transmission cable structure mainly includes at least two insulated cores, a conductive shield layer, and an outer insulating layer. However, the structure of such a conventional cable is unstable, and the capacitance, impedance, etc. of the two cores can not match in use, resulting in poor electrical performance stability, and in particular, SI performance is adversely affected in the case of high-speed data transmission, which needs to be improved. SUMMARY

[0003] To overcome at least one of the above and other problems and drawbacks existing in the prior art, the present disclosure is proposed.

[0004] According to an embodiment of an aspect of the present disclosure, a cable is provided, including: at least two conductive cores spaced apart from each other and extending in a longitudinal direction of the cable; an inner insulating structure circumferentially covering and contacting each of the at least two conductive cores to fix the at least two conductive cores; an inner insulating layer covering and contacting the inner insulating structure on the outside; a first conductive shield layer wrapped on the inner insulating layer on the outside; and an outer insulating layer wrapped on the outside of the first conductive shield layer, the inner insulating structure being a foamed insulating structure in which the at least two conductive cores are fixedly held.

[0005] In some embodiments, the at least two conductive cores are covered in the same foamed insulating structure.

[0006] In some embodiments, the inner insulating structure is an integral extrusion molding structure formed on an outer circumferential surface of the at least two conductive cores in the longitudinal direction of the cable.

[0007] In some embodiments, the inner insulating structure has a substantially elliptical cross-section, and the at least two conductive cores include two conductive cores symmetrically held in the inner insulating structure.

[0008] In some embodiments, the spacing between the two conductive cores is constant in the longitudinal direction of the cable.

[0009] In some embodiments, the dielectric constant of the inner insulating structure is less than or equal to the dielectric constant of the inner insulating layer.

[0010] In some embodiments, the inner insulating layer is an annular layer formed of a solid insulating material.

[0011] In some embodiments, each conductive core includes a single core formed of a single conductor or a twisted core formed of two or more conductors.

[0012] In some embodiments, the cable further includes at least one ground wire disposed between the first conductive shield layer and the outer insulating layer and in electrical contact with the first conductive shield layer.

[0013] In some embodiments, the at least one ground wire includes a single ground wire located on one side of the first conductive shield layer or two ground wires symmetrically arranged on opposite sides of the first conductive shield layer.

[0014] In some embodiments, the cable further includes a second conductive shield layer wrapping the first conductive shield layer and the at least one ground wire on the outside, the outer insulating layer wrapping the second conductive shield layer, and the at least one ground wire positioned between the first conductive shield layer and the second conductive shield layer and in electrical contact with at least one of the first conductive shield layer and the second conductive shield layer.

[0015] In some embodiments, each of the first conductive shield layer and the second conductive shield layer includes an insulating tape and a conductive layer attached to the insulating tape, and the conductive layers of the first conductive shield layer and the second conductive shield layer face each other and contact the at least one ground wire.

[0016] According to embodiments of another aspect of the present disclosure, there is provided a cable assembly, including: at least two cables, each cable being the cable described in any of the embodiments of the present disclosure; an electromagnetic shield structure wrapping the outside of the at least two cables circumferentially; and an outer jacket sleeving the outside of the electromagnetic shield structure.

[0017] In some embodiments, the cable assembly further includes a buffer layer disposed between the electromagnetic shield structure and the outer jacket and / or a filler filling a space between the at least two cables inside the electromagnetic shield structure.

[0018] Other objects and advantages of the present disclosure will become apparent and help to understand the present disclosure from the following detailed description of the present disclosure, made with reference to the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0019] Figure 1 is a cross-sectional view schematically showing a structure of a cable according to one exemplary embodiment of the present disclosure;

[0020] Figure 2 is a cross-sectional view schematically showing a structure of a cable according to another exemplary embodiment of the present disclosure;

[0021] Figure 3 is a cross-sectional view schematically illustrating a structure of a cable according to yet another exemplary embodiment of the present disclosure;

[0022] Figure 4 is a cross-sectional view schematically illustrating a structure of a cable according to yet another exemplary embodiment of the present disclosure; and

[0023] Figure 5 is a cross-sectional view schematically illustrating a structure of a cable assembly according to an exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[0024] Hereinafter, exemplary embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. However, it should be understood that the drawings and description are not intended to limit the scope of the present disclosure as claimed. In the drawings, the same or similar components are indicated by the same or similar reference numerals. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the embodiments of the present disclosure. However, it would be apparent to those skilled in the art that one or more embodiments can be practiced without these specific details. In other instances, well-known structures and devices are illustrated in block diagram form in order to avoid obscuring the present disclosure. Further, descriptions of well-known structures and techniques may be omitted so as to not unnecessarily obscure the concepts of the present disclosure.

