High-speed copper cable and preparation method thereof

Abstract

The invention discloses a high-speed copper cable and a preparation method thereof. The high-speed copper cable comprises a hollow nano composite conductor, a ceramic reinforced insulating layer, a flexible magnetic shielding layer and a flame-retardant weather-resistant sheath which are sequentially arranged from inside to outside. The skin effect is reduced through the hollow nano composite conductor, temperature change resistance is achieved through the ceramic enhanced insulating layer, interference resistance is achieved through the flexible magnetic shielding layer, flame retardance and weather resistance are improved through the flame-retardant weather-resistant sheath, signal attenuation at the 10Gbps transmission rate is smaller than or equal to 0.45 dB / m, the shielding effectiveness is kept larger than or equal to 88 dB after bending is conducted 1000 times at the bending radius of 5 mm, and the shielding performance is kept larger than or equal to 88 dB. The cable can stably work in a temperature range of-40 DEG C to 180 DEG C and in an acid-base environment with a concentration of 5%, is suitable for high-frequency data transmission scenes with extremely high requirements on cable environmental adaptability, and has remarkable environmental adaptability advantages. The problems that a shielding layer of a traditional copper cable is prone to fracture in a dynamic bending scene, transmission performance is suddenly reduced in a low-temperature / high-temperature environment, and chemical corrosion resistance is weak are solved.

Description

Technical Field

[0001] This invention belongs to the field of wire and cable technology, specifically relating to a high-speed copper cable and its preparation method. Background Technology

[0002] With the development of intelligent vehicles and outdoor communication networks, the application scenarios of high-speed copper cables have expanded from fixed equipment rooms / base stations to harsh environments such as dynamic bending (e.g., robot joint wiring), extreme temperature changes (e.g., vehicle engine compartment starting at -40℃ / operating at 120℃), and chemical corrosion (e.g., factory acid and alkali workshops).

[0003] However, existing high-speed copper cables have three major drawbacks: 1) Rapid bending fatigue failure: Traditional solid copper conductor + single-layer metal shielding structure is prone to conductor breakage due to stress concentration when frequently bent (such as repetitive robot movements), and the shielding layer is prone to cracks. After 500 bends (radius 5mm), the shielding effectiveness often drops to below 60dB, which cannot meet the bending life requirement of more than 1000 bends for industrial robots. 2) Poor temperature adaptability: Ordinary PE / PVC insulation layer is prone to brittle cracking below -30℃ and softening above 100℃, resulting in dielectric loss (tanδ) fluctuation exceeding 0.003 during high-frequency transmission, and signal attenuation increasing by more than 30% at 10Gbps rate, making it unsuitable for wide temperature scenarios such as vehicle and outdoor use. 3) Weak corrosion resistance: Most existing copper cable sheaths are made of ordinary polyolefin materials. In the acid and alkali vapor of industrial workshops and the salt spray environment outdoors, surface aging and cracking will occur within 3 months. After the conductor is oxidized, the resistivity increases, which further deteriorates the transmission performance and shortens the service life to 2-3 years. Summary of the Invention

[0004] To address the problems in the prior art, the present invention aims to provide a high-speed copper cable and a method for its preparation.

[0005] To achieve the above objectives and technical effects, the technical solution adopted by this invention is as follows: A high-speed copper cable includes, from the inside out, a hollow nanocomposite conductor, a ceramic-reinforced insulation layer, a flexible magnetic shielding layer, and a flame-retardant and weather-resistant sheath.

[0006] Furthermore, the hollow nanocomposite conductor is made of hollow oxygen-free copper tube, with a graphene film deposited on the inner wall and a silver-tin alloy coating deposited on the outer wall.

[0007] Furthermore, the hollow nanocomposite conductor has an inner diameter of 0.1-0.12 mm and an outer diameter of 0.25-0.28 mm; the graphene film has a thickness of 50-80 nm; and the silver-tin alloy coating has a thickness of 30-50 nm.

[0008] Furthermore, the raw materials for preparing the ceramic-reinforced insulating layer include the following components in weight percentages: 80-87wt% polyimide 10-15 wt% alumina ceramic fiber Silane coupling agent 3-5wt%.

[0009] Furthermore, the thickness of the ceramic-reinforced insulating layer is 0.16-0.19 mm; the diameter of the alumina ceramic fiber is 100-200 nm, and the length is 5-10 μm.

[0010] Furthermore, the flexible magnetic shielding layer comprises a flexible copper-nickel alloy strip and a nano-ferrite coating arranged sequentially from the inside out.

