High-speed transmission cable and production process thereof

Abstract

The invention discloses a high-speed transmission cable and a production process thereof, the high-speed transmission cable comprises at least two signal core wires, a first shielding layer, at least one ground wire, a second shielding layer and an insulating layer, and the at least two signal core wires are arranged in parallel; the first shielding layer wraps the at least two signal core wires; the ground wire is flat and is attached to the first shielding layer; the second shielding layer wraps the ground wire and the first shielding layer; the insulating layer wraps the second shielding layer. According to the technical scheme, the coupling area of the ground wire and the shielding layer can be remarkably increased, an electromagnetic field is more uniformly distributed along the circumferential direction of the cable, loop inductance and a common-mode radiation peak value are reduced, the shielding efficiency is improved under the high-frequency condition, the integrity of differential signals is kept, and meanwhile a geometric stability reference is provided for a continuous production process.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a high-speed transmission cable and its manufacturing process. Background Technology

[0002] High-speed transmission cables are key components in modern communication systems used to transmit high-frequency digital signals. They are mainly used in applications with extremely high signal integrity requirements, such as data centers, server interconnects, and high-speed computer interfaces. These cables typically employ differential signal transmission, using two or more signal cores to carry differential signal pairs, and are equipped with appropriate shielding structures and grounding systems to ensure the stability and reliability of signal transmission.

[0003] High-speed transmission cables in existing technologies typically employ a multi-layer concentric structure design, including a signal core carrying differential signals, a first shielding layer covering the signal core, a ground wire positioned around the first shielding layer, and an outer second shielding layer and insulating protective layer. The ground wire, as a crucial component providing the signal return path and enhancing shielding effectiveness, has traditionally been constructed using a cylindrical conductor. However, under high-frequency signal transmission conditions, the geometric characteristics of a cylindrical ground wire can lead to significant electromagnetic field distribution problems. Specifically, due to the geometric constraints of its circular cross-section, the cylindrical ground wire can only form effective electromagnetic coupling with the first shielding layer in localized areas, resulting in a highly uneven distribution of the electromagnetic field around the ground wire. This uneven distribution manifests as a local peak in electromagnetic field strength in the region closest to the ground wire and the first shielding layer, while weakly coupled regions with relatively low electromagnetic field strength appear in other areas around the ground wire's circumference. As the signal frequency increases, this uneven electromagnetic field distribution is further exacerbated, not only reducing overall shielding efficiency but also inducing undesirable conversions from differential signals to common-mode signals, severely impacting the signal integrity performance of high-speed transmission cables. Summary of the Invention

[0004] The main objective of this invention is to solve the technical problems of limited electromagnetic coupling area and uneven electromagnetic field distribution caused by cylindrical ground wires in existing high-speed transmission cables, which in turn leads to low shielding efficiency and deterioration of signal integrity.

[0005] The first aspect of the present invention provides a high-speed transmission cable, which includes at least two signal core wires, a first shielding layer, at least one ground wire, a second shielding layer, and an insulating layer. The at least two signal core wires are arranged in parallel. The first shielding layer covers the at least two signal core wires. The ground wire is flat and is attached to the first shielding layer. The second shielding layer covers the ground wire and the first shielding layer. The insulating layer covers the second shielding layer.

[0006] A second aspect of the present invention provides a manufacturing process for high-speed transmission cables, comprising: The flat ground wire roll is subjected to tension equalization treatment to form a flat ground wire with uniform tension; Differential core wires are transported in a synchronous traction manner, and molten first shielding material is wrapped around the outer periphery of the differential core wires. During the wrapping process, the flat ground wire with uniform tension is attached to the first shielding material to obtain a pre-solid composite. The initial solidified composite is subjected to delayed lock-up cooling under controlled pressure to obtain an interface-cured composite. An internal tension pulse is applied to the interface-cured composite and vibration response data is collected. Based on the vibration response data, real-time compaction is performed to obtain a self-tested compacted composite. Based on the vibration response data, time-varying tension compensation is performed on the self-testing compacted composite and feedback curing is completed to obtain a high-speed transmission cable semi-finished product with a dense interface.

[0007] Preferably, the tension homogenization treatment of the flat ground wire roll to form a flat ground wire with uniform tension includes: The coil is intermittently unwound from the outside to the inside along the flat ground line. Within each radial segment, the winding is briefly paused and the axial displacement is released to establish a base tension range in which the tension of each layer of the coil is within the same tension range. Under the aforementioned base tension range, the unfolded flat ground wire is subjected to equal-amplitude reverse torsion cycle along the longitudinal direction, so that the left and right edges and the center line of the flat ground wire alternately experience stretching and compression, so as to average the residual camber potential energy and reshape the lateral tension balance. During the continuous conveying of the flat ground wire, it is extended at equal intervals according to the periodic window synchronized with the production line speed. The extension amplitude is limited to within two orders of magnitude below the yield strain of the flat ground wire, which is used to uniformly distribute plastic strain along the length direction and suppress tension peaks. After the micro-extension is completed, the flat ground wire is brought into the constant tension stabilization zone until the tension fluctuation is maintained within a preset threshold before the wrapping station, thereby obtaining a flat ground wire with uniform tension.

[0008] Preferably, the differential core wire is conveyed in a synchronous traction manner, and a first shielding material in a molten state is wrapped around the outer periphery of the differential core wire. During the wrapping process, the flat ground wire with uniform tension is adhered to the first shielding material to obtain a preliminary solidification composite, comprising: During the process of forming an annular flow film from the first shielding material in the molten state, differential traction tension is used to establish two-stage shear rate zones in the flow film thickness direction to obtain flow film layering data between the outer high-viscosity region and the inner low-viscosity region. The flow rate of the outer high-viscosity region is adjusted according to the film layering data to generate a continuous negative pressure wedge extending along the outer surface of the melt film. The uniformly tensioned flat ground wire is introduced tangentially along the continuous negative pressure wedge, so that the uniformly tensioned flat ground wire slides into the inner low-viscosity region in a gapless state and is synchronously embedded in the outer high-viscosity region. While the uniformly tensioned flat ground wire slides into the inner low-viscosity region, instantaneous temperature data of the interface between the molten film and the flat ground wire is acquired, and the surface energy of the molten film is adjusted to a wetting threshold that matches the surface energy of the uniformly tensioned flat ground wire based on the instantaneous temperature data, thereby forming a continuous wetting interface. A cross-sectionally tapering solidification zone is set along the process advancement direction. The inner low-viscosity region is rapidly solidified into a solid-elastic phase through the viscoelastic transformation path of the continuous wetting interface, and the continuous wetting interface is locked in real time to form a primary solid composite.

[0009] Preferably, the step of adjusting the flow rate of the outer high-viscosity region according to the film stratification data to generate a continuous negative pressure wedge extending along the outer surface of the melt film, and introducing the uniformly tensioned flat ground wire tangentially along the continuous negative pressure wedge, includes: Based on the viscosity ratio between the outer high-viscosity region and the inner low-viscosity region in the film layering data, a critical flow velocity difference threshold is calculated, and the flow velocity of the outer high-viscosity region is adjusted to be lower than the critical flow velocity difference threshold, thereby forming a local negative pressure region induced by the flow velocity gradient on the outer surface of the melt film. The outer layer flow velocity distribution is continuously adjusted along the pressure gradient direction of the local negative pressure region, so that the local negative pressure region expands circumferentially along the outer surface of the melt film and forms a continuous negative pressure wedge. The pressure distribution of the continuous negative pressure wedge exhibits a wedge-shaped decreasing characteristic. A flat ground wire introduction point is set at the wedge tip position in the direction of pressure reduction of the continuous negative pressure wedge, so that the flat ground wire with uniform tension enters the continuous negative pressure wedge along a trajectory tangent to the wedge pressure gradient, achieving resistanceless sliding in; During the sliding process of the uniformly tensioned flat ground wire, the pressure change inside the wedge is monitored simultaneously, and the outer layer flow rate is adjusted according to the pressure fluctuation to maintain the stability of the wedge pressure distribution and ensure that the flat ground wire is completely embedded in the inner low viscosity region.

[0010] Preferably, the step of subjecting the initially solidified composite to delayed lock-up cooling under controlled pressure to obtain an interface-cured composite includes: A constant circumferential compressive stress is applied to the initial solidified composite and the temperature is maintained in a constant temperature range of 5K to 15K above the upper limit of the polymer glass transition temperature, so that the first shielding material undergoes viscoelastic creep migration and forms a stress-homogenized composite. According to the stress-homogenized composite, low-frequency radial pulsating compressive stress is synchronously applied along the conveying direction. The pulsation amplitude is 1.2 to 1.8 times that of the constant circumferential compressive stress. This is used to drive the polymer to flow through the interfacial micropores and complete the interfacial sealing, thereby obtaining a pulse-compacted composite. A moving isobaric freezing belt is set in the forward direction of the pulse compaction composite. The temperature of the freezing belt is 10K to 20K lower than the glass transition temperature of the polymer. The freezing belt moves synchronously with the speed of the production line, which sequentially transforms the polymer in the interface into the glassy state and locks the compaction morphology to obtain an isobaric frozen composite. Before the isobaric frozen composite enters the room temperature range, a constant axial micro-tension opposite to the traction direction is applied to the isobaric frozen composite. The amplitude of the micro-tension is 20% to 40% lower than the constant tension in the tension homogenization treatment. This is used to redistribute the axial shrinkage strain and reduce the residual stress gradient of the cross section to obtain an interface-cured composite.

[0011] Preferably, the step of synchronously applying low-frequency radial pulsating compressive stress along the conveying direction based on the stress-homogenized composite, with a pulsation amplitude of 1.2 to 1.8 times the constant circumferential compressive stress, is used to drive the polymer to permeate along the interfacial micropores and complete the interfacial sealing to obtain a pulsed compacted composite, comprising: The frequency window for low-frequency pulsating compressive stress is calculated based on the viscoelastic parameters of the first shielding material in the stress-homogenized composite. The pulsation frequency is set within the reciprocal range of the polymer relaxation time so that the pulsation period matches the polymer molecular chain rearrangement time. A phase distribution of pulsating compressive stress is established along the conveying direction, so that there is a quarter-cycle phase difference between the pulsating compressive stress at adjacent positions, forming a traveling pressure wave in the axial direction, which drives the polymer to generate directional flow. The spatial distribution of the pulsation amplitude is adjusted according to the micropore distribution characteristics of the interface between the flat ground wire and the first shielding material. A larger pulsation amplitude is applied in the region with higher micropore density, and a smaller pulsation amplitude is applied in the dense region to achieve differentiated seepage drive. During the application of pulsating compressive stress, the position of the polymer seepage front is monitored, and the pulsation frequency and amplitude are adjusted according to the seepage rate. When the seepage front completely covers the interfacial micropores, the pulsation is stopped and constant pressure is maintained to obtain the pulsed compacted composite.

[0012] Preferably, the step of applying an intrinsic tension pulse to the interface-cured composite and collecting vibration response data, and then performing real-time compaction based on the vibration response data to obtain a self-compacting composite includes: A first set of broadband tension pulses was applied to the interface-cured composite and vibration response data was collected to obtain modal baseline parameters. Based on the modal baseline parameters, the target resonance frequency is selected, a second set of fixed-frequency tension pulses is applied to the interface-cured composite, and vibration response data is collected to obtain the phase delay peak parameter. Phase reversal tension envelope data is generated based on the aforementioned phase delay peak parameter; A compression pulse is applied to the interface-cured composite according to the phase-reversal tension envelope data to obtain an instantaneously closed composite. A constant compressive tension is applied to the instantaneously closed composite and the attenuation data is collected. The compaction effect is determined based on the attenuation data, and a self-tested compacted composite is obtained.

