Category 6 + follow-up cable and manufacturing method thereof

Abstract

The invention discloses a Category 6 + follow-up cable and a manufacturing method thereof, the Category 6 + follow-up cable comprises a plurality of Category 6 + communication cable cores and a plurality of reinforcing steel wires, the Category 6 + communication cable cores and the reinforcing steel wires are wrapped by a total sheath, and the Category 6 + communication cable cores and the reinforcing steel wires are arranged side by side and are wrapped by the total sheath to form a flat structure; the category 6 + communication cable core comprises four pairs of paired shielding twisted pairs, and each pair of twisted pairs adopts foamed polyethylene insulation and is coated with an aluminum-plastic composite belt shielding layer; the reinforcing steel wires are galvanized steel wires and are used for enhancing the tensile strength of the cable, compared with the prior art, signal attenuation, dielectric loss and crosstalk between wire pairs are remarkably reduced, the cable has the capability of resisting external electromagnetic interference, torsion and deformation are effectively resisted, and the service life is prolonged; the structure is compact and stable; and the flat design saves the wiring channel space.

Description

Technical Field

[0001] This invention relates to the field of Category 6A cable technology, and in particular to a Category 6A follower cable and its manufacturing method. Background Technology

[0002] In fields such as intelligent buildings, data centers, and industrial automation, high-speed network cabling systems are often used in dynamic environments such as elevators, robots, and mobile devices. These environments require cables to not only meet the high-speed transmission standards of Category 6 (A6) but also possess excellent resistance to bending, torsion, tension, and electromagnetic interference. Traditional round cables are prone to torsional stress concentration during repeated bending and movement, have limited tensile strength, and occupy a large amount of space. Furthermore, ordinary unshielded or generally shielded structures are susceptible to external electromagnetic interference and crosstalk between wire pairs in high-frequency, high-density cabling environments, leading to decreased signal integrity and increased bit error rate.

[0003] Therefore, there is an urgent need for a dedicated network cable for mobile applications that integrates high electrical performance, high mechanical reliability, strong anti-interference capability, and compact structure. Summary of the Invention

[0004] The purpose of this invention is to provide a Category 6e follower cable and its manufacturing method, which can solve at least one of the above-mentioned technical problems. The technical solution of this invention is as follows:

[0005] A Category 6A follower cable includes: several Category 6A communication cable cores and several reinforcing steel wires, with a general sheath covering the several Category 6A communication cable cores and several reinforcing steel wires. The Category 6A communication cable cores and reinforcing steel wires are arranged side by side and covered by the general sheath to form a flat structure. Each Category 6A communication cable core includes four pairs of partially shielded twisted pairs. Each pair of twisted pairs is insulated with foamed polyethylene and is covered with an aluminum-plastic composite tape shielding layer. The reinforcing steel wires are galvanized steel wires used to enhance the tensile strength of the cable.

[0006] Furthermore, the dielectric constant of the foamed polyethylene insulation is lower than that of solid polyethylene, the foaming degree is 48%±5%, and the outer diameter of the insulation is 1.05mm±0.05mm.

[0007] Furthermore, the aluminum-plastic composite tape shielding layer has an aluminum layer thickness of 30μm, a plastic layer thickness of 20μm, and a width of 9mm, with each pair of twisted wires being independently wrapped.

[0008] Furthermore, each Category 6e communication cable core also includes an outer sheath made of polyvinyl chloride with a thickness of 0.54mm ± 0.05mm and an outer diameter of 6.5mm ± 0.3mm.

[0009] Furthermore, the main sheath is formed by a full extrusion process, the material is polyvinyl chloride, the shape is flat, and the size is 23.7mm × 8.7mm.

[0010] Furthermore, the reinforcing steel wire is 0.2mm × 49 strands of galvanized steel wire.

[0011] Furthermore, the conductor of the twisted pair is stranded oxygen-free copper, with a wire gauge of AWG26 and a stranded outer diameter of 0.495mm.