[0011] Furthermore, the thickness of the flexible magnetic shielding layer is 0.09-0.11 mm; the thickness of the flexible copper-nickel alloy strip is 50-60 μm, and it is spirally wrapped with a wrapping pitch of 1.5-2 mm; the thickness of the nano-ferrite coating is 40-50 μm.

[0012] Furthermore, the flame-retardant and weather-resistant sheath comprises the following components in weight percentages: Polyethersulfone 72-78wt% 12-15 wt% magnesium hydroxide 8-10 wt% silicon carbide 2-3 wt% UV absorber.

[0013] Furthermore, the thickness of the flame-retardant and weather-resistant sheath is 0.21-0.25 mm; the particle size of the magnesium hydroxide is 1-3 μm; and the particle size of the silicon carbide is 0.5-1 μm.

[0014] This invention also discloses a method for preparing a high-speed copper cable, comprising the following steps: Step 1: Provide a hollow oxygen-free copper tube, deposit a graphene film on the inner wall of the hollow oxygen-free copper tube, and deposit a silver-tin alloy coating on the outer wall of the hollow oxygen-free copper tube to form a hollow nanocomposite conductor. Step 2: Prepare a ceramic-reinforced insulating layer on the outside of the hollow nanocomposite conductor; Step 3: Prepare a flexible magnetic shielding layer outside the ceramic-reinforced insulating layer; Step 4: Prepare a flame-retardant and weather-resistant sheath on the outside of the flexible magnetic shielding layer to finally obtain the high-speed copper cable.

[0015] Compared with the prior art, the beneficial effects of the present invention are as follows: 1) High bending life: The combination of hollow nanocomposite conductor and flexible magnetic shielding layer enables the copper cable to remain unbroken and maintain shielding effectiveness ≥88dB after 1000 bends with a bending radius of 5mm. This is more than double the life of traditional copper cable (which fails after 500 bends), making it suitable for dynamic scenarios such as industrial robots. 2) Stable transmission over a wide temperature range: The ceramic-reinforced insulation layer can operate stably in the range of -40℃ to 180℃. At a rate of 10Gbps (1-12GHz), the signal attenuation is ≤0.45dB / m, the attenuation fluctuation caused by temperature change is ≤0.05dB / m, and the signal attenuation fluctuation after 1000 bends (radius 5mm) is ≤0.02dB / m, solving the pain point of temperature change in vehicle and outdoor applications. 3) Strong weather resistance and corrosion resistance: The silver-tin alloy plating and flame-retardant weather-resistant sheath enable the copper cable to withstand 1000 hours of salt spray, 30 days of acid and alkali corrosion, and 1000 hours of xenon lamp aging, greatly extending its service life by more than 5 times compared to traditional copper cables. 4) High compatibility: The overall outer diameter of the copper cable is ≤2.6mm, which is compatible with industrial / communication connectors such as M12 and RJ45. No need to modify the existing equipment interface, reducing application costs. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the present invention. Detailed Implementation

[0017] The present invention will now be described in detail so that its advantages and features can be more easily understood by those skilled in the art, thereby providing a clearer and more explicit definition of the scope of protection of the present invention.

[0018] The following provides a brief overview of one or more aspects to offer a basic understanding of them. This overview is not an exhaustive summary of all conceived aspects, nor is it intended to identify key or decisive elements of all aspects, nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form to prepare for the more detailed descriptions that follow.

[0019] like Figure 1 As shown, this invention discloses a high-speed copper cable that combines high-speed transmission, resistance to bending fatigue, long bending life, wide temperature stability, and weather resistance and corrosion resistance. It can maintain high-speed and stable transmission under dynamic bending, extreme temperature changes and chemical corrosion environments, meeting the high-frequency and high-speed transmission requirements of harsh scenarios such as industrial, automotive and outdoor applications, and can fill the application gap of existing technologies in harsh scenarios.

[0020] The present invention discloses a high-speed copper cable, comprising, from the inside out, a hollow nanocomposite conductor 1, a ceramic reinforced insulation layer 2, a flexible magnetic shielding layer 3, and a flame-retardant and weather-resistant sheath 4.

[0021] The hollow nanocomposite conductor 1 uses a single hollow oxygen-free copper tube (purity ≥99.999%) with an inner diameter of 0.1-0.12 mm and an outer diameter of 0.25-0.28 mm. The hollow structure reduces the skin effect at high frequencies (current concentrates on the conductor surface, and the hollow portion does not affect transmission). The inner wall of the tube is coated with a 50-80 nm thick graphene film, which improves conductivity and reduces the conductor's surface resistivity (overall resistivity ≤1.55×10⁻⁶ at 20℃). -8 The outer wall of the pipe is coated with a silver-tin alloy coating (Ag-Sn, Sn content 5-8wt%) with a thickness of 30-50nm, which can extend the salt spray corrosion resistance time to more than 1000h (neutral salt spray test GB / T 10125), improve corrosion resistance, and the coating is not easy to fall off when bending. After 1000 bends with a bending radius of 5mm, the coating integrity rate is ≥98%.