[0013] Preferably, the step of performing time-varying tension compensation on the self-testing compacted composite based on the vibration response data and completing feedback curing to obtain a high-speed transmission cable semi-finished product with a dense interface includes: Based on the vibration response data, the self-testing compacted composite is divided into tension unit regions along its length, and tension segmented matrix data is generated based on phase-amplitude mismatch. Based on the tension segmentation matrix data, reverse gradient tension loading is applied to each tension unit region of the self-testing compaction composite to obtain a tension gradient corrected composite. The tension gradient correction composite is subjected to phase-shifted micro-amplitude torsional vibration tension pulses along the axial direction to release the residual shear strain at the interface and obtain a torsional vibration shaping composite. An exponentially decaying tension matching the viscoelastic relaxation modulus curve of the first shielding material is applied to the torsional vibration shaping composite to retain it, thereby obtaining a creep-locked composite. Before the creep-locked composite is cooled to room temperature, vibration response data is collected again and the modal baseline parameters are updated to output a high-speed transmission cable semi-finished product with a dense interface.

[0014] Preferably, the step of applying reverse gradient tension loading to each tension unit region of the self-tested compaction composite based on the tension segmentation matrix data to obtain a tension gradient corrected composite includes: Based on the tension segmented matrix data, identify the tension deviation distribution characteristics in each tension unit area, calculate the tension correction amount and correction direction for each tension unit area, and generate tension correction parameters for the unit area. A reverse gradient tension loading sequence is designed based on the tension correction parameters of the unit region. The gradient direction of the reverse gradient tension loading sequence is opposite to the original tension deviation gradient direction, and the gradient magnitude is proportional to the tension deviation magnitude. The reverse gradient tension loading sequence is applied sequentially to each tension unit region along the axial direction of the self-testing compacted composite. The loading sequence is carried out from the high deviation unit region to the low deviation unit region to ensure the gradualness and continuity of tension correction. During the reverse gradient tension loading process, the tension transfer effect between adjacent tension unit regions is monitored. Based on the tension transfer effect, the tension transition curve of the unit region boundary is adjusted to eliminate tension abrupt changes between unit regions and obtain a tension gradient correction complex.

[0015] The technical solution provided in this application embodiment involves at least two differential core wires tightly wrapped within a first shielding layer, forming a uniform and symmetrical electric field environment. A flat ground wire is then used outside this shielding layer and attached to the side of the first shielding layer facing away from the signal core wires. Because the width of the flat cross-section is significantly greater than its thickness, the ground wire and the first shielding layer no longer exhibit limited coupling along a local area as with cylindrical conductors. Instead, the effective contact area of ​​the return channel is significantly expanded through large-area bonding. This results in a more continuous closure of the loop magnetic field along the bonding surface, significantly reducing single-point high-field peak values ​​and achieving a more uniform electromagnetic energy distribution, thereby effectively reducing non-uniform field distortion at high frequencies.

[0016] A second shielding layer is then wrapped around the outside, forming a layered sandwich structure together with the flat ground wire. This significantly reduces the electromagnetic leakage path that would otherwise be caused by the gap between the cylindrical ground wire and the shielding layer. With this arrangement, the electromagnetic field exhibits a more symmetrical distribution around the "core wire-flat ground wire" during high-frequency operation. Loop inductance and differential-to-common-mode paths are effectively controlled, shielding efficiency is significantly improved, differential impedance maintains better stability, and the entire cable can provide higher integrity signal transmission performance in the gigahertz range.

[0017] Compared to the traditional cylindrical ground wire solution, the flat ground wire effectively solves the problems of local electromagnetic field intensity peaks and weak coupling areas caused by the cylindrical ground wire by increasing the electromagnetic coupling area and improving the uniformity of electromagnetic field distribution, and significantly improves the signal integrity performance of high-speed transmission cables under high-frequency conditions. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of a high-speed transmission cable according to an embodiment of the present invention (in this embodiment, the ground wire is not embedded in the first shielding layer). Figure 2 This is a cross-sectional view of an embodiment of the high-speed transmission cable of the present invention (in this embodiment, part of the ground wire structure is embedded in the first shielding layer). Figure 3 This is a schematic diagram of one embodiment of the manufacturing process of high-speed transmission cables in this invention.

[0019] Labeling explanation: 1. Signal core wire; 2. First shielding layer; 3. Ground wire; 4. Second shielding layer; 5. Insulation layer. Detailed Implementation

[0020] 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.

[0021] One embodiment of this application provides a high-speed transmission cable; please refer to [link / reference]. Figure 1 and Figure 2 In this embodiment, the high-speed transmission cable includes at least two signal core wires 1, a first shielding layer 2, at least one ground wire 3, a second shielding layer 4, and an insulating layer 5. The at least two signal core wires 1 are arranged in parallel. The first shielding layer 2 covers the at least two signal core wires 1. The ground wire 3 is flat and is attached to the first shielding layer 2. The second shielding layer 4 covers the ground wire 3 and the first shielding layer 2. The insulating layer 5 covers the second shielding layer 4.

[0022] Specifically, in this embodiment, the bonding method between the flat ground wire 3 and the first shielding layer 2 can be achieved using various technical approaches. In the first embodiment (not shown in the accompanying drawings), the flat ground wire 3 is embedded, meaning the ground wire 3 is completely embedded within the material matrix of the first shielding layer 2. This embedded structure ensures a tight physical bond between the ground wire 3 and the material of the first shielding layer 2, while ensuring that the ground wire 3 does not protrude beyond the inner side of the first shielding layer 2 (i.e., the side facing the signal core wire 1), thereby avoiding any adverse effects on the electric field distribution around the signal core wire 1. In the second embodiment (see...), ... Figure 2 The ground wire 3 is embedded in the outer surface of the first shielding layer 2 (the surface away from the signal core wire 1), and a portion of the structure of the ground wire 3 is exposed on the outside of the first shielding layer 2. In the third embodiment (see...), Figure 1 The flat ground wire 3 is arranged in a contact manner. Although it is not deeply embedded in the first shielding layer 2, the process ensures that the ground wire 3 maintains stable physical contact and good electrical connection with the surface of the first shielding layer 2.

[0023] Regarding the material selection for the shielding structure, the first shielding layer 2 and the second shielding layer 4 are preferably made of highly conductive metal foil, such as aluminum foil or copper foil, with aluminum foil being widely used due to its good cost-effectiveness and shielding performance. This double-layer metal shielding structure can create a continuous Faraday cage effect around the signal core wire 1 and the flat ground wire 3, effectively isolating the influence of external electromagnetic interference on the internal signal transmission. By ensuring a reliable electrical connection between the flat ground wire 3 and the two shielding layers, a complete shielding potential reference system can be established. When an external electromagnetic field acts on the shielding layer, the induced eddy currents and mirror currents can be quickly discharged through the ground wire 3 system, preventing interference signals from accumulating inside the shielding space, thereby maintaining the stability of the potential environment around the signal core wire 1.

[0024] The choice of insulation layer 5 material has a decisive impact on the electrical performance of high-speed transmission cables. In this embodiment, low-loss polymer insulation materials are preferred, among which fluoropolymers (such as polytetrafluoroethylene (PTFE), ethylene-tetrafluoroethylene copolymer (ETFE), etc.) are ideal choices due to their excellent dielectric properties. These materials have extremely low dielectric loss factors (typically less than 0.0002) under high-frequency conditions, which can effectively reduce signal energy attenuation during transmission. In addition, fluoropolymers also have dielectric constant stability over a wide temperature range and excellent chemical inertness, ensuring that the cable maintains stable impedance characteristics under various environmental conditions. In addition to fluoropolymers, low-loss hydrocarbon polymers such as polyethylene (PE) and polypropylene (PP) can also be used as alternatives. Designers can optimize the material configuration according to specific cost requirements and performance indicators.

[0025] It is easy to understand that in the technical solution provided by this application embodiment, at least two differential core wires are tightly wrapped within the first shielding layer 2, forming a uniform and symmetrical electric field environment. A flat ground wire 3 is used on the outside of this shielding layer and attached to the side of the first shielding layer 2 facing away from the signal core wire 1. Because the width of the flat cross-section is significantly greater than its thickness, the ground wire 3 and the first shielding layer 2 no longer have limited coupling along a local area like a cylindrical conductor. Instead, the effective contact area of ​​the return channel is significantly expanded through large-area bonding. In this way, the loop magnetic field closes more continuously along the bonding surface, significantly weakening the single-point high field peak, and the electromagnetic energy distribution is more uniform, thereby effectively reducing non-uniform field distortion at high frequencies. A second shielding layer 4 is then wrapped around the outside, forming a layered sandwich structure together with the flat ground wire 3, significantly reducing the electromagnetic leakage channels originally caused by the gap between the cylindrical ground wire 3 and the shielding layer. With this arrangement, the electromagnetic field exhibits a more symmetrical distribution around the "core wire - flat ground wire 3" during high-frequency operation. Loop inductance and the differential-to-common-mode path are effectively controlled, shielding efficiency is significantly improved, and differential impedance maintains better stability. The entire cable can provide higher signal integrity performance in the gigahertz range. Compared to the traditional cylindrical ground wire 3 scheme, the flat ground wire 3 effectively solves the problems of local electromagnetic field intensity peaks and weak coupling areas caused by the cylindrical ground wire 3 by increasing the electromagnetic coupling area and improving the uniformity of electromagnetic field distribution, significantly improving the signal integrity performance of high-speed transmission cables under high-frequency conditions.

[0026] Current high-speed transmission cable manufacturing processes typically employ a multi-layer continuous coating method, involving multiple consecutive steps such as signal core wire fabrication, first shielding layer coating, ground wire laying, second shielding layer coating, and outer insulation layer extrusion. During this multi-layer fabrication, complex physical and chemical interactions occur at the interfaces of each layer, forming several critical interfacial bonding regions. However, due to factors such as temperature fluctuations, differences in material flowability, uneven coating pressure, and differences in thermal expansion coefficients between different materials, these interfacial regions are prone to microscopic bonding defects, such as microbubbles, localized separation, abnormal interface roughness, or interface weakening due to poor material compatibility. More critically, these interfacial defects are completely concealed by the outer coating structure, creating a challenge in detecting these hidden defects. Traditional external inspection methods, such as optical inspection, cannot penetrate multi-layer structures; X-ray inspection has insufficient resolution for soft material interfaces; ultrasonic inspection is easily interfered with by differences in acoustic impedance within the multi-layer structure; and conventional electrical testing can only reflect overall performance and cannot accurately identify and locate microscopic defects at specific internal interfaces. The existence of this detection blind spot allows products with hidden interface defects to enter the market, which may lead to gradual degradation of signal transmission performance or even sudden failure during long-term use.

[0027] Therefore, in order to solve the problem of detecting the concealed interface defects in the multi-layer structure of high-speed transmission cables, and to achieve accurate identification and effective monitoring of the internal interface quality, this application also proposes a manufacturing process for high-speed transmission cables. Figure 3 A flowchart illustrating a manufacturing process for a high-speed transmission cable according to an embodiment of this application. In this embodiment, the method includes: Please see Figure 3 Tension homogenization treatment is applied to the flat ground wire roll to form a flat ground wire with uniform tension; In one embodiment of the present invention, the tension homogenization treatment of the flat ground wire roll to form a flat ground wire with uniform tension includes: The coil is intermittently unwound from the outside to the inside along the flat ground line. Within each radial segment, the winding is briefly paused and the axial displacement is released to establish a base tension range in which the tension of each layer of the coil is within the same tension range. Under the aforementioned base tension range, the unfolded flat ground wire is subjected to equal-amplitude reverse torsion cycle along the longitudinal direction, so that the left and right edges and the center line of the flat ground wire alternately experience stretching and compression, so as to average the residual camber potential energy and reshape the lateral tension balance. During the continuous conveying of the flat ground wire, it is extended at equal intervals according to the periodic window synchronized with the production line speed. The extension amplitude is limited to within two orders of magnitude below the yield strain of the flat ground wire, which is used to uniformly distribute plastic strain along the length direction and suppress tension peaks. After the micro-extension is completed, the flat ground wire is brought into the constant tension stabilization zone until the tension fluctuation is maintained within a preset threshold before the wrapping station, thereby obtaining a flat ground wire with uniform tension.