[0012] A method for manufacturing a Category 6e follower cable, characterized by comprising the following steps:

[0013] A foamed polyethylene insulation layer is formed on stranded copper conductors using a foaming extrusion process, with the outer diameter of the insulation controlled at 1.05mm ± 0.02mm and the water capacitance deviation within ±1pF.

[0014] Two insulated wires are twisted into a pair, with a twist pitch tolerance of less than 5% and a de-twist rate controlled at 20%~30%;

[0015] Each pair of stranded wires is individually shielded by wrapping it with aluminum-plastic composite tape.

[0016] Four pairs of shielded twisted wires are cabled together, with the cable pitch and the twisted pair pitch in the same direction, and the pitch tolerance is less than 5%;

[0017] After cabling, a PVC sheath is extruded over the cable core to form a single Category 6a communication cable core.

[0018] The two communication cable cores and two galvanized steel wires are arranged side by side and covered with a total sheath by a full extrusion process to form a flat follower cable.

[0019] Furthermore, the foaming extrusion process employs a four-layer co-extrusion foaming line, which monitors the conductor outer diameter, insulation outer diameter, water capacitance, and eccentricity in real time, with the insulation concentricity not less than 92%.

[0020] Furthermore, the twisting process employs a high-speed un-twist double-twist twisting machine, ensuring that the tension of the two conductors is consistent and their elongation rates are similar during the twisting process.

[0021] In summary, the advantages of this invention over existing technologies are as follows: Superior electrical performance: The use of foamed polyethylene insulation and paired aluminum foil shielding significantly reduces signal attenuation, dielectric loss, and crosstalk between wire pairs, ensuring excellent return loss and resistance to external electromagnetic interference at a 500MHz bandwidth, meeting and exceeding the ANSI / TIA-568.2-D standard; Reliable mechanical performance: The parallel arrangement of galvanized steel wires provides extremely high tensile strength, and the flattened overall sheath structure ensures uniform stress distribution during cable bending, effectively resisting torsion and deformation, and extending service life; Compact and stable structure: The flattened design saves wiring channel space, and the parallel structure avoids the tangling problem that traditional round cables may experience during movement, making it particularly suitable for narrow and mobile applications such as elevators and cable chains; Strong process controllability: From insulation foaming control and precision twisting to paired shielding and double-layer sheath extrusion, key parameters throughout the entire process are digitally monitored and fed back, ensuring high consistency and stability of product performance. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the cross-sectional structure of the Category 6a communication cable core in this invention.

[0023] Figure 2 This is a schematic diagram of the cross-sectional structure of the Category 6e follower cable of the present invention.

[0024] Explanation of reference numerals in the attached diagram: 100, Category 6A communication cable core; 200, reinforcing steel wire; 300, main sheath; 101, twisted pair; 102, polyethylene; 103, aluminum-plastic composite tape shielding layer; 104, outer sheath. Detailed Implementation

[0025] The present invention will be further described below with reference to the accompanying drawings and specific embodiments:

[0026] like Figures 1 to 2 The cable shown is a Category 6A follower cable, characterized in that it comprises: a plurality of Category 6A communication cable cores (100) and a plurality of reinforcing steel wires (200), a general sheath (300) is wrapped around the plurality of Category 6A communication cable cores (100) and the plurality of reinforcing steel wires (200), the Category 6A communication cable cores (100) and the reinforcing steel wires (200) are arranged side by side and covered by the general sheath (300) to form a flat structure; the Category 6A communication cable cores (100) include four pairs of partially shielded twisted pairs (101), each pair of twisted pairs (101) is insulated with foamed polyethylene 102 and is covered with an aluminum-plastic composite tape shielding layer 103; the reinforcing steel wires (200) are galvanized steel wires used to enhance the tensile strength of the cable.