[0022] The ceramic-reinforced insulation layer 2 has a thickness of 0.16-0.19 mm, with polyimide as the base material, and 10-15 wt% of alumina ceramic fibers (100-200 nm in diameter and 5-10 μm in length) and 3-5 wt% of silane coupling agent (KH-550) added.

[0023] The raw materials for preparing the ceramic reinforced insulation layer 2 include the following components by weight percentage: 80-87wt% polyimide 10-15 wt% alumina ceramic fiber Silane coupling agent (KH-550, etc.) 3-5wt%.

[0024] The ceramic-reinforced insulating layer 2 is prepared using the following steps: 1) Dissolve KH-550 in ethanol to prepare a 10% solution, add 10-15 wt% alumina ceramic fiber, stir at 70-80℃ for 1-1.5 h, and dry at 85-95℃ for 1-3 h to obtain modified alumina ceramic fiber. 2) Mix modified alumina ceramic fiber with 80-87 wt% polyimide and 3-5 wt% silane coupling agent, feed it into a twin-screw extruder, with a barrel temperature of 200-250℃ and a screw speed of 100-300 rpm. After extrusion, pelletize and then dry at 150-250℃ for 6-9 hours to remove water to obtain the composite material. 3) Feed the composite material into a single screw extruder, with the feeding section at 220-250℃, the plasticizing section at 350-380℃, the homogenizing section at 370-400℃, the die head at 380-410℃, and the extrusion pressure at 15-25MPa, so that it can be evenly coated on the outside of the hollow nanocomposite conductor 1.

[0025] Alumina ceramic fibers can improve the temperature resistance (long-term operating temperature -40℃ to 180℃, short-term temperature resistance 200℃) and bending toughness of the insulation layer (no cracks after 1000 bending cycles). Silane coupling agents can enhance the bonding force between the alumina ceramic fibers and the substrate, preventing fiber shedding and increased dielectric loss. The ceramic-reinforced insulation layer 2 has a dielectric constant (εr) ≤1.75 and a dielectric loss (tanδ) ≤0.0009 at 1GHz.

[0026] The flexible magnetic shielding layer 3 has a thickness of 0.09-0.11 mm and includes a flexible copper-nickel alloy strip and a nano-ferrite coating arranged sequentially from the inside to the outside.

[0027] Flexible copper-nickel alloy strip (Cu-Ni, Ni content 10-12wt%): thickness 50-60μm, spiral wrapping method (wrapping pitch 1.5-2mm). The high flexibility of the flexible copper-nickel alloy strip can adapt to frequent bending (no breakage when bending radius is 5mm), and it mainly shields low frequency (≤2GHz) electromagnetic interference.

[0028] Nano-ferrite coating (Ni-Zn-Cu ferrite, particle size 20-50nm): 40-50μm thick, applied by spraying onto the surface of the alloy strip. The high permeability of the ferrite (μ≥1000, at 1GHz) can absorb high-frequency (2-12GHz) electromagnetic interference, avoiding the "shielding blind zone" of traditional metal shielding for high-frequency interference. Shielding effectiveness ≥88dB in the 1-12GHz band, with a decrease in shielding effectiveness ≤2dB after 1000 bending cycles.

[0029] Flame-retardant and weather-resistant sheath 4 uses polyethersulfone as the base material and adds 12-15wt% magnesium hydroxide (flame retardant, particle size 1-3μm), 8-10wt% silicon carbide (thermal conductor, particle size 0.5-1μm), and 2-3wt% ultraviolet absorber (such as UV-531).

[0030] The flame-retardant and weather-resistant sheath 4 comprises the following components by weight percentage: Polyethersulfone 72-78wt% 12-15 wt% magnesium hydroxide 8-10 wt% silicon carbide 2-3 wt% UV absorber.

