High-speed communication cable and preparation method thereof

Abstract

The invention discloses a high-speed communication cable and a preparation method thereof. The cable comprises an inner core conductor, an insulation unit, a shielding layer and an outer protection layer. Each inner core conductor is formed by twisting one or more silver-plated copper alloy wires, the number of the inner core conductors is at least two, and the adjacent inner core conductors are arranged in parallel; each insulation unit comprises an insulation layer wrapping the outer side of each inner core conductor and an inner sheath wrapping the outer side of the insulation layer. The shielding layer wraps the outer side of the inner sheath, and the shielding layer is an aluminum foil mylar layer. And the outer protection layers are wound and coated on the outer side of the shielding layer, and the two outer protection layers are simultaneously wound in opposite directions. On the basis of realizing the small size of the cable, the high-speed transmission performance is ensured, the flexibility is high, and the cable can be conveniently bent and used in narrow spaces such as the interior of an automobile and a cabinet.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cables, in particular to a high-speed communication cable and a preparation method thereof. BACKGROUND

[0002] In the field of new energy vehicles, intelligent equipment and data centers, the data transmission performance of cables is required to be high. In the prior art, in order to ensure that the required high-speed communication between key intelligent systems can be achieved, some core communication lines need to meet specific high-speed communication standards, such as Gen5 standard, which means that the cable needs to have extremely high signal integrity and anti-interference capability to achieve a data transmission rate of 32GT / s.

[0003] In order to meet the technical indicators of Gen5 high-speed communication standards, the cable needs a more complex structure design, which results in the inherent shortcomings of large size and hard overall wire in high-speed communication cables. The poor flexibility and large minimum bending radius of the cable lead to a large space occupied by the cable after bending, which greatly limits the electronic and electrical architecture design and overall space layout in the vehicle. The insulation medium of a small-size cable is thin, which is prone to deformation when the outer protective layer is coated, resulting in a decline in cable performance, which is not conducive to high-speed communication of the cable. SUMMARY

[0004] The purpose of the present application is to provide a high-speed communication cable and a preparation method thereof, which solves the problem that a small-size cable applied in a narrow space is difficult to balance high-speed transmission performance and softness.

[0005] To achieve this purpose, the present application adopts the following technical solutions: A high-speed communication cable, comprising: An inner core conductor composed of one or more silver-plated copper alloy wires, the inner core conductor is provided with at least two, and the adjacent inner core conductors are arranged in parallel; An insulation unit comprising an insulation layer wrapped outside each inner core conductor and an inner sheath wrapped outside the insulation layer; A shielding layer wrapped outside the inner sheath, the shielding layer is an aluminum foil Mylar layer; An outer protective layer wrapped around the outside of the shielding layer, the outer protective layer is provided with two layers, and the two layers of the outer protective layer are simultaneously wound in opposite directions.

[0006] Optionally, the silver-plated copper alloy wire has at least two silver plating layers, and each silver plating layer has a transition layer between them, the transition layer is used to bond the two silver plating layers.

[0007] Optionally, the silver-plated copper alloy wire is replaced by a silver-nickel-plated copper alloy wire.

[0008] Optionally, the insulating layer includes an inner insulating layer and an outer insulating layer, wherein the inner insulating layer is a microporous foamed polymer and the outer insulating layer is an elastic polymer.

[0009] Optionally, a silver-plated woven mesh is provided on the outer side of the aluminum foil Mylar layer, and a buffer layer is provided between the aluminum foil Mylar layer and the silver-plated woven mesh, the buffer layer being made of thermoplastic polyurethane material.

[0010] Optionally, the aluminum foil Mylar layer is wrapped around the outside of the inner sheath (3), and the silver-plated woven mesh is woven at an angle of 45°-60° in a counterclockwise direction.

[0011] Optionally, the outer protective layer is a polyester tape, with the first layer of polyester tape spirally wound in a clockwise direction at an angle of 30°-45°, and the second layer of polyester tape spirally wound in a counterclockwise direction at an angle of 45°-60°.

[0012] Optionally, it also includes a ground wire disposed between the shielding layer and the outer sheath, wherein two ground wires are disposed symmetrically on both sides of the two inner core conductors located at the edge.