[0028] The following is a detailed description of the steps involved in the above embodiments: Intermittent unwinding of flat ground wire coils achieves segmented tension release through a programmable unwinding device. This device is equipped with a stepper motor-driven coil support and a tension monitoring system, calculating the radial segment length based on the elastic modulus and thickness of the flat ground wire material. In operation, the unwinding device pulls the flat ground wire at a constant speed. When the set length of a radial segment is reached, the pulling action pauses, and the clamping force on the flat ground wire is reduced by a pressure-reducing roller group. At this point, the flat ground wire retracts axially under its own elastic restoring force; this retraction motion is called axial displacement release, and its physical essence is to eliminate the elastic strain energy accumulated inside the material during winding. Through real-time monitoring by a tension sensor, when the tension of the flat ground wire gradually stabilizes from its initial uneven state, it indicates that the stress release for that radial segment is complete. The base tension range refers to the state where, after multiple intermittent unwinding operations, the tension value at each point along the length of the flat ground wire is controlled within a small fluctuation range. This operation solves the problem of interlayer stress differences caused by gravity compression and temperature changes during coil storage, providing a stress-uniform raw material foundation for subsequent precision processing.

[0029] After the base tension range is established, the flat ground wire is periodically torsionally processed using torsion guide rollers equipped with forward and reverse rotation functions. The torsion guide rollers are driven by servo motors, enabling precise control of the torsion angle and frequency. During the torsion process, the guide rollers rotate alternately clockwise and counterclockwise according to a preset program, maintaining a consistent angular amplitude each time; this constant amplitude characteristic is called constant amplitude. The rotation of the torsion guide rollers causes a spiral micro-deformation along the length of the flat ground wire, resulting in the left and right edge areas and the centerline area of ​​the ground wire alternately bearing stress in different directions during each torsion cycle. When the torsion direction changes, the previously stretched areas become compressed, and the previously compressed areas become stretched, achieving a periodic reversal of the stress state. The sickle-shaped bending potential energy is the internal stress stored in the flat ground wire during the rolling process due to uneven roll gaps or differences in material hardness caused by bending deformation. Through the stress redistribution effect generated by the reverse torsion cycle, these residual stresses, originally concentrated in specific areas, are averaged across the entire cross-section, thereby eliminating the bending tendency of the flat ground wire and re-establishing a transverse stress balance.

[0030] During continuous conveying, the flat ground wire undergoes equidistant micro-extension operations via a precision tension control device. This device comprises two sets of traction rollers, front and rear, and micro-extension is achieved by controlling the speed difference between the two sets of traction rollers. The system establishes a synchronized operating cycle based on the actual operating speed of the production line, ensuring a regular spacing distribution of micro-extension operations on the flat ground wire. The amplitude of micro-extension is controlled through high-precision displacement sensors and strain gauges, with the extension amount strictly limited to less than one percent of the material's yield strain value. Insufficient extension fails to effectively disperse stress concentration, while excessive extension causes the material to enter the plastic deformation region, affecting mechanical properties. The mechanism of micro-extension is to apply uniform tensile stress within the elastic deformation range of the flat ground wire, allowing any stress concentration points within the material to be released and redistributed through minute dislocation movements. This pretreatment effectively suppresses tension fluctuations that may occur during subsequent processing, ensuring the flat ground wire maintains a stable mechanical state during high-speed continuous production.

[0031] After the micro-extension treatment, the flat ground wire enters the constant tension stabilization zone for final stress equalization. This zone employs a closed-loop tension control system, forming a feedback control loop through a tension sensor, a proportional control valve, and a servo traction device. The tension sensor detects the instantaneous tension value of the flat ground wire in real time. The control system compares the detected value with a preset target value. When the deviation exceeds the allowable range, the speed and clamping force of the traction device are automatically adjusted. The preset threshold is determined by comprehensively considering the fatigue characteristics of the flat ground wire material and the accuracy requirements of subsequent coating processes, typically set to a fluctuation of no more than 3% around the target tension value. The length of the stabilization zone is designed based on the material's stress relaxation time constant, ensuring that the flat ground wire completes the full release and redistribution of internal stress within this zone. After constant tension stabilization treatment, the flat ground wire reaches an ideal state of uniform stress and stable geometry, providing a consistent raw material base for the subsequent precision coating process with the molten first shielding material, ensuring the uniformity and reliability of the interface bonding.

[0032] Please continue reading. Figure 3 Differential core wires are transported in a synchronous traction manner, and molten first shielding material is wrapped around the outer periphery of the differential core wires. During the wrapping process, the flat ground wire with uniform tension is attached to the first shielding material to obtain a primary solid composite. In one embodiment of the present invention, the differential core wire is conveyed by synchronous traction, and a first shielding material in a molten state is wrapped around the outer periphery of the differential core wire. During the wrapping process, the flat ground wire with uniform tension is adhered to the first shielding material to obtain a preliminary solidification composite, comprising: During the process of forming an annular flow film from the first shielding material in the molten state, differential traction tension is used to establish two-stage shear rate zones in the flow film thickness direction to obtain flow film layering data between the outer high-viscosity region and the inner low-viscosity region. The flow rate of the outer high-viscosity region is adjusted according to the film layering data to generate a continuous negative pressure wedge extending along the outer surface of the melt film. The uniformly tensioned flat ground wire is introduced tangentially along the continuous negative pressure wedge, so that the uniformly tensioned flat ground wire slides into the inner low-viscosity region in a gapless state and is synchronously embedded in the outer high-viscosity region. While the uniformly tensioned flat ground wire slides into the inner low-viscosity region, instantaneous temperature data of the interface between the molten film and the flat ground wire is acquired, and the surface energy of the molten film is adjusted to a wetting threshold that matches the surface energy of the uniformly tensioned flat ground wire based on the instantaneous temperature data, thereby forming a continuous wetting interface. A cross-sectionally tapering solidification zone is set along the process advancement direction. The inner low-viscosity region is rapidly solidified into a solid-elastic phase through the viscoelastic transformation path of the continuous wetting interface, and the continuous wetting interface is locked in real time to form a primary solid composite.

[0033] The following is a detailed description of the steps involved in the above embodiments: The molten first shielding material is extruded through the die head to form an annular flow film. During this process, a differential traction device applies different traction tensions to the differential core wire and the flat ground wire to establish a shear rate gradient within the flow film. The differential traction device includes independently controlled traction roller sets, applying higher traction tension to the differential core wire and lower traction tension to the flat ground wire, with the tension difference controlled within the range of 20-40N. This tension difference causes a stratified flow effect in the thickness direction of the annular flow film: the molten material near the core wire is subjected to a larger drag force, forming a high shear rate region where the polymer molecular chains are stretched and oriented, exhibiting high viscosity characteristics; the molten material away from the core wire is subjected to relatively smaller shear forces, and the polymer molecular chains remain relatively relaxed, exhibiting low viscosity characteristics. The two-stage shear rate region refers to these two regions with significant viscosity differences formed in the thickness direction of the flow film. The viscosity distribution at different locations is monitored in real time using a rheometer and viscosity sensor to obtain flow film stratification data including parameters such as viscosity value, temperature, and shear rate. This layered structure provides a viscosity gradient basis for the precise embedding of the subsequent flat ground wire. The high-viscosity outer layer acts as a clamping and fixing agent, while the low-viscosity inner layer facilitates the unimpeded sliding of the flat ground wire.

[0034] Based on the film stratification data, the flow velocity of the outer high-viscosity region is precisely controlled by a flow rate regulating device to ensure it is lower than that of the inner low-viscosity region. In practice, the extruder head is equipped with a segmented temperature control system and a flow channel regulating mechanism. The outer layer flow velocity is reduced by lowering the temperature of the outer layer or decreasing the flow channel cross-section. When the outer layer flow velocity is lower than the inner layer flow velocity, according to Bernoulli's law in fluid mechanics, a relatively low-pressure region forms in the outer layer. This pressure difference generates a circumferentially extending negative pressure band on the outer surface of the melt film, called a continuous negative pressure wedge. The pressure distribution of this wedge exhibits a wedge-shaped characteristic, with the pressure gradually decreasing from the wedge bottom to the wedge tip. Utilizing this negative pressure gradient, a flat ground wire inlet is set at the lowest pressure point of the wedge (the wedge tip position), allowing the uniformly tensioned flat ground wire to enter the melt film along a trajectory tangential to the wedge pressure gradient. Under the action of negative pressure, the flat ground wire is naturally attracted into the inner low-viscosity region, while the outer high-viscosity region, due to its higher viscosity, automatically coats the flat ground wire, creating a synchronous encapsulation effect. The air gap-free state means that there is no air interface between the flat ground wire and the molten material. Through the attraction of the negative pressure wedge and the good fluidity of the inner low viscosity region, the molten material is ensured to completely wet the surface of the flat ground wire, eliminating the air bubble entrainment problem common in traditional coating processes.

[0035] During the process of the flat ground wire sliding into the inner low-viscosity region, the temperature change at the interface between the molten film and the flat ground wire is continuously monitored by an infrared temperature sensor array. The sensor array is arranged along the extrusion direction, with a sampling frequency set to 100 times per second. The instantaneous temperature data is transmitted to the control unit in real time via a data acquisition system. The control unit calculates the surface energy difference between the molten film and the flat ground wire under the current state based on the temperature data and adjusts the surface energy matching degree between the two through a surface treatment device. Surface energy refers to the free energy per unit area of ​​surface, which determines the wetting performance of the interface between two materials. The wetting threshold is the minimum surface energy difference required for complete wetting of the two materials. When the surface energy of the molten film is higher than that of the flat ground wire and the difference reaches the wetting threshold, the molten material can completely spread on the surface of the flat ground wire. The surface treatment device dynamically adjusts the surface energy of the molten film through plasma treatment or chemical surface modification to keep the difference between its surface energy and that of the flat ground wire within the wetting threshold range. For example, when a decrease in the contact interface temperature is detected, leading to a reduction in the surface energy of the molten film, the system automatically increases the intensity of the plasma treatment to compensate for the surface energy loss. Through this real-time adjustment, a continuous and stable wetting interface is formed between the flat ground wire and the molten film. This interface has good molecular-level bonding characteristics, providing a high-quality bonding basis for subsequent interface curing.

[0036] A gradually shrinking solidification zone, set along the process direction, achieves synchronous temperature and pressure regulation through a progressively shrinking mold channel. The inlet cross-section of this solidification zone is larger than the outlet cross-section, with a shrinkage ratio controlled between 1.2:1 and 1.5:1, causing the molten material to undergo gradually increasing compression during its passage. Simultaneously, a cooling water circulation system is installed within the solidification zone, with multiple temperature control sections along the channel direction, gradually reducing the temperature from the inlet melting temperature to below the outlet glass transition temperature. The viscoelastic transition path refers to the temperature-time history of a polymer material transitioning from a viscous flow state to an elastic solid state. During this transition, polymer molecular chains at the continuous wetting interface gradually change from free flow to restricted movement, ultimately forming a stable cross-linked network. The inner low-viscosity region, due to its better fluidity, can form dense molecular-level bonds at the interface. When the temperature drops below the glass transition point, these bonds are "frozen" in the solid matrix, forming a solid-elastic phase structure. Real-time locking refers to the stabilization of the molecular bonding state at the continuous wetting interface before the polymer molecular chains completely lose their mobility, preventing further change. The entire solidification process is completed within 2-3 seconds, resulting in a pre-solidified composite with a completely bonded interface between the flat ground wire and the first shielding material, free from delamination defects. This provides a high-quality raw material base for the subsequent delayed-lock cooling process. This rapid solidification process effectively avoids the interface separation and stress concentration problems that may occur during slow cooling, ensuring the uniformity and reliability of the interface bonding.