[0031] The flame-retardant and weather-resistant sheath 4 is prepared using the following steps: 1) Stir magnesium hydroxide, silicon carbide, and ultraviolet absorber at 100-130℃ and 1000-1500r / min for 10-15min; coupling agent and antioxidant may or may not be added in this step. Dry polyethersulfone at 85-100℃ for 4-6 hours; 2) Feed the raw materials obtained in step 1) into an internal mixer and mix them at 85-95℃ for 15-25 minutes, and then continue mixing at 80-90℃ for 10-20 minutes. 3) Melt extrusion using a twin-screw extruder, with an extrusion temperature of 185-200℃ and a screw speed of 150-300 r / min, followed by extrusion plasticization; 4) The extruded material is fed into a pelletizer and cut into 2-4mm pellets. The cut pellets are then placed in an oven for 3-5 hours to remove surface moisture. When using, the pellets are extruded onto the outside of the flexible magnetic shielding layer 3.

[0032] Magnesium hydroxide enables the sheath to meet the UL94 V-0 flame retardant standard (no dripping during vertical burning test, self-extinguishing time ≤10s). Silicon carbide can increase the thermal conductivity of the sheath to 1.1-1.3W / (m•K), rapidly dissipating conductor heat. UV absorbers enhance outdoor weather resistance.

[0033] The flame-retardant and weather-resistant sheath 4 has a thickness of 0.21-0.25mm, a tensile strength of ≥70MPa, and is resistant to corrosion by 5% hydrochloric acid / sodium hydroxide solution. After aging with a xenon lamp for 1000h, the tensile strength retention rate is ≥90%.

[0034] A method for preparing a high-speed copper cable includes the following steps: Step 1: Provide a hollow oxygen-free copper tube, deposit a graphene film on the inner wall of the hollow oxygen-free copper tube, and deposit a silver-tin alloy coating on the outer wall of the hollow oxygen-free copper tube to form a hollow nanocomposite conductor 1. Step 2: Prepare a ceramic-reinforced insulating layer 2 on the outside of the hollow nanocomposite conductor 1; Step 3: Prepare a flexible magnetic shielding layer 3 outside the ceramic reinforced insulating layer 2; Step 4: Prepare a flame-retardant and weather-resistant sheath 4 on the outside of the flexible magnetic shielding layer 3 to finally obtain the high-speed copper cable.

[0035] This invention reduces the skin effect through a hollow nanocomposite conductor 1, resists temperature changes through a ceramic-reinforced insulation layer 2, resists interference through a flexible magnetic shielding layer 3, and improves flame retardancy and weather resistance through a flame-retardant and weather-resistant sheath 4. It achieves signal attenuation ≤0.45dB / m at a transmission rate of 10Gbps (1-12GHz band), and maintains shielding effectiveness ≥88dB after 1000 bends (bending radius 5mm). It can also work stably in a temperature range of -40℃ to 180℃ and in an environment with 5% concentration of acid and alkali. It is suitable for high-frequency data transmission scenarios with extremely high requirements for cable environmental adaptability, such as industrial robots, vehicle communication, and outdoor micro base stations. It has significant environmental adaptability advantages and solves the problems of traditional copper cables such as easy breakage of the shielding layer, sharp drop in transmission performance in low / high temperature environments, and weak resistance to chemical corrosion in dynamic bending scenarios (such as industrial robots and mobile devices).

[0036] Example 1 like Figure 1 As shown, a high-speed copper cable combines high-speed transmission, resistance to bending fatigue, long bending life, wide temperature stability, and weather resistance and corrosion resistance. It can maintain high-speed and stable transmission under dynamic bending, extreme temperature changes and chemical corrosion environments, meeting the high-frequency and high-speed transmission requirements of harsh scenarios such as industrial, automotive and outdoor applications, and can fill the application gap of existing technologies in harsh scenarios.

[0037] The present invention discloses a high-speed copper cable, comprising, from the inside out, a hollow nanocomposite conductor 1, a ceramic reinforced insulation layer 2, a flexible magnetic shielding layer 3, and a flame-retardant and weather-resistant sheath 4.

[0038] The hollow nanocomposite conductor 1 uses a single hollow oxygen-free copper tube (99.999% purity) with an inner diameter of 0.12 mm and an outer diameter of 0.28 mm. The hollow structure reduces the skin effect at high frequencies (current concentrates on the conductor surface, and the hollow portion does not affect transmission). The inner wall of the tube is coated with an 80 nm thick graphene film, which improves conductivity and reduces the conductor's surface resistivity (overall resistivity ≤ 1.55 × 10⁻⁶ at 20℃). -8 The outer wall of the pipe is coated with a 50nm thick silver-tin alloy coating (Ag-Sn, Sn content 5wt%), which can extend the salt spray corrosion resistance time to more than 1000h (neutral salt spray test GB / T 10125), improve corrosion resistance, and the coating is not easy to fall off when bending. With a bending radius of 5mm, the coating integrity rate is ≥98% after 1000 bends.

[0039] The thickness of the ceramic-reinforced insulation layer 2 is 0.19 mm.