[0013] The present invention also provides a method for preparing the high-speed communication cable as described above, characterized by comprising the following steps: S1. High-strength copper wire is selected as the substrate of the inner core conductor. A silver plating layer is electroplated on the surface of the copper wire. A transition layer is formed on the silver plating layer by vacuum evaporation. Then, another silver plating layer is electroplated on the transition layer to obtain the inner core conductor. S2. Extruding microporous foamed polymer material to coat the outside of the conductor to form an inner insulation layer. After it cools and solidifies, extruding elastic polymer material to coat the outside of the inner insulation layer. S3. Place two inner core conductors covered with insulation layers in parallel, and extrude a highly flexible material to cover the outside of the two inner core conductors to form an inner sheath. S4. The aluminum foil Mylar layer is wrapped around the outside of the inner sheath. A buffer layer made of thermoplastic polyurethane material is set on the outside of the aluminum foil Mylar layer. A silver-plated woven mesh formed by high-purity silver wire is wrapped around the outside of the buffer layer. S5. Wrap two layers of polyester tape around the outside of the silver-plated woven mesh simultaneously with a preset tension and in opposite directions to form an outer protective layer.

[0014] Compared with the prior art, the present invention has the following beneficial effects: In a high-speed communication cable of the present invention, the inner core conductor is made of one or more silver-plated copper wires twisted together. The silver-plated copper alloy material has excellent conductivity, which can effectively reduce signal transmission loss and provide a foundation for high-speed transmission. At the same time, the silver-plated copper alloy wire is smaller in size than copper wire. The twisted structure can significantly reduce the rigidity of a single conductor and improve the overall flexibility while ensuring that the conductor cross-sectional area meets the transmission requirements. Furthermore, the layout of at least two inner core conductors arranged in parallel can effectively avoid the increase in size due to structural complexity. The insulation layer covering the outside of each inner core conductor can provide good insulation performance with a relatively thin thickness, which can meet the requirements of high-speed transmission. The cable meets the high-speed transmission requirements for insulation performance without increasing cable size. The inner sheath ensures the overall compactness of the cable structure. The shielding layer uses an aluminum foil Mylar layer. The aluminum foil effectively blocks external electromagnetic interference, ensuring signal integrity during high-speed transmission, while the Mylar layer provides excellent flexibility. This ensures that the shielding layer performs its shielding function without reducing the overall flexibility of the cable, guaranteeing that the shielding performance is not affected when the cable is bent. The outer sheath is set as two layers, wrapped in opposite directions simultaneously. The two outer sheaths effectively balance the internal stress of the cable when covering it, making the cable less prone to structural deformation during bending and ensuring the shielding effect of the shielding layer. This design achieves both high-speed transmission performance and high flexibility while maintaining a small cable size, making it easy to bend and use in confined spaces such as inside cars and in server racks. Attached Figure Description

[0015] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0016] The structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0017] Figure 1 This is a cross-sectional view of the structure of a high-speed communication cable according to the present invention.

[0018] Diagram description: 1. Inner conductor; 2. Insulation layer; 3. Inner sheath; 4. Shielding layer; 5. Outer sheath; 6. Ground wire. Detailed Implementation

[0019] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0020] In the description of this invention, it should be understood that the terms "upper," "lower," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. It should be noted that when a component is considered to be "connected" to another component, it can be directly connected to the other component or there may be a component positioned centrally in the connection.

[0021] This invention provides a high-speed communication cable, comprising an inner conductor, an insulation unit, a shielding layer, and an outer sheath. The inner conductor is formed by stranding one or more silver-plated copper alloy wires, with at least two inner conductors arranged parallel to each other. The insulation unit includes an insulation layer covering the outside of each inner conductor and an inner sheath covering the outside of the insulation layer. The shielding layer covers the outside of the inner sheath and is made of aluminum foil Mylar. The outer sheath is wound around the outside of the shielding layer, and consists of two layers wound simultaneously in opposite directions.

