Vehicle-mounted high-speed communication cable of Ethernet and preparation method thereof

Abstract

The application discloses a kind of vehicle-mounted ethernet high-speed communication cable and preparation method thereof, vehicle-mounted ethernet high-speed communication cable includes inner core conductor, insulating layer, shielding layer and outer covering layer.The inner core conductor is at least provided with two, and adjacent inner core conductor is arranged in parallel;Insulating layer is formed on the outer side of inner core conductor, and inner core conductor is wrapped in;Shielding layer is covered on the outer side of insulating layer, and shielding layer includes copper foil layer and aluminum foil layer which are covered on the outer side of insulating layer in sequence;Outer covering layer has at least high-temperature-resistant layer.Slow-release layer can effectively decompose and absorb thermal stress through microstructure surface, effectively alleviate the influence of thermal stress on cable under the scene of temperature alternation in vehicle, and high-temperature-resistant layer ensures the bearing capacity of cable in high-low temperature alternating environment, effectively improves the reliability of long-term use of cable.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a vehicle-mounted Ethernet high-speed communication cable and its manufacturing method. Background Technology

[0002] With the increasing electrification and intelligence of automobiles, the amount of data interaction between various control units, sensors, cameras, radars, and infotainment systems in vehicle systems is increasing dramatically. Traditional vehicle communication methods such as CAN bus and LIN bus are no longer sufficient to meet the demands for high-speed, high-bandwidth data transmission. Vehicle networks based on Ethernet technology, due to their high bandwidth, low latency, high reliability, and cost advantages, provide a communication path for real-time information transmission from devices such as cameras and lidar, and have become an important development direction for automotive internal networks.

[0003] In automotive Ethernet systems, the performance of communication cables directly affects the stability and interference resistance of signal transmission. Due to the complex operating environment of vehicles, cables must withstand not only extreme temperature changes, mechanical vibration, and electromagnetic interference, but also ensure signal integrity under long-term use. Therefore, the shielding performance and environmental adaptability of the cables are particularly critical.

[0004] In existing technologies, most automotive Ethernet cables use single-layer copper foil or braided shielding structures. While these can suppress electromagnetic interference to some extent, they still suffer from insufficient shielding and poor transmission stability under high-speed signal transmission. Furthermore, in environments with repeated high and low temperature fluctuations, the cables will age faster, harden, or crack, affecting their lifespan and safety.

[0005] Therefore, how to design a high-speed vehicle Ethernet communication cable that balances shielding performance and temperature resistance has become a technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0006] The purpose of this invention is to provide a vehicle-mounted Ethernet high-speed communication cable and its manufacturing method, which solves the problem of low withstand capability of existing vehicle-mounted Ethernet cables in alternating high and low temperature environments.

[0007] To achieve this objective, the present invention adopts the following technical solution: A vehicle-mounted Ethernet high-speed communication cable, comprising: The inner core conductor has at least two conductors, and adjacent inner core conductors are arranged in parallel. An insulating layer is extruded onto the outside of the inner core conductor and encloses the inner core conductor. A shielding layer is wrapped around the outside of the insulating layer, the shielding layer comprising a copper foil layer and an aluminum foil layer that are sequentially wrapped around and covered on the outside of the insulating layer; The outer layer has at least one high-temperature resistant layer.

[0008] Optionally, the outer coating layer further includes a slow-release layer, which is co-extruded with the high-temperature resistant layer and located inside the high-temperature resistant layer. The inner and outer surfaces of the slow-release layer have periodically undulating and staggered microstructure surfaces.

[0009] Optionally, the microstructure surface is one of a microwave texture structure, a micro-helical structure, or a microchannel structure.

[0010] Optionally, an elastic balancing layer is further provided between the sustained-release layer and the high-temperature resistant layer, wherein the hardness of the elastic balancing layer increases radially, and the hardness of the inner side is less than that of the outer side.

[0011] Optionally, the sustained-release layer and the elastic balance layer, as well as the sustained-release layer and the shielding layer, are bonded together by an interlayer adhesive layer, which has functional groups that are polarly compatible with adjacent layers.

[0012] Optionally, the inner surface of the high-temperature resistant layer is provided with grooves at intervals on both sides symmetrically along the axis, and the outer surface of the elastic balance layer is provided with grooves at intervals along the axis for the grooves to be embedded.