[0040] The raw materials for preparing the ceramic reinforced insulation layer 2 include the following components by weight percentage: 87wt% polyimide 10wt% alumina ceramic fiber (200nm in diameter, 10μm in length) KH-550 silane coupling agent 3wt.

[0041] The ceramic-reinforced insulating layer 2 is prepared using the following steps: 1) Dissolve KH-550 in ethanol to prepare a 10% solution, add 10wt% alumina ceramic fiber, stir at 80℃ for 1h, and dry at 95℃ for 1h to obtain modified alumina ceramic fiber. 2) The modified alumina ceramic fiber was mixed with 87wt% polyimide and 3wt% silane coupling agent, and fed into a twin-screw extruder. The barrel temperature was 200℃ and the screw speed was 300rpm. After extrusion, the mixture was pelletized and then dried at 250℃ for 6 hours to remove water, thus obtaining the composite material. 3) The composite material is fed into a single screw extruder at a temperature of 250°C in the feeding section, 350°C in the plasticizing section, 370°C in the homogenizing section, 380°C in the die head, and an extrusion pressure of 15MPa, so as to uniformly coat the hollow nanocomposite conductor 1.

[0042] Alumina ceramic fibers can improve the temperature resistance (long-term operating temperature -40℃ to 180℃, short-term temperature resistance 200℃) and bending toughness of the insulation layer (no cracks after 1000 bending cycles). Silane coupling agents can enhance the bonding force between the alumina ceramic fibers and the substrate, preventing fiber shedding and increased dielectric loss. The ceramic-reinforced insulation layer 2 has a dielectric constant (εr) ≤1.75 and a dielectric loss (tanδ) ≤0.0009 at 1GHz.

[0043] The flexible magnetic shielding layer 3 has a thickness of 0.11 mm and includes a flexible copper-nickel alloy strip and a nano-ferrite coating arranged sequentially from the inside to the outside.

[0044] Flexible copper-nickel alloy strip (Cu-Ni, Ni content 12wt%): 60μm thick, spirally wrapped (wrapping pitch 2mm). The high flexibility of the flexible copper-nickel alloy strip can adapt to frequent bending (no breakage when bending radius is 5mm), and it mainly shields low-frequency (≤2GHz) electromagnetic interference.

[0045] Nano-ferrite coating (Ni-Zn-Cu ferrite, particle size 50nm): 50μm thick, applied to the surface of the alloy strip using a spray coating process. The high magnetic permeability of the ferrite (μ≥1000, at 1GHz) can absorb high-frequency (2-12GHz) electromagnetic interference, avoiding the "shielding blind zone" of traditional metal shielding for high-frequency interference. Shielding effectiveness ≥88dB in the 1-12GHz frequency band, with a shielding effectiveness decrease of ≤2dB after 1000 bending cycles.

[0046] The flame-retardant and weather-resistant sheath 4 comprises the following components by weight percentage: 78wt% polyethersulfone Magnesium hydroxide (flame retardant, particle size 3μm) 12wt% Silicon carbide (thermal conductive agent, particle size 1μm) 8wt% 2wt% UV-531 ultraviolet absorber.

[0047] The flame-retardant and weather-resistant sheath 4 is prepared using the following steps: 1) Stir magnesium hydroxide, silicon carbide, and ultraviolet absorber at 100℃ and 1000r / min for 15min; coupling agent and antioxidant may or may not be added in this step. The polyethersulfone was dried at 85°C for 5 hours. 2) The raw materials obtained in step 1) are fed into an internal mixer and mixed at 95°C for 15 minutes, and then mixed at 80°C for another 20 minutes. 3) Melt extrusion using a twin-screw extruder at an extrusion temperature of 200℃ and a screw speed of 150 r / min, followed by extrusion plasticization; 4) The extruded material is fed into a pelletizer and cut into 2mm pellets. The cut pellets are then placed in an oven for 5 hours to remove surface moisture. When in use, the pellets are extruded onto the outside of the flexible magnetic shielding layer 3.

[0048] Magnesium hydroxide enables the sheath to meet the UL94 V-0 flame retardant standard (no dripping during vertical burning test, self-extinguishing time ≤10s). Silicon carbide can increase the thermal conductivity of the sheath to over 1.1W / (m•K), rapidly dissipating conductive heat. UV absorbers enhance outdoor weather resistance.

[0049] The flame-retardant and weather-resistant sheath 4 has a thickness of 0.25mm, a tensile strength of ≥70MPa, and is resistant to corrosion by 5% hydrochloric acid / sodium hydroxide solution. After aging with a xenon lamp for 1000h, the tensile strength retention rate is ≥90%.