[0022] In a high-speed communication cable of the present invention, the inner core conductor is made of one or more silver-plated copper wires twisted together. The silver-plated copper alloy material has excellent conductivity, which can effectively reduce signal transmission loss and provide a foundation for high-speed transmission. At the same time, the silver-plated copper alloy wire is smaller in size than copper wire. The twisted structure can significantly reduce the rigidity of a single conductor and improve the overall flexibility while ensuring that the conductor cross-sectional area meets the transmission requirements. Furthermore, the layout of at least two inner core conductors arranged in parallel can effectively avoid the increase in size due to structural complexity. The insulation layer covering the outside of each inner core conductor can provide good insulation performance with a relatively thin thickness, which can meet the requirements of high-speed transmission. The cable meets the high-speed transmission requirements for insulation performance without increasing cable size. The inner sheath ensures the overall compactness of the cable structure. The shielding layer uses an aluminum foil Mylar layer. The aluminum foil effectively blocks external electromagnetic interference, ensuring signal integrity during high-speed transmission, while the Mylar layer provides excellent flexibility. This ensures that the shielding layer performs its shielding function without reducing the overall flexibility of the cable, guaranteeing that the shielding performance is not affected when the cable is bent. The outer sheath is set as two layers, wrapped in opposite directions simultaneously. The two outer sheaths effectively balance the internal stress of the cable when covering it, making the cable less prone to structural deformation during bending and ensuring the shielding effect of the shielding layer. This design achieves both high-speed transmission performance and high flexibility while maintaining a small cable size, making it easy to bend and use in confined spaces such as inside cars and in server racks.

[0023] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0024] like Figure 1 As shown, this embodiment of the invention provides a high-speed communication cable for use in scenarios requiring high-speed data transmission, such as new energy vehicles and data centers. In this embodiment, by improving the cable structure, the cable size is effectively reduced and the cable is made highly flexible while ensuring high-performance transmission, making it easy to bend and use in narrow spaces without taking up a large space.

[0025] In this embodiment, the high-speed communication cable includes an inner conductor 1, an insulation unit, a shielding layer 4, and an outer sheath 5. The inner conductor 1 is made of one or more silver-plated copper alloy wires twisted together, and there are at least two inner conductors 1, which are arranged in parallel with each other. The insulation unit includes an insulation layer 2 covering the outside of each inner conductor 1 and an inner sheath 3 covering the outside of the insulation layer 2. The shielding layer 4 covers the outside of the inner sheath 3 and is made of aluminum foil Mylar layer. The outer sheath 5 is wrapped around the outside of the shielding layer 4, and there are two outer sheaths 5, which are wound in opposite directions at the same time.

[0026] Specifically, the inner core conductor 1 is made of silver-plated copper alloy wire stranded together. The base material of each silver-plated copper alloy wire is high-purity oxygen-free copper wire. The surface of the copper wire is formed with a uniform silver plating layer through a combination of chemical plating and electroplating. The thickness of the silver plating layer is controlled within a range that ensures a balance between conductivity and corrosion resistance. For example, there are two inner core conductors 1. Each inner core conductor 1 is made of seven silver-plated copper alloy wires with a diameter of 0.06mm stranded together, with the stranding pitch set to 10-15 times the wire diameter. The inner core conductor 1 is formed by stranding silver-plated copper wire. The silver-plated copper alloy material has excellent conductivity, which can effectively reduce signal transmission loss and provide a foundation for high-speed transmission. At the same time, the silver-plated copper alloy wire is smaller in size than copper wire, which can reduce the overall size of the cable and make it easier for the cable to occupy less space after bending. In addition, the stranded structure can significantly reduce the rigidity of a single conductor while ensuring that the conductor cross-sectional area meets the transmission requirements, thus improving the overall flexibility. Furthermore, the layout of at least two inner core conductors 1 arranged in parallel can effectively avoid the increase in size due to structural complexity.

[0027] The insulation layer 2 can be made of fluoroplastic that is resistant to high and low temperatures and has a low dielectric constant. The insulation layer 2 is uniformly coated on the outside of each inner conductor 1 through an extrusion molding process. The thickness of the insulation layer 2 is 0.05mm-0.1mm, which meets the insulation requirements of high-speed transmission without increasing the radial dimension of the cable.