[0013] This invention also provides a method for preparing the above-described in-vehicle Ethernet high-speed communication cable, characterized by comprising the following steps: S1. Provide at least two inner core conductors; S2. The insulating layer is extruded and wrapped around the outside of the two inner core conductors by twin-helix co-extrusion. S3. By wrapping with differential tension, the copper foil layer and the aluminum foil layer are wrapped around the outside of the insulation layer in sequence; S4. A slow-release layer and a high-temperature resistant layer are formed on the outside of the shielding layer by double-layer co-extrusion. S5. Monitor the wire diameter using a laser diameter measuring device, detect shielding wrapping defects using a high-speed camera device, and feed back the detection results in a closed-loop manner to adjust the wrapping tension.

[0014] Optionally, step S1 includes: S11. Select two copper wires of appropriate spacing as the core conductor substrate; S12. Anneal the inner conductor substrate in an inert environment; S13. The inner conductor substrate is electroplated with silver.

[0015] Optionally, step S3 includes: S31. Copper foil and aluminum foil are selected as shielding materials; S32. The copper foil and aluminum foil are subjected to surface activation treatment in sequence, including degreasing, micro-acid washing, deionized water rinsing and hot air drying. S33. Perform a conversion coating treatment on the aluminum foil; S34. Apply wrapping tensions T1 and T2 to the copper foil and aluminum foil respectively using independent tension channels, such that T1 < T2, and wrap with an overlap angle of 10–30° and an overlap width of 0.2–0.8 mm to form a shielding layer.

[0016] Optionally, step S4 includes: S41. A multi-channel coaxial co-extrusion die is used to coaxially form the slow-release layer, the elastic balance layer and the high-temperature resistant layer. The microstructure surface on the slow-release layer is formed by passing through a pre-set die with a toothed cavity. S42. Perform primary cooling at a set rate to stabilize the thickness and geometry of the outer coating layer; S43. Hold at 60–120℃ for 10–60 min to release residual stress and stabilize the interlayer interface.

[0017] Optionally, during step S41, fiber filaments along the cable axis are laid in the high-temperature resistant layer.

[0018] Compared with the prior art, the present invention has the following beneficial effects: This invention provides a vehicle-mounted Ethernet high-speed communication cable and its manufacturing method. Through a double shielding structure of copper and aluminum foil layers, and a differential tension wrapping process, the cable exhibits low transmission overhead and strong electromagnetic interference suppression capabilities during high-frequency signal transmission, meeting the requirements for high-speed vehicle-mounted Ethernet signal transmission. A multi-layered composite outer sheath structure is employed. The buffer layer, through its microstructure surface design, allows for elastic, microscopic twisting and deformation when the cable is subjected to thermal stress, effectively decomposing and absorbing the thermal stress and mitigating its impact on the cable under fluctuating vehicle temperatures. The high-temperature resistant layer can be made of materials such as fluorinated polymers or polyurethane elastomers, possessing excellent high-temperature, low-temperature, and chemical corrosion resistance, ensuring the cable's ability to withstand alternating high and low temperature environments. This helps maintain stable mechanical properties and effectively improves the cable's long-term reliability. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] The structures, proportions, sizes, etc., shown in the accompanying drawings of this specification are only for the purpose of assisting those skilled in the art in understanding and reading the content disclosed in the specification, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportions, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0021] Figure 1 This is a cross-sectional view of a vehicle-mounted Ethernet high-speed communication cable.

[0022] Figure 2 This is a schematic diagram showing the cross-section of the high-temperature resistant layer and the elastic balance layer of a vehicle-mounted Ethernet high-speed communication cable.

[0023] Figure 3 This is a schematic diagram showing the outer sheath of a vehicle-mounted Ethernet high-speed communication cable after being cut open.

[0024] Illustration: 1. Inner conductor; 2. Insulation layer; 3. Shielding layer; 31. Copper foil layer; 32. Aluminum foil layer; 4. Outer sheath layer; 41. Slow-release layer; 42. Elastic balance layer; 43. High-temperature resistant layer; 44. Microstructure surface; 45. Groove; 46. Insert. Detailed Implementation

[0025] To make the objectives, features, and advantages of this invention more apparent and understandable, the technical solutions of the embodiments of this invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the embodiments described below are only some embodiments of this invention, and not all embodiments. Based on the embodiments of this invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this invention.

[0026] In the description of this invention, it should be understood that the terms "upper," "lower," "top," "bottom," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. It should be noted that when a component is considered to be "connected" to another component, it can be directly connected to the other component or there may be a component positioned centrally in the connection.