[0027] The above-described Category 6A follower cable, during use, controls electrical performance parameters such as water capacitance and impedance. The twisted pair 101 employs a foamed insulation structure; its foamed polyethylene 102 insulation has low dielectric constant and dielectric loss performance, exhibiting less attenuation, lighter weight, and less insulation material usage compared to solid polyethylene 102 insulation. This structure reduces cable attenuation and improves transmission efficiency. The aluminum-plastic composite tape shielding layer 103 uses a braided structure of paired wrapped aluminum foil and tinned copper wire, providing good shielding performance, mechanical properties, and sealing and moisture-proof performance. The paired shielding makes high-frequency transmission signals more stable, with better crosstalk attenuation than unshielded Category 6e, reducing transmission error rate, increasing information throughput, and providing stronger resistance to electromagnetic interference and improved signal integrity. The following cable, with two Category 6e cables and two steel wires extruded into a main sheath, is a cable that frequently bends as the elevator moves up and down. The 200mm tin-plated steel wire enhances the cable's tensile strength, and the side-by-side flat design saves wiring space. The flat design ensures more even cable stress and effectively prevents twisting and tangling, playing an important role in the safe and stable operation of the elevator.

[0028] The dielectric constant of the foamed polyethylene 102 insulation is lower than that of solid polyethylene 102, with a foaming degree of 48%±5% and an insulation outer diameter of 1.05mm±0.05mm. The electrical properties of the insulation are a crucial factor directly affecting the cable's transmission parameters. Polyethylene (PE) is selected to meet the transmission performance requirements of network cables. PE is an excellent high-frequency insulating dielectric material, possessing low dielectric constants ε and tgδ, and low transmission attenuation. Physical foaming further reduces the dielectric constant, improving the cable's high-frequency transmission performance, resulting in higher VP and faster transmission rates. It is suitable for digital transmission systems with high cable transmission frequencies. The insulation outer diameter is designed based on the impedance requirements of the C6A communication cable standard in ANSI / TIA-568.2-D, with a design outer diameter of 1.05±0.05mm.

[0029] The aluminum-plastic composite tape shielding layer 103 has an aluminum layer thickness of 30μm, a plastic layer thickness of 20μm, and a width of 9mm. Each pair of twisted wires (101) is independently wrapped. The aluminum-plastic composite tape shielding layer 103 adopts a pair-by-pair shielding structure, and the material is aluminum-plastic composite tape. Each pair of twisted wires is obliquely wrapped with aluminum-plastic composite tape. Due to the skin effect and reflection and absorption of the metal shield, it can better isolate the surrounding electromagnetic field and reduce crosstalk between individual shielded pairs or between four pairs of wires. It can enhance the anti-interference ability between wire pairs of the cable, play an electromagnetic shielding role, reduce crosstalk between wire pairs, improve crosstalk defense, and make the cable have a larger capacity and better anti-electromagnetic interference. The Category 6A transmission bandwidth reaches 500MHz, and the pair-by-pair shielding makes the high-frequency transmission signal more stable. According to the electrical performance requirements of C6A cable, combined with the dimensions after the insulation is twisted, the thickness of the metal composite foil is designed to be AL / P30 / 20um, and the width is 9mm. The standard for metal composite foil, YD / T 723.5-2007, tests the electrical and mechanical properties of aluminum-plastic composite strips.

[0030] Each Category 6e communication cable core (100) also includes an outer sheath 104, made of polyvinyl chloride, with a thickness of 0.54mm ± 0.05mm and an outer diameter of 6.5mm ± 0.3mm.

[0031] The main sheath (300) is formed by full extrusion extrusion process, the material is polyvinyl chloride, the shape is flat, and the size is 23.7mm×8.7mm.

[0032] In network cables, the sheath primarily serves a protective function. The sheath (300) and outer sheath (104) are made of PVC material. PVC has good processing performance, good corrosion resistance, good weather resistance, stable chemical properties, and certain flame-retardant properties. It also has good mechanical properties; the finished product underwent a cold bending test at -20℃ for 4 hours without cracking, and the operating temperature can range from -10℃ to +65℃. According to the ANSI / TIA-568.2-D standard for C6A communication cables, the design sheath thickness is 0.54±0.05mm, and the outer diameter is 6.5±0.3mm. The following table shows the performance indicators of the PVC material used by our company.

