An interference-resistant data communication cable and a method of making the same

Abstract

The application discloses an anti-interference data communication cable and a preparation method thereof, and belongs to the technical field of communication cables. The cable core is composed of a conductor and a gradient insulation layer coated on the outer side. The conductor is composed of a plurality of super-smooth silver-plated copper alloy filaments which are concentrically stranded. The gradient insulation layer is composed of an inner layer of nano-modified foamed insulation layer and an outer layer of crosslinked solid insulation layer. Two cable cores form a differential signal line pair, and a plurality of differential signal line pairs are coated in a shielding layer and a protective layer. The shielding layer and the protective layer sequentially comprise an inner shielding layer, a functional buffer layer, an outer shielding layer and an outer sheath layer from the inside to the outside. Compared with the prior art, the application realizes a shielding effectiveness of more than 80 dB in a wide frequency band through conductor surface treatment, gradient insulation design and a multi-layer cooperative shielding system, simultaneously significantly reduces high-frequency signal transmission loss, and improves the signal integrity and long-term reliability of the cable in a high-speed, high-density and strong-interference environment.

Description

Technical Field

[0001] This invention relates to the field of communication cable technology, and specifically to an anti-interference data communication cable and its manufacturing method. Background Technology

[0002] Data communication cables are the core transmission medium for digital infrastructure such as data centers, 5G communications, and the industrial internet. As data transmission rates advance to 10Gbps, 25Gbps, and even higher, operating frequency bands continue to increase, and the electromagnetic environment becomes increasingly complex, unprecedented challenges are posed to the transmission loss, signal integrity, and electromagnetic interference resistance of cables.

[0003] Existing high-speed data communication cables typically employ high-purity oxygen-free copper conductors, solid or chemically foamed polyethylene insulation, and a shielding structure consisting of longitudinally wrapped aluminum foil and / or tinned copper wire braid. While these designs meet basic requirements to some extent, they reveal significant shortcomings when addressing next-generation high-speed applications: First, traditional shielding structures have limited effectiveness. Single aluminum foil shielding is prone to failure at high frequencies due to skin effect and fit issues, and it also has poor resistance to bending fatigue. Braided shielding has pores, resulting in leakage at high frequencies. The common "aluminum foil + braided" double-layer shielding lacks synergy between the layers, making it difficult to achieve stable and efficient shielding against complex interference over a wide frequency band, especially above GHz. Shielding effectiveness (SE) typically struggles to exceed 70dB.

[0004] Secondly, the high-frequency losses of conductors and insulation are neglected. Ordinary conductors have large surface roughness, which significantly increases AC resistance under the high-frequency skin effect; solid or traditional foam insulation has high dielectric constant and loss factor, resulting in large signal attenuation and high propagation delay, which limits long-distance high-speed transmission.

[0005] Furthermore, the shielding layers of existing cables are mostly purely physical barriers, lacking active absorption and conversion mechanisms for electromagnetic energy, making them prone to shielding saturation in complex, high-interference environments. In addition, fluctuations in manufacturing processes can lead to uneven cable structures and large fluctuations in characteristic impedance, affecting signal integrity.

[0006] Therefore, there is an urgent need for an anti-interference data communication cable that incorporates systematic innovations in materials, structure, and manufacturing processes to simultaneously achieve extremely low transmission loss, excellent and stable broadband shielding performance, and highly consistent electrical performance. Summary of the Invention

[0007] To address the problems of high transmission loss and low broadband shielding effectiveness in existing data communication cables, the present invention aims to provide an anti-interference data communication cable and its manufacturing method, achieving extremely low transmission loss, excellent and stable broadband shielding effectiveness, and highly consistent electrical performance.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: An anti-interference data communication cable includes a cable core; the cable core consists of a conductor and a gradient insulation layer covering the outside, the conductor is made of multiple strands of ultra-smooth silver-plated copper alloy wires concentrically twisted, and the gradient insulation layer is made of an inner nano-modified foamed insulation layer and an outer cross-linked solid insulation layer co-extruded; two cable cores form a set of differential signal pairs; multiple sets of differential signal pairs are covered by a shielding layer and a protective layer.

[0009] The shielding layer and the protective layer, from the inside out, include the following: The inner shielding layer is a longitudinally wrapped silver-plated copper alloy foil layer; The functional buffer layer is a composite toughening material layer of graphene-conductive carbon black-antistatic agent that covers the outside of the inner shielding layer. The outer shielding layer is a high-density braided silver-plated copper wire layer; The outer sheath layer is a cross-linked elastomer-nano flame retardant-conductive filler composite material layer covering the outside of the outer shielding layer.

[0010] Furthermore, the silver plating layer of the conductor has a thickness of 0.5-2.0 μm, the surface roughness Ra of a single copper alloy wire is ≤0.3 μm, the stranding structure of the conductor is layered reverse stranding, and the stranding pitch ratio is controlled at 12-18 times.

[0011] Furthermore, in the gradient insulation layer: the inner nano-modified foamed insulation layer is a physically foamed fluoroplastic or polyolefin material, with added nano-silica (SiO2) nucleating agent modified by silane coupling agent, the nano-silica particle size is 20-50nm, and the addition amount is 1-3% of the matrix mass; the foaming degree is 60%-75%, and the average cell diameter is ≤20μm; the overall equivalent dielectric constant of the gradient insulation layer is ≤1.8, and the dielectric loss factor tanδ is ≤0.001@10GHz.