[0028] The inner sheath 3 can be made of flame-retardant polyurethane material and is applied to the outside of the insulation layer 2 via an extrusion process. During extrusion, two inner conductors 1, each covered with the insulation layer 2, are simultaneously fed into the extrusion die to form an inner sheath 3 structure that completely encloses the two insulation layers 2. The inner sheath 3 has a thickness of 0.05mm-0.1mm, with its inner side tightly fitted to the outer wall of the insulation layer 2, while its outer side remains flat and smooth to facilitate the subsequent application of the shielding layer 4. The insulation layer 2 can provide good insulation performance with a relatively thin thickness, meeting the insulation performance requirements of high-speed transmission without increasing the cable size.

[0029] The shielding layer 4 can be wrapped around the outside of the inner sheath 3. The shielding layer 4 is made of aluminum foil Mylar layer. The overall thickness of the shielding layer 4 is 0.02mm-0.03mm. The aluminum foil is selected as a soft aluminum foil with a thickness of 0.01mm-0.02mm. The Mylar layer is 0.01mm thick and can be made of polyimide film with a thickness of 0.02mm-0.03mm. The aluminum foil and Mylar layer are bonded together by hot melt adhesive. During bonding, the adhesive layer thickness is controlled at 0.005mm-0.01mm. The aluminum foil Mylar layer is wrapped around the outside of the inner sheath 3. During wrapping, the overlap rate can be maintained at 25%-30%. The wrapping tension is kept constant to avoid wrinkles or breakage of the aluminum foil caused by uneven tension. This ensures both the integrity of the shielding effect and the flexibility of the cable. Aluminum foil can effectively block external electromagnetic interference and ensure signal integrity during high-speed transmission. The Mylar layer has good flexibility, so that the shielding layer 4 can play a shielding role without reducing the overall flexibility of the cable, ensuring that the shielding performance of the cable is not affected when it is bent.

[0030] The outer sheath 5 consists of two layers, formed by simultaneously winding the two outer sheaths 5 in opposite directions using a wrapping machine. During wrapping, a dual-station synchronous winding method can be used. The inner outer sheath 5 is wound clockwise with a winding tension of 5-8N and a winding speed of 10-15m / min, with an overlap rate of 15%-20%. The outer outer sheath 5 is wound counterclockwise with a winding tension of 6-9N, at the same winding speed as the inner layer, with an overlap rate of 20%-25%. After the two outer sheaths 5 are wound, they undergo heat curing treatment at 60℃-80℃ to ensure a tight bond between the two layers. The overall thickness of the outer sheath 5 is controlled between 0.01mm and 0.02mm, balancing internal stress while ensuring the overall cable diameter remains within a small range. The two outer sheaths 5, wound simultaneously in opposite directions, effectively balance internal stress during wrapping, preventing structural deformation during bending and ensuring the shielding effect of the shielding layer 4, thus guaranteeing the high-speed transmission performance of the cable.

[0031] In one embodiment of the present invention, the silver-plated copper alloy wire has at least two silver plating layers, with a transition layer between each silver plating layer for bonding the two silver plating layers. The inner core substrate is made of high-purity oxygen-free copper wire to ensure good conductivity. The copper wire surface is pretreated by sequentially removing surface oil with an alkaline degreasing agent, then acid washing with a dilute sulfuric acid solution to remove the oxide layer, and finally rinsing with deionized water and drying, so that the copper wire surface reaches a clean state free of oil, oxidation, and impurities, providing a reliable substrate for subsequent plating adhesion.

[0032] For example, high-purity silver is used as the plating material. The first silver plating layer is deposited via electroplating. This layer directly contacts the copper substrate, improving the conductivity of the wire and isolating the copper from the external environment, reducing copper oxidation. A copper-nickel alloy is selected as the transition layer material and formed on the surface of the first silver plating layer via electroplating. The copper-nickel alloy has good compatibility with silver, effectively enhancing the adhesion between the two silver plating layers and preventing delamination. A second silver plating layer is then deposited on the transition layer surface via electroplating, further improving the conductivity and wear resistance of the wire. For applications requiring higher performance, a third or more silver plating layers can be added as needed, with transition layers of the same material between each layer.