[0025] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the term "including" "comprising" "having" and the like are meant to be inclusive and to mean that there can be additional features, steps, operations, and / or components that are not specifically recited. The use of "including" "comprising" "having" and the like are not meant to be limiting.

[0026] All terms used herein, including technical and scientific terms, have the meanings commonly understood by one of ordinary skill in the art unless otherwise defined. It should be noted that the terms used herein are defined as having meanings that are consistent with the context of the specification in which the terms are used and should not be interpreted in an idealized or overly formal way.

[0027] As Figures 1-5 Exemplary embodiments according to the present disclosure provide a cable, such as a 112G cable, capable of stable data transmission at a high transmission rate, suitable for OSFP, QSFP-DD, SFP, SFP-DD, CDFP, etc. interface modules, as shown in FIGS. 1A and 1B.

[0028] Cables according to embodiments of this disclosure may include at least two conductive cores 110 for signal or data transmission, which are arranged spaced apart from each other and electrically insulated from each other (via a single internal insulation structure described below) and extend longitudinally or axially. In this document, the conductive cores are made of conductive material and do not include insulating material or are uninsulated, for example, consisting only of conductors. As an example, each conductive core may be made of a highly conductive material such as a copper conductor or a silver-plated conductor. Each conductive core may be a single-core wire formed from a single conductor, or a stranded core wire formed from two or more conductors; this disclosure does not specifically limit this.

[0029] In such Figures 1-4 In the exemplary embodiment shown, the cable also includes an internal insulation structure 120 that extends longitudinally or axially along the conductive cores 110, circumferentially covers each conductive core 110, and contacts (e.g., bonds) the outer peripheral surface of each conductive core 110 to provide electrical insulation and protection to the conductive cores. As an example, the internal insulation structure may be made of insulating materials such as polyester, polyethylene, polypropylene, polyvinyl chloride, polytetrafluoroethylene, perfluoroethylene propylene, polyvinylidene fluoride, tetrafluoroethylene, ethylene copolymers, polyolefins, polyethylene terephthalate (“PET”), etc.

[0030] The internal insulation structure 120 is used to fix the relative positions of the individual conductive cores 110, that is, each conductive core 110 is fixedly held within the internal insulation structure 120. In conventional cables, an insulation layer is wound or bonded around each conductor to form an insulated core. The outer peripheries of the insulation layers of adjacent insulated cores abut against each other. Due to the gaps between adjacent insulated cores, the cable structure is prone to deformation or core displacement, resulting in unstable data transmission performance. Unlike conventional cables, in the embodiments of this disclosure, all conductive cores 110 of the same cable are covered by a single internal insulation structure 120. The material of the internal insulation structure 120 is filled between the covered conductive cores 110. The internal insulation structure 120 and all the conductive cores 110 covered therein form a stable integrated structure, which can ensure that each conductive core 110 will not shift relative to other conductive cores during use, such as during assembly, bending, or other operations. The cable structure does not deform or deforms minimally, improving the stability of cable performance. In other words, the relatively fixed positioning of the conductors forming each conductive core within a single internal insulation structure ensures a stable cable structure, thereby enabling stable electrical performance. As an example, the spacing between the individual conductive cores 110 of the cable can remain constant or unchanged in the longitudinal direction of the cable.

[0031] In embodiments of this disclosure, the internal insulation structure 120 is a single foamed insulation structure, formed of foamed insulating material, in which each conductive core 110 is fixedly held. That is, each conductive core of the cable is spaced apart from each other and encased in the same or a single foamed insulation structure to electrically insulate them from each other. Exemplarily, the foamed insulation structure may include a porous insulation structure or an insulation structure in which bubbles or pores are formed. According to embodiments of this disclosure, by encasing each conductive core in foamed insulating material, particularly by directly encasing the conductive core or conductor itself to form a foamed insulation structure, the dielectric constant of the cable can be significantly reduced, enabling the cable characteristics to meet the requirements of better communication performance. Electrical characteristics such as capacitance, capacitance balance, far-end (near-end) crosstalk, and attenuation can be significantly improved to facilitate high-speed, high-frequency signal transmission. Furthermore, the cable product can be lighter and smaller, thereby optimizing the cable's transmission performance. The internal insulation structure can be prepared using chemical foaming or physical foaming processes, and this disclosure does not impose specific limitations on this method.