[0012] The outer cross-linked solid insulating layer is a cross-linked fluoroplastic or polyolefin material, with added nano-alumina (Al2O3) modified by a silane coupling agent. The nano-alumina has a particle size of 50-100nm and is added at 3-6% of the matrix mass. The cross-linking agent is dicumyl peroxide (DCP), with an addition amount of 0.5-1.0wt% and a cross-linking degree of ≥70%.

[0013] Furthermore, in the aforementioned anti-interference data communication cable, the number of "multiple sets of differential signal pairs" is 2-16 sets. Preferably, depending on different application scenarios, the number of sets can be selected as 2 sets, 4 sets, 8 sets, or 16 sets.

[0014] Furthermore, the thickness of the silver-plated copper alloy foil of the inner shielding layer is 8-15μm, the longitudinal overlap rate is ≥25%, and the electrical connection at the overlap is achieved by conductive adhesive bonding or laser welding.

[0015] Furthermore, the graphene-conductive carbon black-antistatic agent composite toughening material formulation of the functional buffer layer comprises, by weight, 100 parts of thermoplastic elastomer matrix, wherein the matrix is ​​styrene-based thermoplastic elastomer (SEBS) or thermoplastic polyurethane elastomer (TPU); 3-8 parts of graphene, wherein the graphene is few-layer graphene oxide with a sheet thickness of 0.8-2 nm and a sheet diameter of 5-10 μm, modified by a silane coupling agent; 5-12 parts of conductive carbon black, wherein the conductive carbon black is superconducting furnace black with a specific surface area of ​​800-1200 m² / g and a particle size of 20-40 nm; 2-5 parts of antistatic agent, wherein the antistatic agent is a quaternary ammonium salt cationic antistatic agent or a polyether ester amide polymeric antistatic agent; 5-10 parts of plasticizer, wherein the plasticizer is white oil or dioctyl phthalate (DOP); and processing aid: silane coupling agent KH-550. 1-2 parts, antioxidant 1010 0.5-1 part.

[0016] Furthermore, the thickness of the functional buffer layer is 0.2-0.4 mm, and the surface resistivity is 10 Ω·cm. 3 -10 5 Ω / sq, elongation at break ≥250%, forming a synergistic shielding system with the inner and outer shielding layers, improving shielding effectiveness by 10-15dB compared to the traditional aluminum foil + braided structure.

[0017] Furthermore, the outer shielding layer is made of silver-plated copper wire with high-density braiding, and the braiding coverage is ≥90%.

[0018] Furthermore, the crosslinked elastomer-nano flame retardant-conductive filler composite material formulation of the outer sheath layer comprises, by weight: 100 parts of crosslinked elastomer matrix, wherein the matrix is ​​crosslinked thermoplastic polyurethane (TPU) or crosslinked chlorinated polyethylene (CPE), the crosslinking agent is DCP, and the degree of crosslinking is ≥65%; 15-25 parts of nano flame retardant, wherein the nano flame retardant is nano magnesium hydroxide (Mg(OH)2) or nano aluminum hydroxide (Al(OH)3), with a particle size of 50-100nm, and surface modified by silane coupling agent; 5-10 parts of conductive filler, wherein the conductive filler is silver-plated glass microspheres or nickel-plated carbon fiber, with a particle size / diameter of 10-50μm; flame retardant synergist: 5-8 parts of ammonium polyphosphate (APP), 3-5 parts of melamine cyanurate (MCA); processing aid: 1-2 parts of silane coupling agent KH-570, 0.5-1 parts of light stabilizer UV-531.

[0019] The outer sheath has a thickness of 0.8-1.2 mm, a limiting oxygen index ≥30%, and a surface resistivity ≤10. 5Ω / sq, tensile strength ≥15MPa.

[0020] The present invention also provides a method for preparing the anti-interference data communication cable, comprising the following steps: S1. Conductor preparation: The copper alloy rod is drawn through multiple passes, continuously annealed and polished to obtain an ultra-smooth copper alloy wire, which is then electroplated with silver, and finally stranded in layers in reverse through a planetary cage stranding machine to form a conductor. S2. Gradient insulation layer extrusion: A series co-extrusion production line is used to sequentially extrude nano-modified foamed insulation material and cross-linked solid insulation material onto the conductor to form an inner nano-modified foamed insulation layer and an outer cross-linked solid insulation layer. The thickness and degree of foaming are controlled by an online diameter measurement and capacitance monitoring system. S3. Cable forming: The insulated wires obtained in step S2 are twisted together into a cable core according to a preset pitch; S4. Inner shielding layer covering: Silver-plated copper alloy foil strip is wrapped along the longitudinal direction of the cable core, the overlap rate is controlled, and conductive bonding or laser welding is performed at the overlap to form an inner shielding layer (3). S5. Functional buffer layer extrusion: The uniformly mixed graphene-conductive carbon black-antistatic agent composite material is extruded outside the inner shielding layer to form a functional buffer layer, and then cooled and shaped. S6. Outer shielding layer braiding: Outside the functional buffer layer, silver-plated copper wires are braided into an outer shielding layer using a high-speed braiding machine at a set angle and density; S7. Outer sheath extrusion: The cross-linked elastomer-nano flame retardant-conductive filler composite material is extruded onto the outermost layer to form the outer sheath.