[0050] A method for preparing a high-speed copper cable includes the following steps: Step 1: Provide a hollow oxygen-free copper tube, deposit a graphene film on the inner wall of the hollow oxygen-free copper tube, and deposit a silver-tin alloy coating on the outer wall of the hollow oxygen-free copper tube to form a hollow nanocomposite conductor 1. Step 2: Prepare a ceramic-reinforced insulating layer 2 on the outside of the hollow nanocomposite conductor 1; Step 3: Prepare a flexible magnetic shielding layer 3 outside the ceramic reinforced insulating layer 2; Step 4: Prepare a flame-retardant and weather-resistant sheath 4 on the outside of the flexible magnetic shielding layer 3 to finally obtain the high-speed copper cable.

[0051] Example 2 like Figure 1 As shown, a high-speed copper cable includes, from the inside out, a hollow nanocomposite conductor 1, a ceramic-reinforced insulation layer 2, a flexible magnetic shielding layer 3, and a flame-retardant and weather-resistant sheath 4.

[0052] The hollow nanocomposite conductor 1 uses a single hollow oxygen-free copper tube (99.999% purity) with an inner diameter of 0.1 mm and an outer diameter of 0.25 mm. The hollow structure reduces the skin effect at high frequencies (current concentrates on the conductor surface, and the hollow portion does not affect transmission). The inner wall of the tube is coated with a 50 nm thick graphene film, which improves conductivity and reduces the surface resistivity of the conductor (overall resistivity ≤ 1.55 × 10⁻⁶ at 20℃). -8The outer wall of the pipe is coated with a 30nm thick silver-tin alloy coating (Ag-Sn, Sn content 5-8wt%), which can extend the salt spray corrosion resistance time to more than 1000h (neutral salt spray test GB / T 10125), improve corrosion resistance, and the coating is not easy to fall off when bent. After 1000 bends with a bending radius of 5mm, the coating integrity rate is ≥98%.

[0053] The thickness of the ceramic-reinforced insulation layer 2 is 0.16 mm.

[0054] The raw materials for preparing the ceramic reinforced insulation layer 2 include the following components by weight percentage: 80wt% polyimide 15wt% alumina ceramic fiber (100nm in diameter, 5μm in length) KH-550 silane coupling agent 5wt%.

[0055] Alumina ceramic fibers can improve the temperature resistance (long-term operating temperature -40℃ to 180℃, short-term temperature resistance 200℃) and bending toughness of the insulation layer (no cracks after 1000 bending cycles). Silane coupling agents can enhance the bonding force between the alumina ceramic fibers and the substrate, preventing fiber shedding and increased dielectric loss. The ceramic-reinforced insulation layer 2 has a dielectric constant (εr) ≤1.75 and a dielectric loss (tanδ) ≤0.0009 at 1GHz.

[0056] The flexible magnetic shielding layer 3 has a thickness of 0.09 mm and includes a flexible copper-nickel alloy strip and a nano-ferrite coating arranged sequentially from the inside to the outside.

[0057] Flexible copper-nickel alloy strip (Cu-Ni, Ni content 10wt%): 50μm thick, spirally wrapped (1.5mm wrapping pitch). The high flexibility of the flexible copper-nickel alloy strip can adapt to frequent bending (no breakage when bending radius is 5mm), and it mainly shields low-frequency (≤2GHz) electromagnetic interference.

[0058] Nano-ferrite coating (Ni-Zn-Cu ferrite, particle size 20nm): 40μm thick, applied by spraying onto the surface of the alloy strip. The high permeability of the ferrite (μ≥1000, at 1GHz) can absorb high-frequency (2-12GHz) electromagnetic interference, avoiding the "shielding blind zone" of traditional metal shielding for high-frequency interference. Shielding effectiveness ≥88dB in the 1-12GHz band, with a decrease in shielding effectiveness ≤2dB after 1000 bending cycles.

[0059] The flame-retardant and weather-resistant sheath 4 comprises the following components by weight percentage: 72wt% polyethersulfone Magnesium hydroxide (flame retardant, particle size 1μm) 15wt% Silicon carbide (thermal conductive agent, particle size 0.5μm) 10wt% 3wt% UV-531 ultraviolet absorber.

[0060] Magnesium hydroxide enables the sheath to meet the UL94 V-0 flame retardant standard (no dripping during vertical burning test, self-extinguishing time ≤10s). Silicon carbide can increase the thermal conductivity of the sheath to over 1.1W / (m•K), rapidly dissipating conductive heat. UV absorbers enhance outdoor weather resistance.