[0037] In one embodiment of the present invention, the step of regulating the flow rate of the outer high-viscosity region according to the film layering data to generate a continuous negative pressure wedge extending along the outer surface of the melt film, and tangentially introducing the uniformly tensioned flat ground wire along the continuous negative pressure wedge, includes: Based on the viscosity ratio between the outer high-viscosity region and the inner low-viscosity region in the film layering data, a critical flow velocity difference threshold is calculated, and the flow velocity of the outer high-viscosity region is adjusted to be lower than the critical flow velocity difference threshold, thereby forming a local negative pressure region induced by the flow velocity gradient on the outer surface of the melt film. The outer layer flow velocity distribution is continuously adjusted along the pressure gradient direction of the local negative pressure region, so that the local negative pressure region expands circumferentially along the outer surface of the melt film and forms a continuous negative pressure wedge. The pressure distribution of the continuous negative pressure wedge exhibits a wedge-shaped decreasing characteristic. A flat ground wire introduction point is set at the wedge tip position in the direction of pressure reduction of the continuous negative pressure wedge, so that the flat ground wire with uniform tension enters the continuous negative pressure wedge along a trajectory tangent to the wedge pressure gradient, achieving resistanceless sliding in; During the sliding process of the uniformly tensioned flat ground wire, the pressure change inside the wedge is monitored simultaneously, and the outer layer flow rate is adjusted according to the pressure fluctuation to maintain the stability of the wedge pressure distribution and ensure that the flat ground wire is completely embedded in the inner low viscosity region.

[0038] The following is a detailed description of the steps involved in the above embodiments: Based on the viscosity measurements of the outer high-viscosity region and the inner low-viscosity region in the film stratification data, the data processing unit calculates the viscosity ratio of the two regions and determines the critical velocity difference threshold according to fluid mechanics principles. Specifically, the data processing unit first extracts the viscosity values ​​of the outer high-viscosity region (e.g., 1500 Pa·s) and the inner low-viscosity region (e.g., 800 Pa·s), calculating a viscosity ratio of 1.875. Then, based on the relationship between the Reynolds number and the viscosity ratio, the critical velocity difference threshold that generates a negative pressure effect is calculated using the pressure-velocity correlation equation in fluid mechanics. This threshold refers to the minimum difference between the velocity in the outer region and the velocity in the inner region; exceeding this difference is necessary to form a stable negative pressure region on the outer surface. After receiving the threshold data, the velocity regulation device controls the actual velocity of the outer high-viscosity region by adjusting the segmented heating temperature of the extruder head and the cross-sectional area of ​​the flow channel. When the outer flow velocity is adjusted below the critical velocity difference threshold, according to the Bernoulli effect, a relatively high pressure is formed in the area with lower outer velocity, while a relatively low pressure is formed in the inner region with relatively higher velocity. This pressure difference creates a localized negative pressure region on the outer surface of the molten film. This negative pressure region refers to the area on the outer surface of the molten film where the pressure is lower than the surrounding ambient pressure, and its pressure distribution exhibits a gradient characteristic. This precise flow velocity control enables the generation of a negative pressure effect solely based on the fluid's own flow characteristics without the use of external vacuum equipment, creating ideal flow field conditions for the subsequent precise introduction of a flat ground wire.

[0039] Along the pressure gradient direction of the local negative pressure region, a multi-segment flow rate regulation system continuously fine-tunes the outer layer flow rate distribution, gradually expanding the negative pressure region from a localized point to a circumferentially continuous wedge-shaped negative pressure band. The multi-segment flow rate regulation system includes multiple independent temperature control zones and flow channel regulating valves distributed circumferentially along the extruder head. Each control segment is responsible for regulating the flow rate within an arc length of approximately 15-20 degrees. Based on pressure distribution data monitored by a pressure sensor array, the system adjusts the flow rate of each control segment segment by segment, resulting in a smooth gradient change in flow rate between adjacent control segments. The pressure gradient direction refers to the spatial direction in which pressure changes from high to low values. The system continuously reduces the outer layer flow rate along this direction, causing the negative pressure region to gradually expand circumferentially. After the flow rate regulation of all control segments is completed, a continuous negative pressure band is formed on the outer surface of the melt film; this negative pressure band is called a continuous negative pressure wedge band. The wedge-shaped decreasing characteristic of the wedge band means that the pressure distribution exhibits a gradually decreasing wedge-shaped profile from the wedge base to the wedge tip, with relatively high pressure at the wedge base and the lowest pressure at the wedge tip. For example, the negative pressure at the bottom of the wedge is -0.2 kPa, and the pressure gradually decreases along the wedge direction, reaching -0.8 kPa at the tip. This wedge-shaped pressure distribution provides a pressure-reducing guiding channel for the flat ground wire, allowing it to slide naturally along the pressure gradient and avoiding material deformation or interface damage that might be caused by forced insertion.

[0040] At the wedge tip position in the direction of decreasing pressure of the continuous negative pressure wedge, a flat ground wire introduction point is set using a precision positioning device. This position is the area with the highest negative pressure value in the entire wedge. The selection of the introduction point position is based on the pressure distribution measurement results to ensure that the flat ground wire is subjected to the maximum negative pressure attraction upon entry. Under the guidance of the traction device, the flat ground wire with uniform tension enters the continuous negative pressure wedge along a trajectory tangent to the wedge pressure gradient. The tangent trajectory means that the entry path of the flat ground wire is tangent to the pressure isopleths on the wedge surface. This geometric relationship ensures that the flat ground wire enters the wedge with minimal resistance. In specific implementation, the entry angle of the flat ground wire is controlled by a guide roller group, making it tangent to the wedge surface at a 15-25 degree angle. After the flat ground wire enters the wedge, the negative pressure automatically attracts it to the inner low-viscosity region, while the molten material in the outer high-viscosity region automatically flows and coats the upper surface of the flat ground wire under the action of viscous force. Resistanceless sliding refers to the ability of a flat ground wire to smoothly enter a predetermined position without external force under the combined effects of negative pressure attraction and viscous flow, without being squeezed, deformed, or scratched during the entire process. This entry method eliminates stress concentration and interface defects that may occur with traditional forced insertion methods, ensuring an ideal contact state between the flat ground wire and the molten material.

[0041] During the sliding of the uniformly tensioned flat ground wire, a pressure sensor array distributed along the wedge band synchronously monitors pressure changes within the wedge band. The pressure sensor array contains multiple miniature pressure probes arranged at 2-3 mm intervals along the length of the wedge band, collecting pressure data at different locations within the wedge band in real time. The data acquisition system records pressure values ​​at a frequency of 200 times per second and identifies pressure fluctuation patterns using a filtering algorithm. When pressure fluctuations exceed a preset range, the feedback control system immediately initiates a flow rate adjustment program. Pressure fluctuations refer to the deviation of the pressure value within the wedge band from the target pressure distribution curve; these fluctuations affect the sliding process of the flat ground wire and the final embedding quality. The control system precisely adjusts the outer layer flow rate in the corresponding area based on the location and amplitude of the pressure fluctuations, compensating for pressure deviations by increasing or decreasing the flow rate. For example, when a pressure increase is detected at a certain location, the system reduces the outer layer flow rate at that location to enhance the negative pressure effect; when the pressure is detected to be too low, the system appropriately increases the flow rate to avoid excessive suction. Through this closed-loop control, the wedge pressure distribution maintains a stable wedge shape, ensuring that the flat ground wire can be fully embedded into the inner low-viscosity region and reach the predetermined embedding depth. The entire process achieves precise positioning and bonding between the flat ground wire and the molten first shielding material, providing an initial state with the required geometric accuracy and bonding quality for subsequent interface curing.

[0042] Please continue reading. Figure 3 The initial solidified composite is subjected to delayed lock-up cooling under controlled pressure to obtain an interface-cured composite. In one embodiment of the present invention, the step of subjecting the initially solidified composite to delayed lock-up cooling under controlled pressure to obtain an interface-cured composite includes: A constant circumferential compressive stress is applied to the initial solidified composite and the temperature is maintained in a constant temperature range of 5K to 15K above the upper limit of the polymer glass transition temperature, so that the first shielding material undergoes viscoelastic creep migration and forms a stress-homogenized composite. According to the stress-homogenized composite, low-frequency radial pulsating compressive stress is synchronously applied along the conveying direction. The pulsation amplitude is 1.2 to 1.8 times that of the constant circumferential compressive stress. This is used to drive the polymer to flow through the interfacial micropores and complete the interfacial sealing, thereby obtaining a pulse-compacted composite. A moving isobaric freezing belt is set in the forward direction of the pulse compaction composite. The temperature of the freezing belt is 10K to 20K lower than the glass transition temperature of the polymer. The freezing belt moves synchronously with the speed of the production line, which sequentially transforms the polymer in the interface into the glassy state and locks the compaction morphology to obtain an isobaric frozen composite. Before the isobaric frozen composite enters the room temperature range, a constant axial micro-tension opposite to the traction direction is applied to the isobaric frozen composite. The amplitude of the micro-tension is 20% to 40% lower than the constant tension in the tension homogenization treatment. This is used to redistribute the axial shrinkage strain and reduce the residual stress gradient of the cross section to obtain an interface-cured composite.

[0043] The following is a detailed description of the steps involved in the above embodiments: The initial-solidification composite is subjected to constant radial pressure through a circumferential compressive stress application device. This device employs a pneumatic compression ring structure with multiple compressed air bladders evenly distributed along the circumference of the composite. The compressed air bladders are filled with compressed air at a constant pressure, applying radial-inward compressive stress to the initial-solidification composite, with the stress value controlled within the range of 0.5-1.0 MPa. Simultaneously, a temperature control system maintains the ambient temperature around the composite within a constant temperature range of 5K to 15K above the upper limit of the polymer's glass transition temperature. The polymer glass transition temperature refers to the characteristic temperature at which a polymer transitions from a glassy state to a rubbery state; above this temperature, the polymer molecular chains possess strong mobility. For example, for polyethylene materials with a glass transition temperature of 85℃, the constant temperature range is set to 90-100℃. Under the combined action of this temperature and pressure, the polymer molecular chains in the first shielding material begin to undergo slow rearrangement, a process known as viscoelastic creep migration. Creep migration refers to the process by which polymer molecular chains gradually overcome intermolecular forces and rearrange themselves under constant stress, gradually homogenizing the initially uneven internal stress distribution. After a creep migration process of 15-30 minutes, the stress concentration points inside the composite are eliminated, forming a stress-homogenized composite, that is, a composite with a relatively uniform internal stress distribution. This stress homogenization treatment eliminates local stress peaks that may occur during the initial solidification process, prevents the initiation of microcracks caused by stress concentration at the interface, and ensures the uniformity and effectiveness of subsequent pulsation treatment.

[0044] As the stress-homogenized composite continues to move along the conveying direction, it receives periodic pressure through a radial pulsating compressive stress device. This device employs a servo-controlled array of hydraulic cylinders uniformly arranged along the composite's conveying path, with each cylinder generating controllable radial pulsating pressure. The frequency of the pulsating compressive stress is set to 2-5 Hz, falling into the low-frequency range. This frequency range matches the relaxation time of the polymer molecular chains, allowing the chains to move in response to pressure changes. The pulsation amplitude is set to 1.2 to 1.8 times the constant circumferential compressive stress; for example, when the constant compressive stress is 0.8 MPa, the pulsation amplitude is controlled within the range of 0.96-1.44 MPa. This amplitude selection ensures that the pulsating pressure is sufficient to drive polymer flow without damaging the composite structure. Under the action of pulsating compressive stress, the polymer material in the stress-homogenized composite undergoes periodic compression and rebound movements. This movement drives the polymer to flow along the path of least resistance, i.e., seeping through the tiny pores at the interface between the flat ground wire and the first shielding material. Interfacial micropores refer to micron-sized voids formed during interfacial bonding due to material shrinkage, gas entrainment, or surface roughness. Polymers filled these micropores under pulsating pressure, completing the interfacial sealing process and eliminating bonding defects at the interface. Composites treated with pulsation are called pulse-compacted composites, which exhibit significantly improved interfacial bonding density and continuity, with interfacial strength increased by 30-50% compared to untreated composites.