[0021] Further, in step S2, the preparation of the inner nano-modified foamed insulation layer includes: surface modification of nano-silica with vinyltrimethoxysilane (A-171), the modification conditions being: 2% of the mass of nano-silica by the amount of silane coupling agent, ethanol / water mixed solvent (volume ratio 9:1), pH=4-5, temperature 70℃, and time 3h; pre-dispersing the modified nano-silica with fluoroplastics or polyolefin resin in a high-speed mixer at a speed of 1200rpm for 8min; and in the foaming section of the series co-extrusion production line, controlling the injection pressure of foaming gas (nitrogen) to 2.0-3.5MPa and the temperature to 260-300℃ to form a foam structure dominated by closed micropores in the inner layer.

[0022] Further, in step S2, the preparation of the outer cross-linked solid insulating layer includes: surface modification of nano-alumina with vinyltriethoxysilane, the modification conditions being: 2% of the mass of nano-alumina using silane coupling agent, ethanol or isopropanol solvent, temperature 75-85℃, time 4h; mixing the modified nano-alumina, cross-linking agent DCP, and fluoroplastics or polyolefin resin in a mixer at a temperature of 150-170℃ for 6-10min; and cross-linking after co-extrusion by electron beam irradiation or thermal vulcanization, with the degree of cross-linking controlled at ≥70%.

[0023] Further, in step S5, the preparation of the graphene-conductive carbon black-antistatic agent composite material of the functional buffer layer (4) includes: surface modification of graphene oxide with silane coupling agent KH-550, the modification conditions being: silane dosage being 3% of the mass of graphene oxide, water / ethanol (1:1) solvent, temperature 60℃, time 2h; mixing thermoplastic elastomer matrix, modified graphene oxide, conductive carbon black, antistatic agent and additives in a mixer at a temperature of 160-180℃, rotor speed of 50rpm, time 12-15min, to ensure that the uniformity of filler dispersion is ≥90%.

[0024] Further, in step S7, the preparation of the crosslinked elastomer-nano flame retardant-conductive filler composite material of the outer sheath layer (6) includes: surface modification of nano magnesium hydroxide or nano aluminum hydroxide with silane coupling agent KH-570, the modification conditions being: silane dosage being 2% of the mass of the nano flame retardant, ethanol solvent, temperature 70℃, and time 3h; the crosslinked elastomer matrix, modified nano flame retardant, conductive filler, flame retardant synergist and additives being melt-mixed in a twin-screw extruder at a temperature of 150-170℃ and a screw speed of 80rpm, and then extruded and granulated for use in cable sheath extrusion; after extrusion, crosslinking is completed by electron beam irradiation or thermal vulcanization, with a crosslinking degree ≥65%.

[0025] This cable, through innovative conductor design, gradient insulation structure, and multi-layer synergistic shielding system, achieves broadband high shielding effectiveness of over 80dB, high-frequency transmission loss reduction of over 30%, and excellent product performance consistency to meet the stringent requirements of future high-speed, high-reliability communication scenarios. It also achieves unexpected technical benefits. 1. Revolutionary Improvement in Shielding Effectiveness: The innovative synergistic system of "metal foil (electric field shielding) + graphene-conductive carbon black-antistatic agent composite layer (electromagnetic dissipation / toughening / static protection) + high-density woven mesh (all-around shielding)" achieves gradient attenuation and energy dissipation of electromagnetic interference. Graphene and conductive carbon black form a conductive network in the elastomer matrix, which not only dissipates electromagnetic energy but also provides a static discharge channel; the antistatic agent improves surface conductivity and prevents static accumulation. Actual measurements show a stable shielding effectiveness >85dB at 1GHz and >75dB at 6GHz, an improvement of 10-15dB compared to the traditional "aluminum foil + woven" structure, solving the problem of high-frequency shielding failure in traditional shielding.

[0026] 2. Significantly reduced transmission loss: The ultra-smooth silver-plated conductor reduces high-frequency resistance by approximately 25%; the gradient foamed insulation structure reduces the equivalent dielectric constant to approximately 1.7. The combination of these two factors results in a cable attenuation constant at 10GHz that is more than 35% lower than that of traditional solid-insulated cables, effectively extending the transmission distance of high-speed signals.

[0027] 3. Interlayer Synergistic Toughening and Protection: The functional buffer layer uses a thermoplastic elastomer matrix, combined with graphene and conductive carbon black, to significantly improve the cable's resistance to compression and bending fatigue while providing electromagnetic dissipation. This layer, acting as a "flexible transition layer," alleviates the mechanical stress concentration between the inner and outer shielding layers, increasing the cable's bending life by more than two times.

[0028] 4. Multifunctional Integrated Sheath: The outer sheath uses a cross-linked elastomer matrix, integrating nano flame retardants (nano magnesium hydroxide / aluminum) and conductive fillers (silver-plated glass microspheres / nickel-plated carbon fibers), simultaneously achieving flame retardancy (limiting oxygen index ≥30%) and antistatic properties (surface resistance ≤10). 5 The cable's Ω / sq and electromagnetic shielding functions enhance its safety and reliability in complex environments.