[0032] According to an exemplary embodiment of this disclosure, the internal insulation structure 120 can be an integral structure formed by an extrusion process, which is directly formed (extruded) on the outer peripheral surface of the conductive core 110 along the longitudinal or axial direction of the cable. In other words, unlike conventional techniques that extrude or press an insulation layer onto a single core to form an insulated core, in an exemplary embodiment of this disclosure, foamed insulating material can be extruded in one step to directly cover two or more conductive cores or conductors themselves through an extrusion process, forming an integral insulation structure that extends continuously along the length of the cable, such as a foamed insulation structure. This makes the insulation structure fit more closely to the outer peripheral surface of each conductive core or conductor, resulting in better structural stability, and the single integral extrusion or pressing can produce cables more efficiently.

[0033] In the illustrated embodiment, as Figures 1-5 As shown, the internal insulation structure 120 may have a generally elliptical cross-section, and two conductive cores 120 are symmetrically held within the internal insulation structure 120. The two conductive cores 120 may be spaced apart along the major axis of the ellipse, for example, the centers of the two conductive cores 120 may coincide with the two foci of the ellipse. However, this disclosure is not limited to this, and the cross-sectional shape of the internal insulation structure, the arrangement of the conductive cores, etc., may be changed according to actual needs.

[0034] In exemplary embodiments of this disclosure, such as Figures 1-5As shown in the cross-sectional view, the cable also includes an inner insulation layer 130, a first conductive shielding layer (or strip) 140, and an outer insulation layer (or strip) 150 arranged sequentially from the inside out, each extending along the length or longitudinal direction of the cable. The inner insulation layer 130 circumferentially covers and contacts the outer peripheral surface of the inner insulation structure 120 to stably support the inner insulation structure 120 and the conductive core 110 held therein; the first conductive shielding layer (or strip) 140 circumferentially wraps around or surrounds the inner insulation layer 130 to provide signal shielding for the conductive core, while the outer insulation layer 150 wraps around the outside of the first conductive shielding layer 140 to provide protection.

[0035] For example, the internal or external insulation layer can be made of insulating materials such as polyester, polyethylene, polypropylene, polyvinyl chloride, polytetrafluoroethylene, perfluoroethylene propylene, polyvinylidene fluoride, tetrafluoroethylene, ethylene copolymers, polyolefins, polyethylene terephthalate (“PET”), etc. Furthermore, in some embodiments, insulating tape can be wrapped around the outer periphery of the internal insulation structure; alternatively, the internal insulation layer can be formed on the outer periphery of the internal insulation structure using an extrusion molding process. Since the internal insulation structure is an integral structure that firmly holds the individual conductive cores therein, the internal insulation layer can be formed more stably and uniformly. For example, the internal insulation layer can have a uniform distribution on the internal insulation structure and can have a uniform thickness, resulting in more stable cable structure and electrical characteristics, ensuring superior SI performance.

[0036] In some embodiments, the dielectric constant of the internal insulation structure 120 may be less than or equal to the dielectric constant of the internal insulation layer 130. As an example, the internal insulation layer may be formed of the same or different foaming material as the internal insulation structure to further reduce the dielectric constant of the cable; or, depending on specific needs, the internal insulation layer may be formed of solid or non-foamed insulation material to improve the stability of the cable structure. That is, the solid or non-foamed internal insulation layer may have higher strength to stably support and protect the internal insulation structure 120 and the conductive core 110, so that the cable is not easily deformed during operations such as bending, being squeezed in a mold, or assembly, and maintains high and stable SI performance.

[0037] In the illustrated embodiment, as Figures 1-5 As shown in the cross-sectional view, the inner insulation layer 130 is an annular layer surrounding the inner insulation structure 120, and can be formed, for example, into a tubular structure extending along the length of the cable, and can have a uniform layer thickness. However, this disclosure is not limited thereto, and the cross-sectional shape, thickness, etc. of the inner insulation layer can be changed according to actual needs.