[0045] As the pulse-compacted composite continues its journey along the production line, it enters a moving isobaric freezing belt for rapid curing. This belt is a cooling device that moves synchronously with the production line, using a liquid nitrogen or refrigerant circulation system to provide a cryogenic environment. The freezing belt's movement speed is precisely matched to the production line speed, ensuring that the composite does not experience relative movement during cooling and thus avoids surface damage. The internal temperature of the freezing belt is controlled within 10K to 20K below the polymer's glass transition temperature; for example, for a material with a glass transition temperature of 85℃, the freezing belt temperature is set at 65-75℃. In this cryogenic environment, the mobility of the polymer molecular chains within the interface decreases dramatically, rapidly transitioning from a rubbery state to a glassy state. The glassy state refers to the state in which the polymer molecular chains are frozen in a fixed position, losing their long-range mobility; in this state, the interfacial bonding structure is permanently locked. The freezing process employs isobaric methods, maintaining a constant circumferential compressive stress throughout the cooling process to prevent interfacial separation caused by thermal contraction during temperature decrease. The rapid freezing process is completed within 2-5 seconds, resulting in an isobaric frozen composite characterized by strong interfacial bonding and uniform internal stress distribution. This rapid freezing avoids polymer recrystallization and stress redistribution that may occur during slow cooling, and maintains the ideal interface structure established during the pulsating compaction stage.

[0046] Before the isobaric frozen composite is introduced to room temperature, a constant axial micro-tension is applied in the opposite direction to the traction direction using an axial tension adjustment device. This device employs a reverse traction roller assembly, applying a controllable reverse tension through a precise tension control system. The amplitude of the axial micro-tension is precisely controlled within 20% to 40% of the constant tension during tension homogenization; for example, when the constant tension during tension homogenization is 100N, the axial micro-tension is set to 20-40N. This relatively small reverse tension does not damage the composite structure but is sufficient to regulate the strain distribution within the material. The purpose of applying reverse tension is to redistribute the axial shrinkage strain generated during the cooling process. When the material cools from a high temperature to room temperature, thermal shrinkage generates axial shrinkage strain. If this strain distribution is uneven, a residual stress gradient will form on the cross-section. By applying appropriate reverse tension, the shrinkage strain can be redistributed on the cross-section, eliminating the bending tendency and localized stress concentration caused by the stress gradient. The residual stress gradient on the cross-section refers to the stress distribution gradient formed by different residual stress values ​​at different locations on the cross-section of the composite. This gradient can lead to deformation or cracking of the composite during subsequent use. The composite material, after undergoing axial micro-tension treatment, ultimately forms an interface-cured composite material. This composite material possesses excellent characteristics such as complete interface bonding, balanced internal stress, and stable geometry, meeting the stringent requirements of high-speed transmission cables for interface quality and mechanical stability.

[0047] In one embodiment of the present invention, the low-frequency radial pulsating compressive stress is synchronously applied along the conveying direction according to the stress-homogenized composite, with the pulsation amplitude being 1.2 to 1.8 times the constant circumferential compressive stress, to drive the polymer to permeate along the interfacial micropores and complete the interfacial sealing, thereby obtaining a pulse-compacted composite, comprising: The frequency window for low-frequency pulsating compressive stress is calculated based on the viscoelastic parameters of the first shielding material in the stress-homogenized composite. The pulsation frequency is set within the reciprocal range of the polymer relaxation time so that the pulsation period matches the polymer molecular chain rearrangement time. A phase distribution of pulsating compressive stress is established along the conveying direction, so that there is a quarter-cycle phase difference between the pulsating compressive stress at adjacent positions, forming a traveling pressure wave in the axial direction, which drives the polymer to generate directional flow. The spatial distribution of the pulsation amplitude is adjusted according to the micropore distribution characteristics of the interface between the flat ground wire and the first shielding material. A larger pulsation amplitude is applied in the region with higher micropore density, and a smaller pulsation amplitude is applied in the dense region to achieve differentiated seepage drive. During the application of pulsating compressive stress, the position of the polymer seepage front is monitored, and the pulsation frequency and amplitude are adjusted according to the seepage rate. When the seepage front completely covers the interfacial micropores, the pulsation is stopped and constant pressure is maintained to obtain the pulsed compacted composite.

[0048] The following is a detailed description of the steps involved in the above embodiments: Based on the viscoelastic parameters of the first shielding material in the stress-homogenized composite, key parameters such as storage modulus, loss modulus, and relaxation time are determined using a dynamic mechanical analyzer. The dynamic mechanical analyzer applies sinusoidal stress at different frequencies and measures the material's strain response to obtain viscoelastic parameter data. The polymer relaxation time refers to the characteristic time required for the polymer molecular chain to recover from a stressed state to an equilibrium state, reflecting the speed of molecular chain motion. For example, for polyethylene, the relaxation time at 85°C is 0.5 seconds. The data processing unit calculates the reciprocal of the measured relaxation time to obtain the frequency window range. The reciprocal of the relaxation time represents the applied perturbation frequency that matches the molecular chain motion frequency. When the pulsation frequency is set within this range, the polymer molecular chain can effectively respond to changes in external pressure. In specific calculations, if the relaxation time is 0.5 seconds, the frequency window is set to approximately 2Hz. After receiving the frequency window data, the pulsation frequency control system precisely adjusts the frequency of the low-frequency pulsating compressive stress to this range, matching the pulsation period with the polymer molecular chain rearrangement time. This matching ensures that the polymer molecular chains have sufficient time to complete a full rearrangement motion within each pulsation cycle, thereby achieving optimal flow performance. Frequency matching avoids the problems of excessively high frequencies causing the molecular chains to lag behind the pulsation changes, and excessively low frequencies causing low energy transfer efficiency, thus achieving a highly efficient conversion of pulsating energy into polymer flow.

[0049] The phase distribution of pulsating compressive stress along the conveying direction is achieved through a segmented pressure control system. This system comprises multiple hydraulic drive units equidistantly arranged along the composite conveying path. Each drive unit independently controls the pulsating compressive stress in a spatial segment, and the distance between adjacent drive units is calculated based on the production line speed and pulsation frequency. The phase controller, according to a preset program, creates a quarter-cycle time delay (i.e., a 90-degree phase difference) in the pulsating compressive stress at adjacent positions. For example, when the pulsating compressive stress at the first position reaches its peak, the pulsating compressive stress at the second position is at the midpoint of its rising phase, the third position is at zero, and the fourth position is at the midpoint of its falling phase. This phase distribution forms a traveling pressure wave along the composite's axial direction, i.e., a undulating phenomenon where the pressure peak is sequentially transmitted along the conveying direction. The propagation speed of the traveling pressure wave is consistent with the conveying speed of the composite, ensuring that the pressure wave moves synchronously with the composite. Under the action of the traveling pressure wave, the polymer within the composite is driven by the axially propagating pressure gradient, generating a directional flow effect. Directional flow refers to the preferential flow of polymers along the direction of pressure wave propagation. This flow mode is beneficial for transferring polymers from stress concentration areas to areas of lower stress, thereby achieving further stress homogenization. The choice of phase difference is based on the wave propagation theory in fluid mechanics. A quarter-cycle phase difference can generate the most stable traveling wave, avoiding waveform distortion and energy loss caused by excessively large or small phase differences.

[0050] Based on the micropore distribution characteristics at the interface between the flat ground wire and the first shielding material, the microstructure at the interface is detected using a high-resolution ultrasonic scanning device. The ultrasonic scanning device emits high-frequency sound waves and receives reflected signals; the location, size, and density distribution of micropores are identified by analyzing the intensity and phase changes of the signals. The detection data shows that the micropore distribution at the interface is uneven, with some areas having higher micropore density and others relatively denser. Micropore density refers to the number of micropores per unit area; areas with higher density require more polymer filling and therefore require a greater driving force. The pulsation amplitude adjustment system generates a spatially distributed pulsation amplitude control scheme based on the micropore distribution data, applying a larger pulsation amplitude to areas with higher micropore density and a smaller pulsation amplitude to denser areas. For example, in an area with a micropore density of 50 micropores per square millimeter, the pulsation amplitude is set to 1.5 MPa; in a denser area with a micropore density of 10 micropores per square millimeter, the pulsation amplitude is set to 0.8 MPa. This differentiated flow drive ensures that polymers in different regions receive appropriate driving force, avoiding over-extrusion or under-driving problems that may occur with uniform amplitude. Differential drive enables simultaneous filling of interfacial micropores, improving the uniformity and integrity of interfacial bonding.

[0051] During the application of pulsating compressive stress, the position of the polymer seepage front is monitored jointly by a distributed pressure sensor array and an optical detection system. The pressure sensor array is arranged circumferentially along the interface to detect changes in pressure distribution at the interface. When the polymer seeps to a certain location, a characteristic pressure change occurs at that location. The optical detection system uses a laser confocal microscope to observe the polymer flow state at the interface in real time through a transparent viewing window, identifying the specific location of the seepage front. The seepage front refers to the boundary line between the filled and unfilled areas during polymer seepage. The data processing system calculates the seepage rate, i.e., the speed at which the seepage front moves, based on the sensor signals. When the seepage rate is below a preset threshold, the control system automatically increases the pulsation frequency or amplitude to accelerate the seepage process; when the seepage rate is too fast, the system reduces the pulsation parameters to avoid excessive compression. For example, when the detected seepage rate is 0.1 mm / s while the target rate is 0.2 mm / s, the system increases the pulsation frequency from 2 Hz to 2.5 Hz. When the monitoring system confirms that the seepage front completely covers the interfacial micropores, meaning all micropores are filled with polymer, the pulse control system immediately stops the pulsed compressive stress and transitions to a constant pressure holding state. During the constant pressure holding phase, static pressure is maintained to prevent the backflow of the filled polymer and ensure the stability of the seepage effect. After the complete pulsed seepage treatment, a pulsed compacted composite is obtained. This composite achieves its theoretical maximum interfacial bonding density, with a micropore filling rate exceeding 95%, providing a perfect interfacial structural foundation for subsequent curing treatment.

[0052] Please continue reading. Figure 3 An internal tension pulse is applied to the interface-cured composite and vibration response data is collected. Based on the vibration response data, real-time compaction is performed to obtain a self-tested compacted composite. In one embodiment of the present invention, the step of applying an intrinsic tension pulse to the interface-cured composite and collecting vibration response data, and performing real-time compaction based on the vibration response data to obtain a self-testing compacted composite includes: A first set of broadband tension pulses was applied to the interface-cured composite and vibration response data was collected to obtain modal baseline parameters. Based on the modal baseline parameters, the target resonance frequency is selected, a second set of fixed-frequency tension pulses is applied to the interface-cured composite, and vibration response data is collected to obtain the phase delay peak parameter. Phase reversal tension envelope data is generated based on the aforementioned phase delay peak parameter; A compression pulse is applied to the interface-cured composite according to the phase-reversal tension envelope data to obtain an instantaneously closed composite. A constant compressive tension is applied to the instantaneously closed composite and the attenuation data is collected. The compaction effect is determined based on the attenuation data, and a self-tested compacted composite is obtained.