[0029] 5. The preparation method is highly efficient and controllable: The method of this invention achieves large-scale and stable production of high-performance cables through online monitoring and closed-loop control of key process parameters, with a high product qualification rate and strong potential for industrial transformation. Attached Figure Description

[0030] Figure 1 This is a schematic diagram of the radial cross-sectional structure of the anti-interference data communication cable of the present invention.

[0031] Figure 2 for Figure 1 Enlarged schematic diagram of part A in the diagram.

[0032] In the diagram: 1. Conductor; 11. Silver plating layer; 2. Gradient insulation layer; 21. Inner foamed insulation layer; 22. Outer solid insulation layer; 3. Inner shielding layer (silver-plated copper alloy foil); 4. Functional buffer layer (wave-absorbing composite material); 5. Outer shielding layer (silver-plated copper wire braided mesh); 6. Outer sheath layer. Detailed Implementation

[0033] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below in conjunction with the embodiments and accompanying drawings. Obviously, the described embodiments are only a part of the present invention, and not all embodiments. Therefore, the detailed description provided below in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. Based on the described embodiments, all other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of the present invention.

[0034] This invention provides an anti-interference data communication cable.

[0035] like Figure 1 As shown, an anti-interference data communication cable includes a cable core; the cable core consists of a conductor 1 and a gradient insulation layer 2 covering the outside. The conductor 1 is made of multiple strands of ultra-smooth silver-plated copper alloy wire concentrically stranded. The gradient insulation layer 2 is co-extruded from an inner nano-modified foamed insulation layer 21 and an outer cross-linked solid insulation layer 22. Two cable cores form a differential signal pair; multiple differential signal pairs are covered by a shielding layer and a protective layer. Conductor 1: Concentrically stranded from multiple ultra-smooth silver-plated copper alloy wires. The silver plating layer 11 has a thickness of 0.5-2.0μm, effectively reducing surface resistance and resisting oxidation; the surface of the copper alloy wire is precision polished, with a roughness Ra≤0.3μm, significantly reducing additional losses caused by the high-frequency skin effect. The conductor is layered and reverse-stranded with a pitch ratio of 12-18, ensuring structural stability and flexibility.

[0036] Gradient insulation layer 2: Covers the outside of conductor 1, employing a co-extrusion structure of "inner nano-modified foamed outer cross-linked solid". Inner nano-modified foamed insulation layer 21: Made of physically foamed fluoroplastic (such as FEP) or polyolefin material, with silane coupling agent-modified nano-silica (20-50nm, 1-3wt%) added as a nucleating agent. Nano-SiO2 effectively regulates the cell structure, forming a large number of closed microbubbles (diameter ≤20μm), with a foaming degree of 60%-75%, reducing the local dielectric constant to a low level while ensuring the mechanical strength of the foamed layer. Outer cross-linked solid insulation layer 22: Made of thin-layer cross-linked fluoroplastic or polyolefin material, with silane-modified nano-alumina (50-100nm, 3-6wt%) added to improve hardness and wear resistance. Cross-linking agent DCP (0.5-1.0wt%) ensures a cross-linking degree ≥70%, forming a dense protective layer that effectively blocks moisture penetration and improves long-term reliability. This design enables the overall equivalent dielectric constant of the insulation layer to be ≤1.8, significantly reducing signal propagation delay and dielectric loss.

[0037] The shielding layer and the protective layer, from the inside out, consist of: Inner shielding layer 3: This is a silver-plated copper alloy foil layer longitudinally wrapped around the cable core, with a thickness of 8-15μm. Compared with traditional aluminum foil, it has superior conductivity, flexibility, and bending resistance. The longitudinal overlap rate is ≥25%, and the overlap is ensured by conductive adhesive or laser welding to ensure electrical continuity, forming the first seamless high-frequency electric field shield.

[0038] Functional Buffer Layer 4: Extruded outside the inner shielding layer, this is a composite toughening material layer of graphene, conductive carbon black, and antistatic agent. Using thermoplastic elastomer (SEBS or TPU) as the matrix, it contains: Graphene (3-8 wt%): Few-layer graphene oxide, modified with silane and uniformly dispersed, forms a conductive and thermally conductive network between the layers, dissipating electromagnetic energy and improving interlayer thermal conduction; Conductive carbon black (5-12 wt%): Superconducting furnace black constructs a three-dimensional conductive network in the matrix, providing electromagnetic shielding and electrostatic discharge functions; Antistatic agent (2-5 wt%): Quaternary ammonium salts or polyether ester amide antistatic agents migrate to the material surface, reducing surface resistance and preventing static accumulation. This layer, as a "functional transition layer," achieves synergy between electromagnetic dissipation, electrostatic protection, and mechanical toughening, which is key to achieving a shielding effectiveness exceeding 80 dB.

[0039] Outer Shielding Layer 5: Outside the functional buffer layer, a high-density braided silver-plated copper wire layer is used. The silver plating treatment ensures long-term stable low contact resistance. The braiding angle is preferably 45°±5°, and the braiding coverage is ≥95%, forming a dense metal mesh cover that provides all-around electromagnetic shielding and excellent mechanical strength.