[0033] For example, the inner conductor 1 can also use a silver-nickel-plated copper alloy wire as the base. Silver-nickel alloy wires have higher tensile strength and better high-temperature resistance. Furthermore, the bonding force between the silver-nickel alloy wire and the silver plating is superior to that of pure silver-plated copper wire, which helps to reduce the contact resistance of the wire, thereby reducing the attenuation of high-frequency signal transmission and better meeting the high-speed communication requirements of the cable.

[0034] In one embodiment of the present invention, the insulating layer 2 includes an inner insulating layer and an outer insulating layer, wherein the inner insulating layer is a microporous foamed polymer and the outer insulating layer is an elastic polymer.

[0035] For example, the microporous foamed polymer uses low-dielectric-constant polyolefin materials as the base material, specifically a blend of high-density polyethylene and ethylene-tetrafluoroethylene copolymer, to improve the material's temperature resistance and chemical stability. The elastic polymer can be a thermoplastic polyurethane elastomer with a Shore hardness of 85-90A and an elongation at break ≥400%, exhibiting excellent elastic recovery and wear resistance. The closed-cell structure of the microporous foamed polymer reduces the dielectric constant of the insulation layer 2 by 20%-30%, significantly reducing high-speed signal transmission loss. The elastic polymer also improves the flexibility of the cable, facilitating bending.

[0036] In one embodiment of the present invention, a silver-plated braided mesh is disposed on the outer side of the aluminum foil Mylar layer, and a buffer layer is provided between the aluminum foil Mylar layer and the silver-plated braided mesh. The buffer layer is made of thermoplastic polyurethane. The silver-plated braided mesh and the aluminum foil Mylar layer work together to effectively improve the shielding performance. The buffer layer, made of thermoplastic polyurethane, has a Shore hardness of 75-80A, exhibits excellent elastic recovery and bending resistance, and has good compatibility with both the aluminum foil Mylar layer and the silver-plated braided mesh. It can effectively protect the integrity of the aluminum foil Mylar layer and the silver-plated braided mesh in scenarios involving repeated bending, ensuring stable shielding performance and providing a guarantee for high-speed signal transmission.

[0037] In this embodiment of the invention, an aluminum foil Mylar layer is wrapped around the outside of the inner sheath, and a silver-plated woven mesh is woven in a counterclockwise direction at an angle of 45°-60°.

[0038] Furthermore, the outer protective layer 5 is a polyester tape, with the first layer of polyester tape spirally wound in a clockwise direction at an angle of 30°-45°, and the second layer of polyester tape spirally wound in a counterclockwise direction at an angle of 45°-60°.

[0039] Understandably, the symmetrical winding structure formed by the aluminum foil Mylar and the first layer of polyester tape, and the silver-plated braided mesh and the second layer of polyester tape, helps to ensure a uniform radial stress distribution when the cable is bent.

[0040] In this embodiment of the invention, the high-speed communication cable also includes a ground wire 6 disposed between the shielding layer 4 and the outer sheath 5. Two ground wires 6 are provided, symmetrically arranged on both sides of the two inner core conductors 1 located at the edges. Specifically, the symmetrical arrangement of the ground wires 6 can balance the electromagnetic environment of the cable, reduce signal interference, and meet the reliability requirements of vehicle-mounted Ethernet grounding.

[0041] This invention also provides a method for preparing the high-speed communication cable described above, comprising the following steps: S1. High-strength copper wire is selected as the substrate of the inner core conductor 1. A silver plating layer is electroplated on the surface of the copper wire. A transition layer is formed on the silver plating layer by vacuum evaporation. Then, another silver plating layer is electroplated on the transition layer to obtain the inner core conductor 1.