[0033] project describe standard Test equipment Actual test results 1 Tensile strength ≥13.8MPa Tensile strength testing machine 18.8MPa 2 Elongation at break ≥100% Tensile strength testing machine 340% 3 Tensile strength after aging ≥11.73 Tensile strength testing machine 16.2MPa 4 Tensile strength change rate ≥50% Tensile strength testing machine 268%

[0034] The reinforcing steel wire (200) is 0.2mm × 49 strands of galvanized steel wire.

[0035] The conductor of the twisted pair (101) is stranded oxygen-free copper, with a wire gauge of AWG26 and a stranded outer diameter of 0.495mm.

[0036] A method for manufacturing a Category 6e follower cable, characterized by comprising the following steps:

[0037] A foamed polyethylene insulation layer is formed on stranded copper conductors using a foaming extrusion process. The insulation outer diameter is controlled at 1.05mm ± 0.02mm, and the water capacitance deviation is within ±1pF. Controlling the insulation extrusion is a crucial factor determining cable quality. In actual production, a four-layer co-extrusion foaming tandem production line uses active feeding to stably feed the BC 0.165*7 stranded copper conductor. Online monitoring of conductor outer diameter, insulation outer diameter, water capacitance, eccentricity, etc., ensures production quality. This production line is computer-controlled with high precision, capable of simultaneously monitoring all production parameters and providing feedback adjustments. Insulation produced using this tandem line has an outer diameter of 1.05 ± 0.02 mm, a concentricity of up to 92%, an insulation foaming degree of over 48%, and water capacitance controlled within ±1pF. The stability of the insulation's water capacitance determines whether a qualified Category 6 cable can be produced.

[0038] Two insulated wires are twisted together, with a twist pitch tolerance of less than 5% and a de-twist rate controlled between 20% and 30%. After the production of eight colors of insulation, two insulated wires are twisted together to form a pair of twisted wires (blue-white-blue, orange-white-orange, green-white-green, brown-white-brown). The most important control parameters in the twisting process are the twist pitch and the de-twist rate. The twist pitch is a key factor affecting crosstalk in the product. The accuracy of the pitch and the stability of the spacing place high demands on the twisting equipment. An imported high-speed de-twist double-twist twisting machine is used for production, and the pitch is automatically fed back through digital settings. To ensure the stability of the center distance between the two conductors, single-wire de-twist technology is used during the twisting process, with the de-twist rate controlled between 20% and 30%. At the same time, the tension of the two conductors is kept consistent, and the elongation of the two conductors is similar to ensure the consistency of the twisted wire.

[0039] Each pair of stranded wires is individually shielded by wrapping it with aluminum-plastic composite tape.

[0040] Four pairs of shielded twisted wires are cabled together, with the cable pitch and twist pair pitch in the same direction and a pitch tolerance of less than 5%. The four pairs of twisted wires are then processed into the cable core through the cabling process. The cable pitch has a significant impact on crosstalk and return loss; therefore, a pitch tolerance of <5% is set, and the cable direction is the same as the twist pair direction. The pitch control of the cabling machine is provided by a signal feedback from the traction machine. The pitch deviation can be controlled within the process requirements. The wire tension is controlled by a dancing wheel, ensuring constant tension of the four pairs of twisted wires during production and a round cable core. A round cable core improves the cable's crosstalk protection capability and transmission stability.

[0041] After cabling, a PVC sheath is extruded over the cable core to form a single Category 6a communication cable core. The cable core is then covered with an outer sheath by a sheathing machine. Polyvinyl chloride (PVC) material is used depending on the cable's operating environment. PVC has excellent mechanical properties, chemical corrosion resistance, is non-flammable, has good weather resistance, low cost, sufficient electrical insulation properties, is easy to process, and has a certain degree of flame retardancy, making it suitable for communication cable sheaths.

[0042] Two communication cable cores and two galvanized steel wires are arranged side by side and wrapped with a full extrusion process to form a flat follower cable. Two Category 6 sheaths and two 0.2*49mm galvanized steel wires are passed side by side through a sheath extruder head. The extrusion method is full extrusion to extrude a flat sheath with a size of 23.7*8.7mm.