[0040] Outer Sheath Layer 6: The outermost extruded cross-linked elastomer-nano flame retardant-conductive filler composite material. Based on cross-linked TPU or CPE, it contains: Nano flame retardant (15-25wt%): Nano magnesium hydroxide or aluminum hydroxide, uniformly dispersed after silane modification, decomposes upon heating, absorbs heat, and releases water vapor to dilute oxygen, with a limiting oxygen index ≥30%; Conductive filler (5-10wt%): Silver-plated glass microspheres or nickel-plated carbon fibers form conductive pathways, with a surface resistivity ≤10 Ω·cm. 5 Ω / sq provides the sheath with antistatic and electromagnetic shielding functions; flame retardant synergists APP and MCA work together to promote char formation and improve flame retardant efficiency. This sheath integrates flame retardancy, antistatic properties, and electromagnetic shielding, enhancing the environmental safety and reliability of the cable.

[0041] The present invention also provides a method for preparing the anti-interference data communication cable.

[0042] The key to its preparation method lies in the following precisely controlled steps: S1. Conductor preparation: The copper alloy rod is drawn through multiple passes, continuously annealed online and electropolished to obtain an ultra-smooth wire, which is then electroplated on a special silver-plated wire, and finally layered reverse stranding is completed under constant tension through a planetary cage stranding machine. S2. Gradient insulation layer extrusion: A series co-extrusion production line is adopted, and through precision molds and online feedback systems (laser diameter gauge, capacitance scanner), the injection of foaming gas, foaming degree, and the thickness and concentricity of the inner foaming layer are synchronously controlled. S3. Cabling: Insulated wires are stranded with a precisely controlled pitch (pitch-to-diameter ratio 12-18) and may be filled with non-hygroscopic material to maintain roundness; S4. Inner shielding layer covering: High-precision longitudinal wrapping equipment is used to control the foil tension and wrapping angle to ensure the overlap rate, and the overlap seams are bonded with conductive adhesive or low-power laser welding. S5. Functional buffer layer extrusion: The graphene-conductive carbon black-antistatic agent composite material that has been fully mixed (uniformity ≥95%) is extruded through an extruder at a temperature of 160-180℃ and then cooled and shaped. S6. Outer shielding layer braiding: Using a multi-spindle high-speed braiding machine, combined with a tension closed-loop control system, to ensure that the silver-plated copper wire is braided with constant tension and angle, and the coverage is uniform; S7. Outer sheath extrusion and subsequent treatment: The composite material is extruded at 150-170℃ and cross-linked by electron beam irradiation or thermal vulcanization to form a dense sheath. Example

[0043] See Figure 1 and Figure 2An anti-interference data communication cable includes a cable core; the cable core consists of a conductor 1 and a gradient insulation layer 2 covering the outside, the conductor 1 being made of multiple strands of ultra-smooth silver-plated copper alloy wire concentrically stranded, and the gradient insulation layer 2 being co-extruded from an inner nano-modified foamed insulation layer 21 and an outer cross-linked solid insulation layer 22; two cable cores form a differential signal pair; four differential signal pairs are covered by a shielding layer and a protective layer. Conductor 1: 26AWG specification, made of 19 strands of ultra-smooth silver-plated copper alloy wire with a diameter of 0.08mm. The silver plating layer 11 is approximately 1.2μm thick, the final conductor diameter is approximately 0.45mm, and the surface roughness Ra≈0.25μm.

[0044] Gradient insulating layer 2: Total outer diameter approximately 0.90 mm. Inner nano-modified foamed insulating layer 21: Matrix is ​​FEP, containing A-171 silane-modified nano-SiO2 (30 nm, 2 wt%). Physically foamed with nitrogen, foaming degree 70%, average cell diameter 15 μm, thickness 0.60 mm. Outer cross-linked solid insulating layer 22: Matrix is ​​FEP, containing silane-modified nano-Al2O3 (80 nm, 4 wt%), cross-linking agent DCP 0.8 wt%, electron beam irradiation cross-linking (dose 80 kGy), cross-linking degree 75%, thickness 0.30 mm. Overall equivalent dielectric constant approximately 1.75, dielectric loss factor tanδ = 0.0008 @ 10 GHz.

[0045] The shielding and protective layers, from the inside out, include: an inner shielding layer 3, a functional buffer layer 4, an outer shielding layer 5, and an outer sheath layer 6; the specific details are as follows: Inner shielding layer 3: It is made of 10μm thick silver-plated copper alloy foil strip wrapped longitudinally with an overlap rate of 30%, and the overlap is bonded with conductive silver glue.

[0046] Functional buffer layer 4: Thickness 0.30 mm. Formulation (parts by weight): SEBS matrix 100 parts, silane-modified graphene oxide (8 μm diameter) 5 parts, superconducting carbon black (specific surface area 1000 m² / g) 8 parts, quaternary ammonium salt antistatic agent 3 parts, white oil plasticizer 7 parts, KH-550 coupling agent 1.5 parts, antioxidant 1010 0.8 parts. Properties: Surface resistivity 5 × 10³ Ω / sq, elongation at break 300%.

[0047] Outer shielding layer 5: It is made of silver-plated copper wire with a diameter of 0.05mm using a 24-spindle braiding machine at a braiding angle of 48°, with a coverage of 96%.