[0038] In some embodiments of the present disclosure, instead of the conventional wrap-around arrangement of the conductive shielding layer in a cable, a mold can be utilized to fit or wrap the first conductive shielding layer 140 in a full or half longitudinal wrap form on the outer circumferential surface of the inner insulating layer 130, which can be a half or full tubular structure that wraps circumferentially on the inner insulating layer 130 and extends along the length or longitudinal direction of the cable, can be better fitted (e.g., by heat fusion or by adhesive bonding) on the inner insulating layer, thereby improving the stability of the SI performance of the cable, and can eliminate the pitch of the conventional wrap-around structure, further eliminating the return loss caused by the wrap-around structure as a whole, improving the frequency bandwidth of the cable, and meeting the requirement of high-speed data transmission. The first conductive shielding layer 140 can include a metal shielding layer or tape, which can include an insulating tape layer or tape and a conductive layer (e.g., a metal layer) attached to the insulating tape layer or tape. Exemplarily, the outer insulating layer (or tape) 150 can include an insulating layer or tape in a wrap-around or longitudinal wrap form.

[0039] In some embodiments, as shown in Figures 1-3 and Figure 5 , the cable can further include a drain wire or ground wire 160 arranged separately, such as at least one drain wire or ground wire 160 arranged between the first conductive shielding layer (or tape) 140 and the outer insulating layer (or tape) 150, which can be in electrical contact with the first conductive shielding layer 140 to improve the electromagnetic shielding effect of the cable. For example, the conductive layer of the first conductive shielding layer (or tape) 140 can face outwardly towards the outer insulating layer (or tape) 150 to contact the drain wire or ground wire 160.

[0040] In the embodiments shown in Figure 1 , 2 and 5, two ground wires 150 are arranged, such as symmetrically arranged on opposite sides of the first conductive shielding layer (or tape) 140 in the radial direction. In Figure 3 , only a single ground wire 150 is arranged on one side of the first conductive shielding layer (or tape) 140. In the embodiments of Figure 4 , no separate drain wire or ground wire is arranged, and the first conductive shielding layer can be electrically connected to an external grounding structure to serve as a ground wire. In some examples, the ground wires 150 are aligned in the radial direction with the conductive core 110, such as their centers can be located in substantially the same plane. Although the ground wires are shown as having a circular cross-section in the illustrated embodiments, the present disclosure is not limited thereto, and in other embodiments, the ground wires can have a flat structure or layered structure attached to the conductive shielding layer.

[0041] In the embodiments shown in Figure 2In the illustrated embodiment, the cable can further include a second conductive shield layer (or tape) 170 wrapping the first conductive shield layer (or tape) 140 and the at least one ground wire 160 on the outside, the at least one ground wire 160 being positioned between the first conductive shield layer (or tape) 140 and the second conductive shield layer (or tape) 170 and in electrical contact with at least one of the conductive shield layers (or tapes) therein, while the outer insulating layer 150 wraps on the second conductive shield layer (or tape) 170 on the outside to secure the inner conductive shield layers (or tapes) and ground wires. Such a double-layer shield structure can enhance the overall EMC and EMI capability of the cable, further improving the stability of the electrical performance of the cable. The second conductive shield layer (or tape) 170 can employ a similar construction as the first conductive shield layer (or tape) 140, such as a longitudinal wrap structure, although the present disclosure is not limited thereto.

[0042] As an example, each of the first conductive shield layer (or tape) 140 and the second conductive shield layer (or tape) 170 can include an insulating tape layer or strip and a conductive layer attached to the insulating tape layer or strip, and the conductive layers of the first conductive shield layer (or tape) 140 and the second conductive shield layer (or tape) 170 face and contact each other and electrically contact the ground wire 160 positioned therebetween.

[0043] In the case where the conductive shield layer employs a longitudinal wrap structure, the ground wire position of the cable can be fixed at the center line of the longitudinal wrap structure using a mold, for example, the ground wire can be adhered to the surface of the longitudinal wrap structure via an adhesive layer, such as a viscous layer, an adhesive, or a hot melt adhesive, etc. disposed on the surface of the longitudinal wrap structure. The conductive shield layer in the form of a longitudinal wrap can better conform to and cover the ground wire, so that the ground wire can be stably fixed, and the ground wire substantially extends linearly or is fixed in position along the longitudinal or axial direction of the cable, i.e., the positional deviation of the ground wire in the longitudinal or length range of the cable is reduced or eliminated, further improving the SI performance of the cable.

[0044] Embodiments of the present disclosure also provide a cable assembly 10, as illustrated, which can include at least two cables described herein arranged within an outer jacket 11. For example, the cables can be parallel to each other, spaced apart from each other, or twisted or wound together in a longitudinal direction. Figure 5

[0045] The outer jacket 11 can be in the form of a sleeve, such as a metal tube or a plastic tube, to provide protection for the internal structure of the cable. As shown, the cable assembly 10 can further include an electromagnetic shield structure 12 disposed within the outer jacket 11, which can take the form of a layer or strip of metal or other conductive material wrapped or wound around the outside of all the cables to provide a further improved electromagnetic shielding effect.