[0042] Specifically, high-strength copper wire with a purity of ≥99.95% is selected as the base material, and the diameter of the copper wire is set to 0.3mm-0.5mm according to the cable specifications. The copper wire is ultrasonically cleaned with an alkaline degreasing agent at 60℃ for 10 minutes to remove surface oil; then it is acid-washed with 10% dilute sulfuric acid solution for 3 minutes to remove the oxide layer; finally, it is rinsed with deionized water until neutral and dried. The copper wire is placed in an electroplating solution containing 50-60 g / L of silver nitrate, the temperature is controlled at 25℃-30℃, the current density is 1-1.5 A / dm², and the electroplating time is 15-20 minutes to form a uniform silver layer with a thickness of 0.5 μm-1 μm. Vacuum degree ≤ 5 × 10 - In an environment of ³Pa, nickel-chromium alloy is evaporated and deposited onto the surface of the silver plating layer at a evaporation rate of 0.1-0.2μm / min to form a transition layer with a thickness of 0.1μm-0.2μm, which enhances the adhesion of the plating layer. The composition and temperature of the electroplating solution are the same as those of the first layer. The current density is adjusted to 0.8-1.2 A / dm², and the electroplating time is 20-25 minutes to form a surface silver layer with a thickness of 1μm-1.5μm, thus completing the preparation of the inner core conductor 1.

[0043] S2. Extrude microporous foamed polymer material to coat the outside of the conductor to form an inner insulation layer. After it cools and solidifies, extrude elastic polymer material to coat the outside of the inner insulation layer.

[0044] Specifically, the inner insulation layer is made of microporous foamed polypropylene material. It is extruded using a twin-screw extruder, with the barrel temperature set in sections from 160℃ to 180℃, the die temperature at 170℃, and the screw speed at 40-50 r / min. Nitrogen gas is injected during extrusion as a foaming agent, causing the material to form a microporous structure with an average pore size of 5-10 μm, uniformly coating the outer side of the inner conductor 1 with a thickness of 0.2 mm, and then cured by water cooling (water temperature 20℃-25℃).

[0045] After the inner insulation layer has fully cured, the outer insulation layer is coated using a single-screw extruder. The barrel temperature is 150℃-170℃, the screw speed is 30-40 r / min, and the extrusion thickness is 0.15mm-0.2mm. This ensures a tight fit with the inner insulation layer without bubbles or peeling.

[0046] S3. Place two inner core conductors 1 covered with insulation layer 2 in parallel, and extrude a highly flexible material to cover the outside of the two inner core conductors 1 to form an inner sheath 3.

[0047] Specifically, flame-retardant polyurethane material is selected as the highly flexible coating material. It is extruded at 180℃-200℃ using an extruder to completely cover the two conductors with a thickness of 0.3mm-0.4mm. The extrusion speed is matched with the conductor forward speed to ensure that the surface of the inner sheath 3 is flat and the two conductors are stably positioned within the sheath without any displacement.

[0048] S4. The aluminum foil Mylar layer is wrapped around the outside of the inner sheath 3. A buffer layer made of thermoplastic polyurethane material is set on the outside of the aluminum foil Mylar layer. A silver-plated woven mesh formed by high-purity silver wire is wrapped around the outside of the buffer layer.

[0049] Specifically, the aluminum foil Mylar layer uses a composite structure of 0.012mm thick aluminum foil and 0.02mm thick Mylar film, and is wrapped around the outside of the inner sheath 3 with a winding tension of 5-6N and an overlap rate of 25%-30% to ensure no missing wrapping. The buffer layer is made of thermoplastic polyurethane material with a Shore hardness of 75A. It is uniformly covered on the outside of the aluminum foil Mylar layer through a coating process with a coating thickness of 0.05mm-0.08mm. After coating, it is pre-cured by drying with hot air at 60℃ for 30 seconds. The silver-plated woven mesh is made of high-purity silver wire with a diameter of 0.08mm. It is woven by a braiding machine at a counterclockwise angle of 45°-60° with a braiding density of ≥90% and a braiding tension of 8-10N. It is wrapped on the outside of the buffer layer to ensure that the mesh surface is flat and wrinkle-free.

[0050] S5. Wrap two layers of polyester tape around the outside of the silver-plated woven mesh simultaneously with a preset tension and in opposite directions to form the outer protective layer 5.