[0048] Outer Sheath Layer 6: Thickness 1.0 mm. Formulation (parts by weight): Crosslinked TPU matrix (DCP crosslinking, 70% crosslinking) 100 parts, silane-modified nano-magnesium hydroxide (80 nm) 20 parts, silver-plated glass microspheres (30 μm particle size) 7 parts, APP 6 parts, MCA 4 parts, KH-570 1.5 parts, UV-531 0.8 parts. Properties: Limiting oxygen index 32%, surface resistivity 3 × 10⁻⁶. 4 Ω / sq, tensile strength 18MPa. Finished cable outer diameter approximately 4.8mm.

[0049] 1. Surface modification of nanofillers: Nano SiO2 and nano Al2O3 are modified with silane (silane dosage 2%, ethanol / water system, 70-80℃, 3-4h) to improve compatibility with fluoroplastic matrix.

[0050] 2. Foaming process control: Nitrogen injection pressure 2.8MPa, temperature 280℃, and foaming degree fluctuation controlled within ±3% through online capacitor monitoring feedback adjustment.

[0051] 3. Functional buffer layer mixing: SEBS matrix is ​​mixed with graphene and conductive carbon black in an internal mixer (170℃, 50rpm, 13min) to ensure uniform dispersion of fillers.

[0052] 4. Sheath crosslinking process: After extrusion, electron beam irradiation (dose 100kGy) is performed, and the crosslinking degree reaches 70%, forming a stable three-dimensional network.

[0053] Performance testing: Supports 25GBASE-SR transmission over 7 meters with a bit error rate of <1E-15.

[0054] Based on this, the anti-interference data communication cable is suitable for high-speed interconnection of SFP28 DAC (direct-connect cable) in data center cabinets, as well as for 5G base station radio frequency remote unit connection. Example

[0055] This embodiment is an optimization based on embodiment 1. To meet the long-distance weather-resistant transmission requirements of industrial IoT, the structural changes are as follows: 8 sets of differential signal pairs are wrapped in a shielding layer and a protective layer.

[0056] Conductor 1: The thickness of the silver plating layer 11 is increased to 2.0μm, improving corrosion resistance.

[0057] Gradient insulation layer 2: The outer solid insulation layer 22 material is changed to PFA with better temperature resistance, the amount of nano Al2O3 added is increased to 5wt%, the degree of crosslinking is increased to 80%, and the temperature resistance level is increased to 200℃.

[0058] Functional buffer layer 4: The matrix is ​​changed to weather-resistant TPU, the amount of graphene added is increased to 7 parts, the amount of conductive carbon black is increased to 10 parts, the antistatic agent is changed to polyether ester amide (better migration resistance), and the plasticizer is changed to DOP to improve low-temperature flexibility.

[0059] Outer sheath layer 6: The matrix is ​​changed to cross-linked CPE (better weather resistance than TPU), the thickness is increased to 1.2mm, the amount of nano magnesium hydroxide is increased to 25 parts, and 8 parts of nickel-plated carbon fiber (diameter 10μm, length 200μm) are added to replace the silver-plated glass microspheres to enhance conductivity and mechanical strength; two aramid yarns are embedded inside to enhance tensile strength.

[0060] Performance characteristics: This cable has an extended operating temperature range of -40℃ to 105℃ and can still stably support 10GBASE-T transmission over a length of 100 meters. After 1500 hours of humid heat aging at 85℃ / 85%RH, the shielding effectiveness decreases by <3dB, and the surface resistance changes by <half an order of magnitude, demonstrating excellent environmental durability.

[0061] Application scenarios: Suitable for harsh industrial environments such as factory automation, outdoor monitoring, and smart grids. Example

[0062] This embodiment is an optimization based on embodiment 1. To meet the requirements of ultra-short distance and ultra-high speed interconnection inside ultra-high density servers, the structural changes are as follows: 4 sets of differential signal pairs are wrapped in shielding and protective layers.

[0063] Conductor 1: It adopts 30AWG ultra-fine specification and is made of 7 strands of ultra-smooth silver-plated copper alloy wire with a diameter of 0.06mm. The conductor diameter is 0.25mm.

[0064] Gradient insulation layer 2: The inner foamed insulation layer 21 is made of foamed PTFE, the amount of nano SiO2 added is increased to 3wt%, the foaming degree is 75%, the equivalent dielectric constant is reduced to 1.65, and the thickness is 0.35mm; the outer cross-linked solid layer 22 has a thickness reduced to 0.08mm.

[0065] Functional buffer layer 4: The thickness is reduced to 0.20mm, and the formula is optimized to: 100 parts SEBS, 3 parts graphene, 6 parts conductive carbon black, and 2 parts antistatic agent, with a focus on improving the performance of ultra-fine processing.

[0066] Outer shielding layer 5: It adopts double-layer, anisotropic braided silver-plated copper wire (inner layer 35° / outer layer 55°), with each layer having a coverage of >97% and a total optical coverage of >99.5%.

[0067] Outer sheath layer 6: only 0.60mm thick, made of ultra-thin cross-linked TPU, 15 parts nano magnesium hydroxide, and 5 parts silver-plated glass microspheres, ensuring that the ultra-thin sheath still has flame-retardant and anti-static functions.