[0061] The flame-retardant and weather-resistant sheath 4 has a thickness of 0.21 mm, a tensile strength of ≥70 MPa, and is resistant to corrosion by 5% hydrochloric acid / sodium hydroxide solution. After aging with a xenon lamp for 1000 h, the tensile strength retention rate is ≥90%.

[0062] A method for preparing a high-speed copper cable includes the following steps: Step 1: Provide a hollow oxygen-free copper tube, deposit a graphene film on the inner wall of the hollow oxygen-free copper tube, and deposit a silver-tin alloy coating on the outer wall of the hollow oxygen-free copper tube to form a hollow nanocomposite conductor 1. Step 2: Prepare a ceramic-reinforced insulating layer 2 on the outside of the hollow nanocomposite conductor 1; Step 3: Prepare a flexible magnetic shielding layer 3 outside the ceramic reinforced insulating layer 2; Step 4: Prepare a flame-retardant and weather-resistant sheath 4 on the outside of the flexible magnetic shielding layer 3 to finally obtain the high-speed copper cable.

[0063] The rest is the same as in Example 1.

[0064] Example 3 like Figure 1 As shown, a high-speed copper cable includes, from the inside out, a hollow nanocomposite conductor 1, a ceramic-reinforced insulation layer 2, a flexible magnetic shielding layer 3, and a flame-retardant and weather-resistant sheath 4.

[0065] The hollow nanocomposite conductor 1 uses a single hollow oxygen-free copper tube (99.999% purity) with an inner diameter of 0.11 mm and an outer diameter of 0.26 mm. The hollow structure reduces the skin effect at high frequencies (current concentrates on the conductor surface, and the hollow portion does not affect transmission). The inner wall of the tube is coated with a 60 nm thick graphene film, which improves conductivity and reduces the surface resistivity of the conductor (overall resistivity ≤ 1.55 × 10⁻⁶ at 20℃). -8 The outer wall of the pipe is coated with a 40nm thick silver-tin alloy coating (Ag-Sn, Sn content 7wt%), which can extend the salt spray corrosion resistance time to more than 1000h (neutral salt spray test GB / T 10125), improve corrosion resistance, and the coating is not easy to fall off when bending. With a bending radius of 5mm, the coating integrity rate is ≥98% after 1000 bends.

[0066] The thickness of the ceramic-reinforced insulation layer 2 is 0.18 mm.

[0067] The raw materials for preparing the ceramic reinforced insulation layer 2 include the following components by weight percentage: 85wt% polyimide 11wt% alumina ceramic fiber (150nm in diameter, 8μm in length) KH-550 silane coupling agent 4wt.

[0068] Alumina ceramic fibers can improve the temperature resistance (long-term operating temperature -40℃ to 180℃, short-term temperature resistance 200℃) and bending toughness of the insulation layer (no cracks after 1000 bending cycles). Silane coupling agents can enhance the bonding force between the alumina ceramic fibers and the substrate, preventing fiber shedding and increased dielectric loss. The ceramic-reinforced insulation layer 2 has a dielectric constant (εr) ≤1.75 and a dielectric loss (tanδ) ≤0.0009 at 1GHz.

[0069] The flexible magnetic shielding layer 3 has a thickness of 0.10 mm and includes a flexible copper-nickel alloy strip and a nano-ferrite coating arranged sequentially from the inside to the outside.

[0070] Flexible copper-nickel alloy strip (Cu-Ni, Ni content 11wt%): 55μm thick, spirally wrapped (1.8mm wrapping pitch). The high flexibility of the flexible copper-nickel alloy strip can adapt to frequent bending (no breakage when bending radius is 5mm), and it mainly shields low-frequency (≤2GHz) electromagnetic interference.

[0071] Nano-ferrite coating (Ni-Zn-Cu ferrite, particle size 40nm): 45μm thick, applied to the surface of the alloy strip using a spray coating process. The high magnetic permeability of the ferrite (μ≥1000, at 1GHz) can absorb high-frequency (2-12GHz) electromagnetic interference, avoiding the "shielding blind zone" of traditional metal shielding for high-frequency interference. Shielding effectiveness ≥88dB in the 1-12GHz frequency band, with a shielding effectiveness decrease of ≤2dB after 1000 bending cycles.

[0072] The flame-retardant and weather-resistant sheath 4 comprises the following components by weight percentage: 75wt% polyethersulfone Magnesium hydroxide (flame retardant, particle size 2μm) 14wt% Silicon carbide (thermal conductive agent, particle size 0.8μm) 8wt% 3wt% UV-531 ultraviolet absorber.