[0027] This invention provides a vehicle-mounted Ethernet high-speed communication cable and its manufacturing method. The vehicle-mounted Ethernet high-speed communication cable includes an inner conductor, an insulation layer, a shielding layer, and an outer sheath. At least two inner conductors are provided, with adjacent inner conductors arranged in parallel. The insulation layer is formed on the outside of the inner conductors and encloses them. The shielding layer covers the outside of the insulation layer and includes a copper foil layer and an aluminum foil layer sequentially wrapped around and covering the outside of the insulation layer. The outer sheath is a multi-layer composite structure, including at least an inner slow-release layer and an outer high-temperature resistant layer. The inner and outer surfaces of the slow-release layer have periodically undulating and staggered microstructure surfaces.

[0028] This invention provides a vehicle-mounted Ethernet high-speed communication cable and its manufacturing method. Through a double shielding structure of copper and aluminum foil layers, and a differential tension wrapping process, the cable exhibits low transmission overhead and strong electromagnetic interference suppression capabilities during high-frequency signal transmission, meeting the requirements for high-speed vehicle-mounted Ethernet signal transmission. A multi-layered composite outer sheath structure is employed. The buffer layer, through its microstructure surface design, allows for elastic, microscopic twisting and deformation when the cable is subjected to thermal stress, effectively decomposing and absorbing the thermal stress and mitigating its impact on the cable under fluctuating vehicle temperatures. The high-temperature resistant layer can be made of materials such as fluorinated polymers or polyurethane elastomers, possessing excellent high-temperature, low-temperature, and chemical corrosion resistance, ensuring the cable's ability to withstand alternating high and low temperature environments. This helps maintain stable mechanical properties and effectively improves the cable's long-term reliability.

[0029] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0030] Example 1: like Figure 1 , Figure 2 and Figure 3 As shown, this embodiment of the invention provides a vehicle-mounted Ethernet high-speed communication cable, including an inner conductor 1, an insulation layer 2, a shielding layer 3, and an outer sheath 4. At least two inner conductors 1 are provided, with adjacent inner conductors 1 arranged in parallel. The insulation layer 2 is basically formed on the outside of the inner conductors 1 and wraps around them. The shielding layer 3 covers the outside of the insulation layer 2, and includes a copper foil layer 31 and an aluminum foil layer 32 sequentially wrapped around and covering the outside of the insulation layer 2. The outer sheath 4 is a multi-layer composite structure, including at least an inner slow-release layer 41 and an outer high-temperature resistant layer 43. The inner and outer surfaces of the slow-release layer 41 have periodically undulating and staggered microstructure surfaces 44.

[0031] Specifically, there may be two inner core conductors 1, which are arranged in parallel. Each inner core conductor 1 is made of multiple strands of silver-plated copper alloy wires concentrically twisted together. Its cross-sectional shape may be circular. The base material of the silver-plated copper alloy wire is high-purity oxygen-free copper wire. The surface of the copper wire can be formed with a uniform silver plating layer by a combination of chemical plating and electroplating. The thickness of the silver plating layer is controlled within a range that ensures a balance between conductivity and corrosion resistance, effectively reducing signal transmission loss and providing a foundation for high-speed transmission.

[0032] Insulation layer 2 is used to wrap the two inner conductors 1 and is made of fluoroplastic through extrusion molding, specifically perfluoroethylene propylene copolymer (FEP) or tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA). For example, insulation layer 2 is made of FEP. During preparation, FEP granules are plasticized through a high-temperature extruder at a processing temperature of 300°C-360°C, and then molten fluoroplastic is symmetrically and uniformly extruded onto the outside of the two inner conductors 1. Using fluoroplastic to prepare insulation layer 2 provides a lower dielectric constant and loss, which significantly reduces signal attenuation and greatly expands bandwidth when the cable transmits high-speed automotive Ethernet signals. At the same time, the long-term operating temperature range of insulation layer 2 made of fluoroplastic can reach -65°C to 200°C, allowing the cable to not only adapt to low-temperature environments for startup but also to be placed close to high heat sources such as engines, gearboxes, and motors.

[0033] For example, supercritical nitrogen can be injected into the melt during the extrusion process. By precisely controlling the amount and speed of nitrogen injection, uniform microporous closed-cell foaming can be formed in the insulating layer, which can further reduce the dielectric constant of the insulating layer.