[0043] The foaming extrusion process uses a four-layer co-extrusion foaming line to monitor the conductor outer diameter, insulation outer diameter, water capacitance, and eccentricity in real time, with the insulation concentricity not less than 92%.

[0044] The twisting process employs a high-speed un-twist double-twist twisting machine, ensuring consistent tension and similar elongation of the two conductors during the twisting process.

[0045] The foregoing has shown and described the basic principles and main features of the present invention, as well as its advantages. Those skilled in the art should understand that the present invention is not limited to the above embodiments. The embodiments and descriptions in the specification are merely illustrative of the principles of the invention. Various changes and modifications can be made to the invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. A Category 6a follower cable, characterized in that, include: The cable comprises several Category 6e communication cable cores and several reinforcing steel wires, all wrapped with a general sheath. The Category 6e communication cable cores and reinforcing steel wires are arranged side by side and covered by the general sheath to form a flat structure. Each Category 6e communication cable core includes four pairs of partially shielded twisted pairs. Each pair of twisted pairs is insulated with foamed polyethylene and is covered with an aluminum-plastic composite tape shielding layer. The reinforcing steel wires are galvanized steel wires used to enhance the tensile strength of the cable.

2. The Category 6e follower cable according to claim 1, characterized in that, The dielectric constant of the foamed polyethylene insulation is lower than that of solid polyethylene, the foaming degree is 48%±5%, and the outer diameter of the insulation is 1.05mm±0.05mm.

3. The Category 6e follower cable according to claim 1, characterized in that, The aluminum-plastic composite tape shielding layer has an aluminum layer thickness of 30μm, a plastic layer thickness of 20μm, and a width of 9mm, with each pair of twisted wires being independently wrapped.

4. The Category 6e follower cable according to claim 1, characterized in that, Each Category 6e communication cable core also includes an outer sheath made of polyvinyl chloride, with a thickness of 0.54mm ± 0.05mm and an outer diameter of 6.5mm ± 0.3mm.

5. The Category 6e follower cable according to claim 1, characterized in that, The main sheath is formed by full extrusion extrusion process, the material is polyvinyl chloride, the shape is flat, and the size is 23.7mm×8.7mm.

6. The Category 6e follower cable according to claim 1, characterized in that, The reinforcing steel wire is 0.2mm × 49 strands of galvanized steel wire.

7. The Category 6e follower cable according to claim 1, characterized in that, The conductor of the twisted pair is stranded oxygen-free copper, with a wire gauge of AWG26 and a stranded outer diameter of 0.495mm.

8. A method for manufacturing a Category 6e follower cable, characterized in that, Includes the following steps: A foamed polyethylene insulation layer is formed on stranded copper conductors using a foaming extrusion process, with the outer diameter of the insulation controlled at 1.05mm ± 0.02mm and the water capacitance deviation within ±1pF. Two insulated wires are twisted into a pair, with a twist pitch tolerance of less than 5% and a de-twist rate controlled at 20%~30%; Each pair of stranded wires is individually shielded by wrapping it with aluminum-plastic composite tape. Four pairs of shielded twisted wires are cabled together, with the cable pitch and the twisted pair pitch in the same direction, and the pitch tolerance is less than 5%; After cabling, a PVC sheath is extruded over the cable core to form a single Category 6a communication cable core. The two communication cable cores and two galvanized steel wires are arranged side by side and covered with a total sheath by a full extrusion process to form a flat follower cable.

9. The manufacturing method according to claim 8, characterized in that, The foaming extrusion process uses a four-layer co-extrusion foaming line to monitor the conductor outer diameter, insulation outer diameter, water capacitance, and eccentricity in real time, with the insulation concentricity not less than 92%.

10. The manufacturing method according to claim 8, characterized in that, The twisting process employs a high-speed un-twist double-twist twisting machine, ensuring consistent tension and similar elongation rates for the two conductors during the twisting process.

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