[0073] Magnesium hydroxide enables the sheath to meet the UL94 V-0 flame retardant standard (no dripping during vertical burning test, self-extinguishing time ≤10s). Silicon carbide can increase the thermal conductivity of the sheath to over 1.1W / (m•K), rapidly dissipating conductive heat. UV absorbers enhance outdoor weather resistance.

[0074] The flame-retardant and weather-resistant sheath 4 has a thickness of 0.23 mm, a tensile strength of ≥70 MPa, and is resistant to corrosion by 5% hydrochloric acid / sodium hydroxide solution. After aging with a xenon lamp for 1000 h, the tensile strength retention rate is ≥90%.

[0075] A method for preparing a high-speed copper cable includes the following steps: Step 1: Provide a hollow oxygen-free copper tube, deposit a graphene film on the inner wall of the hollow oxygen-free copper tube, and deposit a silver-tin alloy coating on the outer wall of the hollow oxygen-free copper tube to form a hollow nanocomposite conductor 1. Step 2: Prepare a ceramic-reinforced insulating layer 2 on the outside of the hollow nanocomposite conductor 1; Step 3: Prepare a flexible magnetic shielding layer 3 outside the ceramic reinforced insulating layer 2; Step 4: Prepare a flame-retardant and weather-resistant sheath 4 on the outside of the flexible magnetic shielding layer 3 to finally obtain the high-speed copper cable.

[0076] The rest is the same as in Example 1.

[0077] Any parts or structures not specifically described in this invention can be made using existing technologies or products, and will not be elaborated upon here.

[0078] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A high-speed copper cable, characterized in that, It includes, from the inside out, a hollow nanocomposite conductor, a ceramic-reinforced insulation layer, a flexible magnetic shielding layer, and a flame-retardant and weather-resistant sheath.

2. The high-speed copper cable according to claim 1, characterized in that, The hollow nanocomposite conductor is made of hollow oxygen-free copper tube, with a graphene film coated on the inner wall and a silver-tin alloy coating on the outer wall.

3. A high-speed copper cable according to claim 2, characterized in that, The hollow nanocomposite conductor has an inner diameter of 0.1-0.12 mm and an outer diameter of 0.25-0.28 mm; the graphene film has a thickness of 50-80 nm; and the silver-tin alloy coating has a thickness of 30-50 nm.

4. A high-speed copper cable according to claim 1, characterized in that, The raw materials for preparing the ceramic reinforced insulation layer include the following components by weight percentage: 80-87wt% polyimide 10-15 wt% alumina ceramic fiber Silane coupling agent 3-5wt%.

5. A high-speed copper cable according to claim 2, characterized in that, The thickness of the ceramic-reinforced insulating layer is 0.16-0.19 mm; the diameter of the alumina ceramic fiber is 100-200 nm and the length is 5-10 μm.

6. A high-speed copper cable according to claim 1, characterized in that, The flexible magnetic shielding layer comprises a flexible copper-nickel alloy strip and a nano-ferrite coating arranged sequentially from the inside out.

7. A high-speed copper cable according to claim 6, characterized in that, The thickness of the flexible magnetic shielding layer is 0.09-0.11 mm; the thickness of the flexible copper-nickel alloy strip is 50-60 μm, and it is spirally wrapped with a wrapping pitch of 1.5-2 mm; the thickness of the nano-ferrite coating is 40-50 μm.

8. A high-speed copper cable according to claim 1, characterized in that, The flame-retardant and weather-resistant sheath comprises the following components by weight percentage: Polyethersulfone 72-78wt% 12-15 wt% magnesium hydroxide 8-10 wt% silicon carbide 2-3 wt% UV absorber.

9. A high-speed copper cable according to claim 8, characterized in that, The thickness of the flame-retardant and weather-resistant sheath is 0.21-0.25 mm; the particle size of the magnesium hydroxide is 1-3 μm; and the particle size of the silicon carbide is 0.5-1 μm.

10. A method for preparing a high-speed copper cable according to any one of claims 1-9, characterized in that, Includes the following steps: Step 1: Provide a hollow oxygen-free copper tube, deposit a graphene film on the inner wall of the hollow oxygen-free copper tube, and deposit a silver-tin alloy coating on the outer wall of the hollow oxygen-free copper tube to form a hollow nanocomposite conductor. Step 2: Prepare a ceramic-reinforced insulating layer on the outside of the hollow nanocomposite conductor; Step 3: Prepare a flexible magnetic shielding layer outside the ceramic-reinforced insulating layer; Step 4: Prepare a flame-retardant and weather-resistant sheath on the outside of the flexible magnetic shielding layer to finally obtain the high-speed copper cable.

Images