[0034] The shielding layer 3 covers the outside of the insulation layer 2 and consists of a copper foil layer 31 and an aluminum foil layer 32 wrapped sequentially. The copper foil layer 31 and aluminum foil layer 32 are wrapped at a wrapping angle of 10–30° and an overlap width of 0.2–0.8 mm. The wrapping tension of the copper foil layer 31 is less than that of the aluminum foil layer 32. By applying differential tension, a dense and continuous double-layer shielding structure is formed. The dual shielding structure of the copper and aluminum foils together constitutes a wide-bandwidth, high-strength electromagnetic shielding system, effectively suppressing internal and external electromagnetic interference. For example, with a copper foil layer 31 thickness of 8–12 μm and an aluminum foil layer 32 thickness of 6–15 μm, the transmission impedance of the cable in the 1 GHz frequency range can be less than 50 mΩ / m.

[0035] The outermost protective layer 4 comprises a slow-release layer 41 and a high-temperature resistant layer 43. The slow-release layer 41 can be made of fluoroplastics, specifically perfluoroethylene propylene copolymer (FEP) or ethylene-tetrafluoroethylene copolymer (ETFE). This ensures the slow-release layer 41 made of fluoroplastics possesses high-temperature resistance and media resistance while enhancing its elasticity, flexibility, and compression resistance. Consequently, the microstructure of the slow-release layer made of fluoroplastics exhibits extremely strong deformation recovery under extreme high and low temperatures, preventing plastic collapse due to material aging and ensuring the long-lasting effectiveness of thermal stress buffering. Furthermore, because fluoroplastics have high resistance to fuel, engine oil, brake fluid, coolant, and various automotive cleaning agents, the use of fluoroplastic-based composite materials in the outer sheath effectively improves the defects of cable sheaths caused by contact with chemicals, such as swelling, cracking, and aging, thus extending their lifespan.

[0036] The inner and outer surfaces of the slow-release layer 41 form periodically undulating and staggered microstructure surfaces 44, with a period of 50–500 μm and a peak height of 5–100 μm. For example, the microstructure surface 44 can be a microwave textured structure, a spiral structure, or a microchannel structure. Under thermal stress, the microstructure surface 44 can undergo elastic, microscopic twisting and deformation, effectively decomposing, absorbing, and dissipating linear shear stress. The staggered arrangement of the microstructure surfaces 44 on both sides of the slow-release layer 41 can extend the stress transmission path, avoid stress concentration, and effectively prevent the outer sheath 4 from cracking or detaching from the shielding layer 3 due to thermal cycling, greatly improving the long-term reliability of the cable in the alternating high and low temperature environment of automobiles.

[0037] The high-temperature resistant layer 43 is also made of fluoroplastics, specifically perfluoroethylene propylene copolymer (FEP). This gives the high-temperature resistant layer 43 excellent flame retardancy and high-temperature resistance, significantly improving the cable's fire resistance rating. The multi-layered composite outer sheath 4 exhibits excellent high-temperature resistance, low-temperature resistance, and chemical corrosion resistance, ensuring the cable's ability to withstand alternating high and low temperature environments. This helps maintain the stability of the cable's mechanical properties and effectively improves the cable's long-term reliability.

[0038] like Figure 2 and Figure 3 As shown, further, there is an elastic balancing layer 42 between the slow-release layer 41 and the high-temperature resistant layer 43. The hardness of the elastic balancing layer 42 increases radially, and the hardness of the inner side is less than that of the outer side.

[0039] Specifically, the elastic balance layer 42 is not composed of a single material, but is a thermoplastic dynamically vulcanized elastomer prepared through a dynamic vulcanization process. Its matrix is ​​polypropylene, and the dispersed phase is fully vulcanized ethylene propylene rubber particles. During the co-extrusion preparation of the outer sheath layer 4, a two-stage screw and static mixer are used to precisely control the content and crosslinking density of the rubber phase. The two components of the thermoplastic dynamically vulcanized elastomer are then mixed in a controllable, non-uniform manner, resulting in a material distribution with gradually increasing hardness from the inner wall to the outer wall in the extrusion channel. Finally, the material is shaped by a die, achieving a radial gradient change in the hardness of the elastic balance layer 42. Therefore, when thermal or mechanical stress is transmitted within the cable, the hardness gradient design of the elastic balance layer 42 enables stepless stress transmission and gradual release, effectively eliminating potential micro-stress concentration points and improving fatigue resistance.