[0051] Specifically, a polyester tape with a thickness of 0.03mm-0.05mm is selected as the outer sheath material 5, and a double-head wrapping machine is used for wrapping. The first layer of polyester tape is wrapped at a clockwise angle of 30°-45° with a tension of 6-7N; the second layer of polyester tape is wrapped at a counterclockwise angle of 45°-60° with a tension of 7-8N. Both layers are wrapped simultaneously, and the wrapping speed is consistent with the cable's forward speed. The overlap rate is ≥25%, forming a structurally stable outer sheath 5.

[0052] The cables manufactured using the above process have tightly bonded layers, achieving a small cable size while ensuring high-speed transmission performance and high flexibility, meeting the high-speed communication requirements of automotive Ethernet. They also possess excellent flexibility and bending resistance, making them suitable for installation in confined spaces.

[0053] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A high-speed communication cable, characterized in that, include: The inner core conductor (1) is made of one or more silver-plated copper alloy wires twisted together. There are at least two inner core conductors (1), and adjacent inner core conductors (1) are arranged in parallel. The insulating unit includes an insulating layer (2) covering the outside of each of the inner core conductors (1) and an inner sheath (3) covering the outside of the insulating layer (2); A shielding layer (4) is wrapped around the outside of the inner sheath (3), and the shielding layer (4) is made of aluminum foil Mylar layer; The outer protective layer (5) is wrapped around the outside of the shielding layer (4). The outer protective layer (5) has two layers, which are wound in opposite directions at the same time.

2. The high-speed communication cable according to claim 1, characterized in that, The silver-plated copper alloy wire has at least two silver plating layers, with a transition layer between each silver plating layer for bonding the two silver plating layers.

3. The high-speed communication cable according to claim 2, characterized in that, Replace the silver-plated copper alloy wire with a silver-nickel-plated copper alloy wire.

4. The high-speed communication cable according to claim 1, characterized in that, The insulating layer (2) includes an inner insulating layer and an outer insulating layer. The inner insulating layer is a microporous foamed polymer, and the outer insulating layer is an elastic polymer.

5. The high-speed communication cable according to claim 1, characterized in that, A silver-plated woven mesh is provided on the outside of the aluminum foil Mylar layer, and a buffer layer is provided between the aluminum foil Mylar layer and the silver-plated woven mesh. The buffer layer is made of thermoplastic polyurethane material.

6. The high-speed communication cable according to claim 5, characterized in that, The aluminum foil Mylar layer is wrapped around the outside of the inner sheath (3), and the silver-plated woven mesh is woven at an angle of 45°-60° in a counterclockwise direction.

7. The high-speed communication cable according to claim 6, characterized in that, The outer protective layer (5) is a polyester tape. The first layer of polyester tape is spirally wound in a clockwise direction at an angle of 30°-45°, and the second layer of polyester tape is spirally wound in a counterclockwise direction at an angle of 45°-60°.

8. The high-speed communication cable according to claim 1, characterized in that, It also includes a ground wire (6) disposed between the shielding layer (4) and the outer sheath (5), wherein two ground wires (6) are disposed symmetrically on both sides of the two inner core conductors (1) located at the edge.

9. A method for preparing a high-speed communication cable as described in any one of claims 1-8, characterized in that, Includes the following steps: S1. High-strength copper wire is selected as the substrate of the inner core conductor (1). A silver plating layer is electroplated on the surface of the copper wire. A transition layer is formed on the silver plating layer by vacuum evaporation. Then, a silver plating layer is electroplated on the transition layer to obtain the inner core conductor (1). S2. Extruding microporous foamed polymer material to coat the outside of the conductor to form an inner insulation layer. After it cools and solidifies, extruding elastic polymer material to coat the outside of the inner insulation layer. S3. Place two inner core conductors (1) covered with insulation layer (2) in parallel, and extrude a highly flexible material to cover the outside of the two inner core conductors (1) to form an inner sheath (3). S4. The aluminum foil Mylar layer is wrapped around the outside of the inner sheath (3). A buffer layer made of thermoplastic polyurethane material is set on the outside of the aluminum foil Mylar layer. A silver-plated woven mesh formed by high-purity silver wire is wrapped around the outside of the buffer layer. S5. Wrap two layers of polyester tape around the outside of the silver-plated woven mesh simultaneously with a preset tension and in opposite directions to form an outer protective layer (5).

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