[0068] Performance characteristics: The cable has an outer diameter of only 3.0mm, a bending radius of <8mm, and under 56Gbps PAM4 modulation signal, the insertion loss is <1.8dB / m and the return loss is >22dB, meeting the requirements of the IEEE 802.3bs standard.

[0069] Application scenarios: Suitable for ultra-high density servers, and extremely short-distance high-speed connections between chips and backplanes within storage arrays. Example

[0070] Comparative Example (Conventional Technology): To verify the technical effect of the present invention, a conventional technology comparison group was set up: the conductor is tin-plated copper wire (surface roughness Ra≈0.8μm), the insulation is solid polyethylene (dielectric constant 2.3), the shielding is aluminum foil + tin-plated copper braid (coverage 90%), there is no functional buffer layer, and the sheath is ordinary polyurethane.

[0071] The above comparative data proves that the present invention, through the modification of nanofillers and the synergistic design of functional layers, has achieved significant superiority over traditional technologies in terms of transmission performance, shielding effectiveness, environmental adaptability, and mechanical reliability.

[0072] Finally, it should be noted that the above embodiments of the present invention are merely illustrative examples and not intended to limit the implementation of the invention. Those skilled in the art can make other variations and modifications based on the above description. It is impossible to exhaustively list all possible implementations here. All obvious variations or modifications derived from the technical solutions of this invention are still within the scope of protection of this invention.

Claims

1. An anti-interference data communication cable, comprising a cable core; the cable core is composed of a conductor (1) and a gradient insulation layer (2) covering the outside, the conductor (1) is made of multiple strands of ultra-smooth silver-plated copper alloy wires concentrically twisted, and the gradient insulation layer (2) is composed of an inner nano-modified foamed insulation layer (21) and an outer cross-linked solid insulation layer (22) co-extruded; two cable cores (7) form a set of differential signal pairs; 2-16 sets of differential signal pairs are covered in a shielding layer and a protective layer; The shielding layer and the protective layer, from the inside out, consist of: The inner shielding layer (3) is a silver-plated copper alloy foil layer with a longitudinally wrapped structure; The functional buffer layer (4) is a graphene-conductive carbon black-antistatic agent composite toughening material layer covering the outside of the inner shielding layer (3); The outer shielding layer (5) is a high-density braided silver-plated copper wire layer; The outer sheath layer (6) is a cross-linked elastomer-nano flame retardant-conductive filler composite material layer covering the outside of the outer shielding layer (5).

2. The anti-interference data communication cable according to claim 1, characterized in that, The silver plating layer of the conductor (1) has a thickness of 0.5-2.0 μm, the surface roughness of a single copper alloy wire Ra≤0.3 μm, and the stranding structure of the conductor (1) is layered reverse stranding with a stranding pitch ratio controlled at 12-18 times.

3. The anti-interference data communication cable according to claim 1, characterized in that, In the gradient insulation layer (2): the inner nano-modified foamed insulation layer (21) is a physically foamed fluoroplastic or polyolefin material, with added nano-silica (SiO2) nucleating agent modified by silane coupling agent, the nano-silica particle size is 20-50nm, the amount added is 1-3% of the matrix mass; the foaming degree is 60%-75%, and the average diameter of the cell is ≤20μm; The outer cross-linked solid insulating layer (22) is a cross-linked fluoroplastic or polyolefin material, with added nano-alumina (Al2O3) modified by silane coupling agent. The nano-alumina has a particle size of 50-100nm and is added at 3-6% of the matrix mass. The cross-linking agent is dicumyl peroxide (DCP), with an addition amount of 0.5-1.0wt% and a cross-linking degree of ≥70%.

4. The anti-interference data communication cable according to claim 1, characterized in that, The thickness of the silver-plated copper alloy foil of the inner shielding layer (3) is 8-15μm, the longitudinal overlap rate is ≥25%, and the overlap is electrically connected by conductive adhesive bonding or laser welding.

5. The anti-interference data communication cable according to claim 1, characterized in that, The graphene-conductive carbon black-antistatic agent composite toughening material formulation of the functional buffer layer (4) includes, by weight: 100 parts of thermoplastic elastomer matrix, wherein the matrix is ​​styrene-based thermoplastic elastomer (SEBS) or thermoplastic polyurethane elastomer (TPU); 3-8 parts of graphene, wherein the graphene is few-layer graphene oxide with a sheet thickness of 0.8-2 nm and a sheet diameter of 5-10 μm, modified by a silane coupling agent; 5-12 parts of conductive carbon black, wherein the conductive carbon black is superconducting furnace black with a specific surface area of ​​800-1200 m² / g and a particle size of 20-40 nm; 2-5 parts of antistatic agent, wherein the antistatic agent is a quaternary ammonium salt cationic antistatic agent or a polyether ester amide polymeric antistatic agent; 5-10 parts of plasticizer, wherein the plasticizer is white oil or dioctyl phthalate (DOP); and processing aid: silane coupling agent KH-550. 1-2 parts, antioxidant 1010 0.5-1 part.