[0053] The following is a detailed description of the steps involved in the above embodiments: The interface-cured composite receives the first set of tension pulse excitations via a broadband tension pulse generator. This generator employs an electromagnetic drive mechanism to produce a composite pulse signal covering multiple frequency components. A broadband tension pulse refers to a tension excitation signal containing multiple frequency components from low to high frequencies, covering a frequency range of 10Hz to 1000Hz, with a pulse duration of 100 milliseconds. The pulses are applied to the interface-cured composite via a tension loading device, causing the composite to produce a multimodal vibration response. A vibration sensor array is arranged at equal intervals along the composite's axial direction, using a combination of accelerometers and strain gauges to detect the composite's vibration signals. The data acquisition system records vibration response data, including amplitude, frequency, and phase information, at a sampling frequency of 10,000 times per second. The signal processing unit performs a Fast Fourier Transform on the acquired vibration response data to extract the amplitude and phase characteristics of each frequency component, identifying the inherent vibration modes of the composite. Modal baseline parameters refer to the characteristic parameters of each vibration mode of the composite under intact interface conditions, including resonant frequency, damping ratio, and mode shape coefficient. For example, the resonant frequency of the first bending mode is 150 Hz, and the damping ratio is 0.02, while the resonant frequency of the second torsional mode is 380 Hz. These parameters constitute the benchmark data for subsequent defect detection, as any interface defect will cause a shift in the modal parameters. Broadband excitation can simultaneously excite multiple vibration modes of the composite, providing comprehensive dynamic characteristic information and a reliable benchmark for accurate defect identification.

[0054] Based on modal baseline parameters, the defect identification algorithm selects the target resonant frequency most sensitive to interface defects from multiple resonant frequencies. The selection criterion is based on modal sensitivity analysis, i.e., an assessment of the impact of interface state changes on different modal parameters. Typically, the first bending mode or the second torsional mode is chosen as the target mode because the deformation of these modes is mainly concentrated in the interface region, exhibiting the highest sensitivity to interface defects. After determining the target resonant frequency, a fixed-frequency tension pulse generator applies a second set of tension pulses to the interface-cured composite. The frequency of these pulses is precisely set to the target resonant frequency, and the pulse amplitude and duration are optimized to obtain the best signal-to-noise ratio. The vibration response detection system employs lock-in amplification technology to detect the vibration response signal at the target frequency, filtering out interference from other frequency components. The peak phase delay parameter refers to the degree of phase lag of the output vibration signal relative to the input excitation signal when the composite is excited at the target resonant frequency. In an ideal defect-free state, the phase delay has a specific value; when interface defects exist, increased damping or decreased stiffness at the defect location will cause changes in the phase delay. The data processing unit calculates the phase difference between the input and output signals using a phase detection algorithm, identifying the peak position and amplitude of the phase delay. For example, the phase delay in a defect-free region is 45 degrees, while the phase delay increases to 60 degrees in regions with micro-debonding. The fixed-frequency excitation method improves detection accuracy and signal-to-noise ratio, enabling the system to identify minute interface defects with a detection resolution at the micrometer level.

[0055] Based on the peak phase delay parameter, the signal inversion processing unit generates phase-inverted tension envelope data. The phase characteristics of this data are 180 degrees inversely related to the detected phase delay. In the specific processing, the system first analyzes the frequency and time domain characteristics of the peak phase delay parameter, extracting the amplitude envelope and phase distribution of the delayed signal. Then, a phase inversion algorithm is used to flip the delayed signal by 180 degrees while maintaining the shape of the amplitude envelope. The phase-inverted tension envelope data refers to the tension control signal after phase inversion processing. The time-domain waveform of this signal is opposite in phase to the original delayed signal, but the amplitude distribution is the same. For example, if the original delayed signal has a positive peak at a certain moment, the inverted signal will have a negative peak at the same moment. The purpose of the inversion processing is to generate a compensation signal that cancels out the response characteristics of the interface defect, thus counteracting the vibration anomalies caused by the defect by applying this inverse signal. The data conversion unit converts the phase-inverted tension envelope data into control commands that the compression pulse generator can execute, including the pulse timing, amplitude, and application position. The compression pulse generator applies spatially distributed compression pulses to the interface-cured composite according to control commands. The pulse's point of application precisely corresponds to the detected defect location, and the pulse intensity is proportional to the defect severity. This precise reverse compensation enables active repair of interface defects, allowing areas that previously exhibited micro-debonding or stress concentration to be recompacted and closed, forming an instantaneously closed composite.

[0056] After the compression pulse completes, the instantaneously closed composite material receives continuous static compression force through a constant compression tension holding device, which uses a hydraulic or pneumatic system to provide stable compression force. The amplitude of the constant compression tension is set to 60-80% of the peak value of the compression pulse, and the holding time is 10-30 seconds to ensure the stabilization of the closure effect. During the compression holding process, the vibration monitoring system continuously collects the vibration response signal of the composite material and records the decay process of the signal amplitude over time. The decay data refers to the time history data of the vibration signal amplitude gradually decreasing from the initial value to the steady value, which reflects the quality and stability of the interface closure. Ideally, the interface closure should exhibit rapid exponential decay characteristics, with a decay time constant in the range of 2-5 seconds; if the interface closure is incomplete, the decay process will show a plateau or oscillation phenomenon. The decay data analysis algorithm determines the decay time constant and steady-state amplitude by fitting the decay curve and compares them with preset quality standards. When the decay time constant is less than the threshold and the steady-state amplitude is lower than the noise level, the compaction effect is judged to be good; otherwise, it is judged that the compaction process needs to be repeated. For example, when the decay time constant is 3 seconds and the steady-state amplitude is less than 5% of the initial amplitude, the compaction effect is considered acceptable. The output of the quality judgment algorithm is used to control subsequent process parameters. Acceptable composites proceed directly to the next process, while unacceptable composites require re-compaction. The resulting self-inspected compacted composite exhibits excellent characteristics of completely closed interfaces and internal defect repair, with its interface bonding strength and electrical properties meeting design requirements. This self-inspection and self-repair mechanism enables real-time quality control during production, preventing defective products from entering subsequent processes or reaching end users.

[0057] Please continue reading. Figure 3 Based on the vibration response data, time-varying tension compensation is performed on the self-testing compacted composite and feedback curing is completed to obtain a high-speed transmission cable semi-finished product with a dense interface.

[0058] In one embodiment of the present invention, the step of performing time-varying tension compensation on the self-testing compacted composite based on the vibration response data and completing feedback curing to obtain a high-speed transmission cable semi-finished product with a dense interface includes: Based on the vibration response data, the self-testing compacted composite is divided into tension unit regions along its length, and tension segmented matrix data is generated based on phase-amplitude mismatch. Based on the tension segmentation matrix data, reverse gradient tension loading is applied to each tension unit region of the self-testing compaction composite to obtain a tension gradient corrected composite. The tension gradient correction composite is subjected to phase-shifted micro-amplitude torsional vibration tension pulses along the axial direction to release the residual shear strain at the interface and obtain a torsional vibration shaping composite. An exponentially decaying tension matching the viscoelastic relaxation modulus curve of the first shielding material is applied to the torsional vibration shaping composite to retain it, thereby obtaining a creep-locked composite. Before the creep-locked composite is cooled to room temperature, vibration response data is collected again and the modal baseline parameters are updated to output a high-speed transmission cable semi-finished product with a dense interface.

[0059] The following is a detailed description of the steps involved in the above embodiments: Based on vibration response data, the spatial analysis and processing unit divides the self-compacted composite into tension unit zones along its length, based on the spatial distribution characteristics of the vibration response. The data processing system first performs spatial spectrum analysis on the vibration signals collected along the composite's length, identifying locations where significant changes in vibration characteristics occur as boundary points. For example, in a 2-meter-long composite, based on the variation characteristics of vibration amplitude and phase, it is divided into 10 tension unit zones, each 200 millimeters long. Each tension unit zone refers to a continuous segment with similar vibration characteristics and tension states; the tension distribution within a unit zone is relatively uniform, while tension differences exist between different unit zones. The phase-amplitude analysis algorithm statistically analyzes the vibration response data within each tension unit zone, calculating the average phase and average amplitude of the region and comparing them with ideal reference values. Phase-amplitude mismatch refers to the deviation between the actual measured phase and amplitude and the ideal reference values; this deviation reflects the degree of tension anomaly in the region. The data processing unit arranges the mismatch data of each tension unit zone in spatial order, forming a tension segmented matrix data. This matrix contains information such as the position coordinates, phase deviation, amplitude deviation, and correction amount for each unit area. For example, the phase deviation of the third unit area is +15 degrees, the amplitude deviation is -20%, and the corresponding tension correction amount is +0.3 MPa. The matrix data provides spatially distributed control commands for subsequent precise tension compensation, realizing a refined control transition from overall detection to local correction.

[0060] Based on the tension segmentation matrix data, the reverse gradient tension loading system implements differentiated tension compensation for each tension unit zone of the self-compacted composite. This system comprises multiple independent tension adjustment devices distributed along the length of the composite, each responsible for controlling the tension state of a tension unit zone. Reverse gradient tension loading refers to a tension adjustment method where the applied tension gradient direction is opposite to the detected tension deviation gradient direction. In practice, the control system calculates the target tension value for each unit zone based on the tension segmentation matrix data; this value equals the reference tension value minus the detected tension deviation value. For example, if the detected tension deviation for a unit zone is +0.2 MPa (i.e., the tension is too high), a tension adjustment of -0.2 MPa is applied to that area to bring it back to the reference value. The tension adjustment device employs a precise hydraulic drive mechanism, capable of independently controlling the tension of each unit zone with an adjustment accuracy of ±0.01 MPa. The loading process proceeds sequentially from high-deviation unit zones to low-deviation unit zones, ensuring the gradual and stable nature of the tension correction. A transition adjustment zone is set between adjacent unit zones, eliminating abrupt tension changes at unit zone boundaries through a smooth tension transition curve. The entire loading process is completed within 30-60 seconds, resulting in a tension gradient-corrected composite material characterized by uniform tension distribution along its length and no localized stress concentration. This spatially segmented, precise tension control enables fine-tuning of the stress state within the composite material, eliminating the localized tension anomaly problem that traditional integral loading methods cannot solve.

[0061] The tension gradient correction composite receives axially distributed micro-amplitude torsional vibrations via a torsional vibration tension pulse device. This device employs a multi-point torque application mechanism to generate spatially distributed torsional vibration signals. Multiple torque excitation points are arranged at fixed intervals along the composite's axial direction, each capable of independently applying a torsional pulse. The phase-staggered micro-amplitude torsional vibration tension pulses refer to a sequence of torsional pulses with a fixed phase difference between adjacent excitation points, set at 60-90 degrees, forming torsional ripples propagating axially. The pulse amplitude is controlled within a small torsional angle range of ±5 degrees to avoid damage to the composite structure. The torsional vibration frequency is set at 20-50Hz, a range that effectively excites interfacial shear deformation without causing overall structural resonance. Under torsional vibration, periodic relative sliding motion occurs at the interface between the flat ground wire and the first shielding material, releasing the shear strain accumulated at the interface. Residual interfacial shear strain refers to the shear deformation remaining at the interface due to material deformation inconsistencies during initial processing; this strain affects the interfacial bonding strength and electrical contact performance. Torsional vibration, by altering the strain state of the interface, releases and redistributes the previously locked shear strain, resulting in a more uniform and stable interfacial bond. The torsional vibration treatment process lasts 2-5 minutes, producing a torsional-shaped composite structure characterized by complete release of interfacial shear strain and optimized interfacial bonding. This micro-amplitude torsional vibration treatment avoids structural damage that can be caused by large-amplitude mechanical vibration, while simultaneously achieving precise adjustment of the interfacial strain state.