[0046] In some examples, as Figure 5 ​As shown, the cable assembly can also include additional cushioning layers 13, such as braided layers, disposed within the outer jacket 11, for example, in a ring-like fashion between the electromagnetic shielding structure 12 and the outer sleeve 11 to provide cushioning or damping action to the cable. In further examples, the spaces between the cables within the outer jacket and / or the spaces between the cables and the cushioning layers or shielding structure can also be at least partially filled with a filler 14, such that the structure of the cable assembly is less prone to deformation, remains stable in use.

[0047] While example embodiments of the present disclosure have been shown and described, it is to be understood that the embodiments can be varied in many ways, and that such variations are not to be regarded as a departure from the spirit and scope of the present disclosure, which is defined by the following claims and their equivalents. Accordingly, it is to be understood that, within the scope of the present disclosure, the features noted in the various embodiments and / or claims of the present disclosure can be combined or / and incorporated in other embodiments in an arbitrary manner, even if such combinations or incorporations are not expressly noted in the present disclosure. In particular, the features noted in the various embodiments and / or claims of the present disclosure can be combined and / or incorporated in various combinations, without departing from the spirit and teachings of the present disclosure. All such combinations and / or incorporations are within the scope of the present disclosure.

Claims

1. A cable, comprising: At least two conductive cores (110) are spaced apart from each other and extend along the longitudinal direction of the cable; An internal insulation structure (120) circumferentially covers and contacts each of the at least two conductive cores (110) to secure the at least two conductive cores (110); The inner insulating layer (130) covers and contacts the inner insulating structure on the outside; A first conductive shielding layer (140) wrapped around the inner insulating layer on the outside; and An outer insulating layer (150) wrapped around the outside of the first conductive shielding layer. The internal insulation structure is a foamed insulation structure that fixes the at least two conductive wire cores therein.

2. The cable according to claim 1, wherein, The at least two conductive cores are encased in the same foamed insulation structure.

3. The cable according to claim 2, wherein, The internal insulation structure is an integrally extruded structure formed along the longitudinal direction of the cable on the outer peripheral surface of at least two conductive cores.

4. The cable according to claim 3, wherein, The internal insulation structure has a generally elliptical cross-section, and the at least two conductive cores include two conductive cores that are symmetrically held within the internal insulation structure.

5. The cable according to claim 4, wherein, The spacing between the two conductive cores is constant along the longitudinal direction of the cable.

6. The cable according to claim 1, wherein, The dielectric constant of the internal insulation structure is less than or equal to the dielectric constant of the internal insulation layer.

7. The cable according to claim 6, wherein, The inner insulation layer is a ring-shaped layer formed of solid insulating material.

8. The cable according to any one of claims 1-7, wherein, Each conductive core comprises a single-core wire formed by a single conductor or a stranded core wire formed by two or more conductors.

9. The cable according to any one of claims 1-7, wherein, The cable also includes at least one ground wire (160) disposed between the first conductive shielding layer and the outer insulation layer and in electrical contact with the first conductive shielding layer.

10. The cable according to claim 9, wherein, The at least one ground wire includes a single ground wire located on one side of the first conductive shielding layer, or two ground wires symmetrically arranged on opposite sides of the first conductive shielding layer.

11. The cable according to claim 9 or 10, wherein, The cable also includes a second conductive shielding layer (170) that wraps the first conductive shielding layer and the at least one ground wire on the outside. The outer insulating layer is wrapped around the second conductive shielding layer, and The at least one ground wire is positioned between the first conductive shielding layer and the second conductive shielding layer and is in electrical contact with at least one of the first conductive shielding layer and the second conductive shielding layer.

12. The cable according to claim 11, wherein, Each of the first and second conductive shielding layers includes an insulating strip and a conductive layer attached to the insulating strip, and the conductive layers of the first and second conductive shielding layers face each other and are in contact with the at least one ground wire.

13. A cable assembly (10), comprising: At least two cables, each cable being the cable described in any one of claims 1-12; An electromagnetic shielding structure (11) is circumferentially wrapped around the outside of the at least two cables; and Outer sheath (12), which is fitted over the outside of the electromagnetic shielding structure.

14. The cable assembly of claim 13 further includes a buffer layer (13) disposed between the electromagnetic shielding structure and the outer sheath and / or filler (14) filling the space between the at least two cables inside the electromagnetic shielding structure.

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