6. The anti-interference data communication cable according to claim 1, characterized in that, The crosslinked elastomer-nano flame retardant-conductive filler composite material formulation of the outer sheath layer (6) includes, by mass parts: 100 parts of crosslinked elastomer matrix, wherein the matrix is ​​crosslinked thermoplastic polyurethane (TPU) or crosslinked chlorinated polyethylene (CPE), the crosslinking agent is DCP, and the degree of crosslinking is ≥65%; 15-25 parts of nano flame retardant, wherein the nano flame retardant is nano magnesium hydroxide (Mg(OH)2) or nano aluminum hydroxide (Al(OH)3), with a particle size of 50-100nm, and surface modified by silane coupling agent; 5-10 parts of conductive filler, wherein the conductive filler is silver-plated glass microspheres or nickel-plated carbon fiber, with a particle size / diameter of 10-50μm; flame retardant synergist: 5-8 parts of ammonium polyphosphate (APP), 3-5 parts of melamine cyanurate (MCA); processing aid: 1-2 parts of silane coupling agent KH-570, 0.5-1 parts of light stabilizer UV-531.

7. A method for preparing an anti-interference data communication cable as described in any one of claims 1-6, characterized in that, Includes the following steps: S1. Conductor preparation: The copper alloy rod is drawn through multiple passes, continuously annealed and polished to obtain an ultra-smooth copper alloy wire, which is then electroplated with silver and finally stranded in layers in reverse through a planetary cage stranding machine to form a conductor (1). S2. Gradient insulation layer extrusion: A series co-extrusion production line is used to extrude nano-modified foamed insulation material and cross-linked solid insulation material onto the conductor (1) in sequence to form an inner nano-modified foamed insulation layer (21) and an outer cross-linked solid insulation layer (22). The thickness and degree of foaming are controlled by an online diameter measurement and capacitance monitoring system. S3. Cable forming: The insulated wires obtained in step S2 are twisted together into a cable core according to a preset pitch; S4. Inner shielding layer covering: Silver-plated copper alloy foil strip is wrapped along the longitudinal direction of the cable core, the overlap rate is controlled, and conductive bonding or laser welding is performed at the overlap to form an inner shielding layer (3). S5. Functional buffer layer extrusion: The uniformly mixed graphene-conductive carbon black-antistatic agent composite material is extruded outside the inner shielding layer (3) to form a functional buffer layer (4), and then cooled and shaped. S6. Outer shielding layer braiding: Outside the functional buffer layer (4), silver-plated copper wire is braided into an outer shielding layer (5) using a high-speed braiding machine at a set angle and density. S7. Outer sheath extrusion: The cross-linked elastomer-nano flame retardant-conductive filler composite material is extruded on the outermost layer to form an outer sheath (6).

8. The preparation method according to claim 7, characterized in that: In step S2, the preparation of the inner nano-modified foamed insulating layer (21) includes: surface modification of nano-silica with vinyltrimethoxysilane (A-171), the modification conditions being: 2% of the mass of nano-silica by the amount of silane coupling agent, ethanol / water mixed solvent (volume ratio 9:1), pH=4-5, temperature 70℃, time 3h; pre-dispersing the modified nano-silica with fluoroplastics or polyolefin resin in a high-speed mixer at a speed of 1200rpm for 8min; in the foaming section of the series co-extrusion production line, by controlling the injection pressure of foaming gas (nitrogen) at 2.0-3.5MPa and the temperature at 260-300℃, the inner layer forms a foam structure mainly composed of closed micropores; The preparation of the outer cross-linked solid insulating layer (22) includes: surface modification of nano-alumina with vinyltriethoxysilane, the modification conditions being: 2% of the mass of nano-alumina using silane coupling agent, ethanol or isopropanol solvent, temperature 75-85℃, time 4h; mixing the modified nano-alumina, cross-linking agent DCP with fluoroplastics or polyolefin resin in a mixer, temperature 150-170℃, time 6-10min; and cross-linking after co-extrusion by electron beam irradiation or thermal vulcanization, with the degree of cross-linking controlled ≥70%.

9. The preparation method according to claim 7, characterized in that: In step S5, the preparation of the graphene-conductive carbon black-antistatic agent composite material of the functional buffer layer (4) includes: surface modification of graphene oxide with silane coupling agent KH-550, the modification conditions being: silane dosage being 3% of the mass of graphene oxide, water / ethanol (1:1) solvent, temperature 60℃, time 2h; mixing thermoplastic elastomer matrix, modified graphene oxide, conductive carbon black, antistatic agent and additives in a mixer at a temperature of 160-180℃, rotor speed of 50rpm, time 12-15min, to ensure that the uniformity of filler dispersion is ≥90%.

10. The preparation method according to claim 7, characterized in that: In step S7, the preparation of the crosslinked elastomer-nano flame retardant-conductive filler composite material of the outer sheath layer (6) includes: surface modification of nano magnesium hydroxide or nano aluminum hydroxide with silane coupling agent KH-570, the modification conditions being: silane dosage is 2% of the mass of nano flame retardant, ethanol solvent, temperature 70℃, time 3h; the crosslinked elastomer matrix, modified nano flame retardant, conductive filler, flame retardant synergist and additives are melt-mixed in a twin-screw extruder at a temperature of 150-170℃ and a screw speed of 80rpm, and after extrusion granulation, it is used for cable sheath extrusion; after extrusion, crosslinking is completed by electron beam irradiation or thermal vulcanization, and the degree of crosslinking is ≥65%.

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