[0062] The torsional vibration-shaping composite receives tension control matched to the viscoelastic properties of the first shielding material through an exponentially decaying tension holding device. This device designs a tension decay program based on the material's viscoelastic relaxation modulus curve, which, determined through dynamic mechanical analysis, reflects the stress decay over time under constant strain. The viscoelastic relaxation modulus curve is a characteristic curve of a polymer material under fixed deformation, where internal stress decays exponentially over time; its shape is determined by the material's molecular structure and temperature conditions. The tension holding device calculates the time constant and decay amplitude of the tension decay based on the relaxation modulus curve parameters and adjusts the applied tension according to an exponential function. For example, with an initial tension set at 1.0 MPa and a time constant of 300 seconds, the tension gradually decreases to 0.3 MPa according to the exponential decay law. This tension control, matched to the material's intrinsic properties, synchronizes the stress release process within the composite with the material's natural relaxation process, avoiding internal damage that might be caused by forced stress release. Under exponentially decaying tension, the long-range stress within the composite gradually dissipates, and the molecular chains rearrange to their most stable configuration, forming a creep-locked composite. This composite exhibits excellent properties such as complete release of internal stress, stable molecular structure, and reliable interfacial bonding. The creep-locking process achieves a smooth transition from dynamic adjustment to static stability, ensuring the long-term stability of the composite in subsequent use.

[0063] Before the creep-locked composite is cooled to room temperature, vibration response data is collected again using a vibration detection system to verify the effectiveness of the initial treatment and update quality control parameters. The detection system uses the same excitation method and sensor configuration as the initial test to ensure data comparability and consistency. The newly collected vibration response data is compared and analyzed with the initial modal baseline parameters to assess changes in the composite's dynamic characteristics. The data update algorithm incorporates the new test results into the modal baseline parameter database, forming a complete data record containing information comparing the before and after processing. Modal baseline parameter updating refers to revising quality judgment criteria and control parameters based on the latest test results, enabling the control system to adapt to changes in production conditions and process improvements. The updated parameters provide a more accurate benchmark for the quality control of subsequent products. After a complete processing and verification process, the final output high-speed transmission cable semi-finished product with a dense interface exhibits excellent characteristics such as complete interface bonding, internal defect repair, uniform stress distribution, and stable electrical performance. The interface density of this semi-finished product is close to the theoretical maximum value, and the signal transmission loss and crosstalk indicators meet the stringent requirements for high-speed transmission. The entire process achieves closed-loop control from defect detection and precise repair to quality verification, ensuring the consistency and reliability of product quality.

[0064] In one embodiment of the present invention, the step of applying reverse gradient tension loading to each tension unit region of the self-tested compaction composite based on the tension segmentation matrix data to obtain a tension gradient corrected composite includes: Based on the tension segmented matrix data, identify the tension deviation distribution characteristics in each tension unit area, calculate the tension correction amount and correction direction for each tension unit area, and generate tension correction parameters for the unit area. A reverse gradient tension loading sequence is designed based on the tension correction parameters of the unit region. The gradient direction of the reverse gradient tension loading sequence is opposite to the original tension deviation gradient direction, and the gradient magnitude is proportional to the tension deviation magnitude. The reverse gradient tension loading sequence is applied sequentially to each tension unit region along the axial direction of the self-testing compacted composite. The loading sequence is carried out from the high deviation unit region to the low deviation unit region to ensure the gradualness and continuity of tension correction. During the reverse gradient tension loading process, the tension transfer effect between adjacent tension unit regions is monitored. Based on the tension transfer effect, the tension transition curve of the unit region boundary is adjusted to eliminate tension abrupt changes between unit regions and obtain a tension gradient correction complex.

[0065] The following is a detailed description of the steps involved in the above embodiments: Based on the segmented tension matrix data, the tension deviation identification algorithm performs a detailed analysis of the tension distribution within each tension unit region. The algorithm first extracts the tension measurement value sequence within each tension unit region and calculates the mean, standard deviation, and gradient distribution of the tension within the region through statistical analysis. Tension deviation distribution characteristics refer to the deviation pattern of the tension value within a tension unit region relative to the target reference value, including the magnitude of the deviation, the spatial distribution of the deviation, and the directionality of the deviation. For example, if the average tension in the 5th tension unit region is 0.85 MPa while the target reference value is 0.80 MPa, the deviation magnitude is +0.05 MPa, indicating that the tension in this region is too high. The algorithm further analyzes the spatial distribution characteristics of the deviation to identify whether the tension within the region is uniformly high, excessively high at the edges, or excessively high at the center. Based on the deviation distribution characteristics, the calculation unit determines the tension correction amount and correction direction for each tension unit region. The correction amount is equal to the absolute value of the detected deviation, and the correction direction is opposite to the deviation direction. For example, for a unit region with a tension deviation of 0.05 MPa, the tension correction amount is set to 0.05 MPa, and the correction direction is to decrease the tension. For a unit region with a tension deviation of 0.05 MPa, the correction direction is to increase the tension. The data processing unit integrates the correction amount and correction direction information of all tension unit areas to form unit area tension correction parameters. These parameters include information such as the location number of each unit area, the current tension value, the target tension value, the correction amount, and the correction direction. This refined deviation identification and correction parameter generation enables accurate diagnosis of the tension state inside the composite, providing a reliable data foundation for subsequent precise tension compensation.

[0066] Based on the tension correction parameters of the unit region, the inverse gradient design algorithm constructs a tension loading scheme with characteristics opposite to the original tension deviation. The design process first analyzes the spatial gradient distribution of the original tension deviation, i.e., the rate of change of tension deviation between adjacent tension unit regions. For example, from the 1st to the 10th unit region, the tension deviations are +0.02MPa, +0.04MPa, +0.06MPa, +0.05MPa, +0.03MPa, 0MPa, -0.02MPa, -0.04MPa, -0.03MPa, and -0.01MPa, forming a gradient distribution that first increases and then decreases. The inverse gradient tension loading sequence refers to a tension adjustment sequence with a gradient direction opposite to the original deviation gradient; its gradient direction is completely opposite, and the gradient magnitude is proportional to the deviation magnitude. In specific implementation, the algorithm multiplies the correction amount of each unit region by a proportionality coefficient to obtain the loading amount. The proportionality coefficient is determined based on material properties and a safety factor, with a value ranging from 0.8 to 1.2. For example, for a cell region with a deviation of +0.06 MPa, when the scaling factor is 1.0, the reverse loading amount is -0.06 MPa. The algorithm arranges the reverse loading amounts of all cell regions in spatial order, forming a complete loading sequence. The characteristic of this sequence is that it applies a negative gradient loading to regions where the original tension deviation has a positive gradient, and applies a positive gradient loading to regions where the original deviation has a negative gradient, thus achieving a balance in the overall tension distribution. The reverse gradient design ensures the systematic and coordinated nature of tension correction, avoiding new tension imbalance problems that may be caused by local corrections.

[0067] Along the axial direction of the self-compacting composite, the tension loading execution system applies a reverse gradient tension loading sequence to each tension unit zone according to a preset timing sequence. The execution system employs a distributed hydraulic drive device, with each tension unit zone corresponding to an independent hydraulic cylinder, enabling precise control of tension adjustment in that area. The loading timing controller arranges the loading time from high-deviation unit zones to low-deviation unit zones, ensuring priority processing of areas with larger deviations. For example, unit zones with a deviation of +0.06 MPa receive tension adjustment first, followed by those with a deviation of +0.05 MPa, and finally those with smaller deviations. The loading duration for each unit zone is 10-20 seconds, with a 5-second time interval between adjacent unit zones, and the entire sequential loading process is completed within 2-3 minutes. Graduality means that tension correction is performed sequentially according to the degree of deviation, avoiding potential system shocks caused by simultaneously adjusting all unit zones. Continuity means that the loading times of adjacent unit zones overlap appropriately, ensuring a smooth transition in the tension adjustment process. The hydraulic control system precisely adjusts the thrust of the hydraulic cylinder according to the loading amount of each unit zone, achieving a tension control accuracy of ±0.01 MPa. During the loading process, pressure sensors monitor the tension changes in each unit area in real time to verify the accuracy of the loading effect. This orderly segmented loading method achieves systematic correction of the tension state of the composite, avoiding the inhomogeneity and uncontrollability of traditional whole-body loading methods.

[0068] During the reverse gradient tension loading process, the tension transfer monitoring system uses a high-precision strain sensor array to detect the tension transfer phenomenon between adjacent tension unit regions in real time. The sensor array is positioned at the boundaries of each tension unit region to detect the propagation and distribution changes of tension within the unit region. The tension transfer effect refers to the phenomenon where, when tension adjustment is applied to a tension unit region, the adjustment is transmitted to adjacent unit regions through the elastic deformation of the material, causing tension changes. For example, when a tension adjustment of -0.05 MPa is applied to the 5th unit region, the adjacent 4th and 6th unit regions may experience tension increases of +0.01 MPa and +0.015 MPa, respectively. The data processing unit analyzes the amplitude and range of the transfer effect and calculates the tension gradient at the boundaries of adjacent unit regions. When a sudden tension change is detected at the unit region boundary, the boundary tension adjustment device initiates the tension transition curve adjustment program. This program applies gradual tension adjustment in the boundary region, allowing the tension to transition smoothly within the unit region. The tension transition curve is a spatial distribution curve at the boundaries of adjacent unit regions where the tension value changes according to a smooth function, eliminating step-like tension abrupt changes. The transition curve adjustment range covers a 10-20 mm area on both sides of the boundary, with an adjustment amplitude of 80-120% of the abrupt change. The adjustment time is synchronized with the main loading process. For example, when a tension abrupt change of 0.03 MPa is detected at the boundary, the transition adjustment applies a smooth tension gradient within a 15 mm range on both sides of the boundary, making the tension change exhibit a continuous curve characteristic. After complete reverse gradient loading and boundary transition adjustment, the obtained tension gradient corrected composite exhibits excellent characteristics such as uniform tension distribution along the length direction, no local stress concentration, and smooth transition between element intervals, providing an ideal tension foundation state for subsequent torsional vibration shaping.

[0069] It is easy to understand that the high-speed transmission cable manufacturing process of this invention effectively solves the problem of detecting the concealment of interface defects in multi-layer structures through an internal detection and adaptive repair mechanism. The process begins with tension homogenization of the flat ground wire roll, and through pretreatment steps such as intermittent unwinding, reverse torsion cycling, and micro-extension, eliminates stress unevenness and geometric defects in the raw material, ensuring a uniform interface bonding foundation during subsequent coating. In the dual-dielectric coating stage, the process utilizes differential traction tension to establish a viscosity gradient in the molten shielding material, achieving gapless embedding of the flat ground wire through negative pressure wedges. Simultaneously, surface energy matching forms a continuous wetting interface, reducing the generation of interface defects from the source. The delayed locking cooling process employs a four-stage treatment: isothermal creep, pulsating compaction, isobaric freezing, and axial micro-tension. By controlling the viscoelastic transformation process of the polymer, it drives the polymer to fill the interface micropores and lock in the ideal interface structure, further eliminating any possible residual microscopic defects.

[0070] The core innovation of this process lies in the establishment of an internal detection system based on vibration response, overcoming the technical bottleneck of traditional external detection methods being unable to penetrate multi-layered structures. By applying internal tension pulses to the interface-cured composite, the composite's own vibration modes are excited. Any minute defects at the interface will change the dynamic response characteristics of the material, manifested as shifts in vibration frequency, phase, and damping. By collecting and analyzing this vibration response data, the process can accurately identify the location, type, and extent of interface defects, achieving accurate detection of the internal interface quality that is completely obscured by the outer layer. This process establishes a closed-loop control mechanism from detection to repair. Based on the vibration response data, a phase-reversed tension envelope is generated, and precise compression pulses are applied to the detected defect locations to achieve instantaneous closure and repair of the defects. Finally, through time-varying tension compensation and feedback curing, the composite is spatially discretized for precise tension adjustment, eliminating the risks of stress concentration and interface separation, ensuring a dense and complete interface bond. This integrated quality control system, encompassing prevention, detection, repair, and verification, fundamentally solves the problem of the concealment of interface defects in high-speed transmission cable manufacturing, enabling real-time monitoring and proactive optimization of internal interface quality.

[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 high-speed transmission cable, characterized in that, include: At least two signal core lines (1) are arranged in parallel; A first shielding layer (2) is provided, which covers the at least two signal core wires (1); At least one ground wire (3), the ground wire (3) is flat and is attached to the first shielding layer (2); The second shielding layer (4) covers the ground wire (3) and the first shielding layer (2); An insulating layer (5) is provided, which covers the second shielding layer (4).

2. A manufacturing process for a high-speed transmission cable, characterized in that, The manufacturing process for the high-speed transmission cable is used to produce the high-speed transmission cable as described in claim 1, and the manufacturing process for the high-speed transmission cable includes: The flat ground wire roll is subjected to tension equalization treatment to form a flat ground wire with uniform tension; Differential core wires are transported in a synchronous traction manner, and molten first shielding material is wrapped around the outer periphery of the differential core wires. During the wrapping process, the flat ground wire with uniform tension is attached to the first shielding material to obtain a pre-solid composite. The initial solidified composite is subjected to delayed lock-up cooling under controlled pressure to obtain an interface-cured composite. An internal tension pulse is applied to the interface-cured composite and vibration response data is collected. Based on the vibration response data, real-time compaction is performed to obtain a self-tested compacted composite. Based on the vibration response data, time-varying tension compensation is performed on the self-testing compacted composite and feedback curing is completed to obtain a high-speed transmission cable semi-finished product with a dense interface.

3. The manufacturing process of the high-speed transmission cable according to claim 2, characterized in that, The process of performing tension equalization treatment on the flat ground wire roll to form a flat ground wire with uniform tension includes: The coil is intermittently unwound from the outside to the inside along the flat ground line. Within each radial segment, the winding is briefly paused and the axial displacement is released to establish a base tension range in which the tension of each layer of the coil is within the same tension range. Under the aforementioned base tension range, the unfolded flat ground wire is subjected to equal-amplitude reverse torsion cycle along the longitudinal direction, so that the left and right edges and the center line of the flat ground wire alternately experience stretching and compression, so as to average the residual camber potential energy and reshape the lateral tension balance. During the continuous conveying of the flat ground wire, it is extended at equal intervals according to the periodic window synchronized with the production line speed. The extension amplitude is limited to within two orders of magnitude below the yield strain of the flat ground wire, which is used to uniformly distribute plastic strain along the length direction and suppress tension peaks. After the micro-extension is completed, the flat ground wire is brought into the constant tension stabilization zone until the tension fluctuation is maintained within a preset threshold before the wrapping station, thereby obtaining a flat ground wire with uniform tension.

4. The manufacturing process of the high-speed transmission cable according to claim 2, characterized in that, The differential core wire is conveyed by synchronous traction, and a first shielding material in a molten state is wrapped around the outer periphery of the differential core wire. During the wrapping process, the flat ground wire with uniform tension is adhered to the first shielding material to obtain a preliminary solidification composite, comprising: During the process of forming an annular flow film from the first shielding material in the molten state, differential traction tension is used to establish two-stage shear rate zones in the flow film thickness direction to obtain flow film layering data between the outer high-viscosity region and the inner low-viscosity region. The flow rate of the outer high-viscosity region is adjusted according to the film layering data to generate a continuous negative pressure wedge extending along the outer surface of the melt film. The uniformly tensioned flat ground wire is introduced tangentially along the continuous negative pressure wedge, so that the uniformly tensioned flat ground wire slides into the inner low-viscosity region in a gapless state and is synchronously embedded in the outer high-viscosity region. While the uniformly tensioned flat ground wire slides into the inner low-viscosity region, instantaneous temperature data of the interface between the molten film and the flat ground wire is acquired, and the surface energy of the molten film is adjusted to a wetting threshold that matches the surface energy of the uniformly tensioned flat ground wire based on the instantaneous temperature data, thereby forming a continuous wetting interface. A cross-sectionally tapering solidification zone is set along the process advancement direction. The inner low-viscosity region is rapidly solidified into a solid-elastic phase through the viscoelastic transformation path of the continuous wetting interface, and the continuous wetting interface is locked in real time to form a primary solid composite.

5. The manufacturing process of the high-speed transmission cable according to claim 4, characterized in that, The step of regulating the flow rate of the outer high-viscosity region based on the film layering data to generate a continuous negative pressure wedge extending along the outer surface of the melt film, and tangentially introducing the uniformly tensioned flat ground wire along the continuous negative pressure wedge, includes: Based on the viscosity ratio between the outer high-viscosity region and the inner low-viscosity region in the film layering data, a critical flow velocity difference threshold is calculated, and the flow velocity of the outer high-viscosity region is adjusted to be lower than the critical flow velocity difference threshold, thereby forming a local negative pressure region induced by the flow velocity gradient on the outer surface of the melt film. The outer layer flow velocity distribution is continuously adjusted along the pressure gradient direction of the local negative pressure region, so that the local negative pressure region expands circumferentially along the outer surface of the melt film and forms a continuous negative pressure wedge. The pressure distribution of the continuous negative pressure wedge exhibits a wedge-shaped decreasing characteristic. A flat ground wire introduction point is set at the wedge tip position in the direction of pressure reduction of the continuous negative pressure wedge, so that the flat ground wire with uniform tension enters the continuous negative pressure wedge along a trajectory tangent to the wedge pressure gradient, achieving resistanceless sliding in; During the sliding process of the uniformly tensioned flat ground wire, the pressure change inside the wedge is monitored simultaneously, and the outer layer flow rate is adjusted according to the pressure fluctuation to maintain the stability of the wedge pressure distribution and ensure that the flat ground wire is completely embedded in the inner low viscosity region.

6. The manufacturing process of the high-speed transmission cable according to claim 2, characterized in that, The step of subjecting the initially solidified composite to delayed lock-up cooling under controlled pressure to obtain an interface-cured composite includes: A constant circumferential compressive stress is applied to the initial solidified composite and the temperature is maintained in a constant temperature range of 5K to 15K above the upper limit of the polymer glass transition temperature, so that the first shielding material undergoes viscoelastic creep migration and forms a stress-homogenized composite. According to the stress-homogenized composite, low-frequency radial pulsating compressive stress is synchronously applied along the conveying direction. The pulsation amplitude is 1.2 to 1.8 times that of the constant circumferential compressive stress. This is used to drive the polymer to flow through the interfacial micropores and complete the interfacial sealing, thereby obtaining a pulse-compacted composite. A moving isobaric freezing belt is set in the forward direction of the pulse compaction composite. The temperature of the freezing belt is 10K to 20K lower than the glass transition temperature of the polymer. The freezing belt moves synchronously with the speed of the production line, which sequentially transforms the polymer in the interface into the glassy state and locks the compaction morphology to obtain an isobaric frozen composite. Before the isobaric frozen composite enters the room temperature range, a constant axial micro-tension opposite to the traction direction is applied to the isobaric frozen composite. The amplitude of the micro-tension is 20% to 40% lower than the constant tension in the tension homogenization treatment. This is used to redistribute the axial shrinkage strain and reduce the residual stress gradient of the cross section to obtain an interface-cured composite.

7. The manufacturing process of the high-speed transmission cable according to claim 6, characterized in that, The process involves synchronously applying low-frequency radial pulsating compressive stress along the conveying direction to the stress-homogenized composite. The pulsation amplitude is 1.2 to 1.8 times that of the constant circumferential compressive stress. This is used to drive the polymer to permeate along the interfacial micropores and complete interfacial sealing, thereby obtaining a pulse-compacted composite. The process includes: The frequency window for low-frequency pulsating compressive stress is calculated based on the viscoelastic parameters of the first shielding material in the stress-homogenized composite. The pulsation frequency is set within the reciprocal range of the polymer relaxation time so that the pulsation period matches the polymer molecular chain rearrangement time. A phase distribution of pulsating compressive stress is established along the conveying direction, so that there is a quarter-cycle phase difference between the pulsating compressive stress at adjacent positions, forming a traveling pressure wave in the axial direction, which drives the polymer to generate directional flow. The spatial distribution of the pulsation amplitude is adjusted according to the micropore distribution characteristics of the interface between the flat ground wire and the first shielding material. A larger pulsation amplitude is applied in the region with higher micropore density, and a smaller pulsation amplitude is applied in the dense region to achieve differentiated seepage drive. During the application of pulsating compressive stress, the position of the polymer seepage front is monitored, and the pulsation frequency and amplitude are adjusted according to the seepage rate. When the seepage front completely covers the interfacial micropores, the pulsation is stopped and constant pressure is maintained to obtain the pulsed compacted composite.

8. The manufacturing process of the high-speed transmission cable according to claim 2, characterized in that, The process of applying an intrinsic tension pulse to the interface-cured composite and collecting vibration response data, followed by real-time compaction based on the vibration response data to obtain a self-compacted composite, includes: A first set of broadband tension pulses was applied to the interface-cured composite and vibration response data was collected to obtain modal baseline parameters. Based on the modal baseline parameters, the target resonance frequency is selected, a second set of fixed-frequency tension pulses is applied to the interface-cured composite, and vibration response data is collected to obtain the phase delay peak parameter. Phase reversal tension envelope data is generated based on the aforementioned phase delay peak parameter; A compression pulse is applied to the interface-cured composite according to the phase-reversal tension envelope data to obtain an instantaneously closed composite. A constant compressive tension is applied to the instantaneously closed composite and the attenuation data is collected. The compaction effect is determined based on the attenuation data, and a self-tested compacted composite is obtained.

9. The manufacturing process of the high-speed transmission cable according to claim 2, characterized in that, The process of performing time-varying tension compensation on the self-testing compacted composite based on the vibration response data and completing feedback curing to obtain a high-speed transmission cable semi-finished product with a dense interface includes: Based on the vibration response data, the self-testing compacted composite is divided into tension unit regions along its length, and tension segmented matrix data is generated based on phase-amplitude mismatch. Based on the tension segmentation matrix data, reverse gradient tension loading is applied to each tension unit region of the self-testing compaction composite to obtain a tension gradient corrected composite. The tension gradient correction composite is subjected to phase-shifted micro-amplitude torsional vibration tension pulses along the axial direction to release the residual shear strain at the interface and obtain a torsional vibration shaping composite. An exponentially decaying tension matching the viscoelastic relaxation modulus curve of the first shielding material is applied to the torsional vibration shaping composite to retain it, thereby obtaining a creep-locked composite. Before the creep-locked composite is cooled to room temperature, vibration response data is collected again and the modal baseline parameters are updated to output a high-speed transmission cable semi-finished product with a dense interface.

10. The manufacturing process of the high-speed transmission cable according to claim 9, characterized in that, The step of applying reverse gradient tension loading to each tension unit region of the self-tested compaction composite based on the tension segmentation matrix data to obtain a tension gradient corrected composite includes: Based on the tension segmented matrix data, identify the tension deviation distribution characteristics in each tension unit area, calculate the tension correction amount and correction direction for each tension unit area, and generate tension correction parameters for the unit area. A reverse gradient tension loading sequence is designed based on the tension correction parameters of the unit region. The gradient direction of the reverse gradient tension loading sequence is opposite to the original tension deviation gradient direction, and the gradient magnitude is proportional to the tension deviation magnitude. The reverse gradient tension loading sequence is applied sequentially to each tension unit region along the axial direction of the self-testing compacted composite. The loading sequence is carried out from the high deviation unit region to the low deviation unit region to ensure the gradualness and continuity of tension correction. During the reverse gradient tension loading process, the tension transfer effect between adjacent tension unit regions is monitored. Based on the tension transfer effect, the tension transition curve of the unit region boundary is adjusted to eliminate tension abrupt changes between unit regions and obtain a tension gradient correction complex.

Images