[0040] Furthermore, the sustained-release layer 41 and the elastic balance layer 42, as well as the sustained-release layer 41 and the shielding layer 3, are bonded together by an interlayer adhesive layer (not shown in the figure), which has functional groups that are polarly compatible with the adjacent layers.

[0041] Specifically, the interlayer adhesive layer can be a polyolefin elastomer grafted with maleic anhydride, and the maleic anhydride functional groups have strong polarity. For example, the sustained-release layer 41 can also be prepared using a compatible blend of ethylene-tetrafluoroethylene copolymer (ETFE) and thermoplastic polyurethane (TPU). Thus, an interlayer adhesive layer is provided between the sustained-release layer 41 and the shielding layer 3. On the one hand, the maleic anhydride functional groups can form strong coordination and ionic bonds with the oxide layer on the surface of the aluminum foil layer 32. On the other hand, the maleic anhydride can also react chemically with the amino or ester groups in the sustained-release layer 41 supported by the polyurethane elastomer through graft chains, forming amide bonds or strong hydrogen bonds. Therefore, the interlayer adhesive layer can greatly improve the bonding strength between the sustained-release layer 41 and the shielding layer 3, thereby improving the reliability and durability of the cable.

[0042] Meanwhile, an interlayer bonding layer can also be provided between the sustained-release layer 41 and the elastic balance layer 42. Maleic anhydride can be compatible with the elastic balance layer 42 through grafted chains, so as to achieve a firm bond between the sustained-release layer 41 and the elastic balance layer 42.

[0043] When extruding the outer layer 4 using a multi-channel co-extruder and composite mold, the interlayer adhesive layer material, the slow-release layer 41 material, the elastic balance layer 42 material and the high-temperature resistant material are melted and plasticized by different extruders, and then introduced into the same mold. Through multi-channel layering and merging, they are extruded in one go to form a complete multi-layer composite structure outer layer 4 with each layer firmly bonded by chemical bonds.

[0044] For example, the inner surface of the high-temperature resistant layer 43 is provided with grooves 45 spaced apart on both sides symmetrically along the axis, and the outer surface of the elastic balance layer 42 is provided with grooves 46 spaced apart along the axis for the grooves 45 to be fitted. The grooves 45 are elongated, protruding shapes. When the grooves 45 and 46 cooperate, a mechanical anchor is formed between the high-temperature resistant layer 43 and the elastic balance layer 42, which improves the reliability of the connection and achieves axial locking. Furthermore, the cooperation of the spaced grooves with the 46 divides the entire bonding surface into multiple independent micro-regions. When stress is transmitted, it can be effectively decomposed, blocked, and redistributed, avoiding continuous stress transmission and accumulation.

[0045] Example 2: This invention also provides a cable manufacturing method for manufacturing the above-mentioned vehicle-mounted Ethernet high-speed communication cable, comprising the following steps: S1. Provide at least two inner core conductors 1; Two multi-stranded oxygen-free copper core conductors are provided. Before proceeding to the next process, a constant and equal low tension is applied to the two conductors by a guide wheel tension system to ensure their straightness and stability.

[0046] S2. The insulating layer 2 is extruded and wrapped around the outside of the two inner core conductors 1 by double spiral co-extrusion; A plastic extruder equipped with a twin-screw co-extrusion die head is used. FEP granules and chemical foaming masterbatch are mixed in a predetermined ratio and fed into the extruder as insulating material. Simultaneously, two inner conductors 1 are drawn parallel to each other and maintained at a constant distance, passing together through the twin-screw co-extrusion die head. The die head has two independent spiral channels symmetrically distributed at 180 degrees. Molten insulating material passes through these two channels, simultaneously and uniformly wrapping the two inner conductors 1 from two axially symmetrical directions.

[0047] S3. By wrapping with differential tension, the copper foil layer 31 and the aluminum foil layer 32 are wrapped around the outside of the insulating layer 2 in sequence; A rolled copper foil with a thickness of 9-12 μm is longitudinally wrapped with a first set tension to make the copper foil more flexibly conform to the contour of the insulating layer 2, forming the first layer of shielding and preventing excessive tension from damaging the insulating layer 2. An aluminum foil with a thickness of 6-15 μm is wrapped around the copper foil layer 31 with a second set tension and an overlap rate of not less than 25%, so that the second tension is greater than the first tension, ensuring that the aluminum foil layer 32 can be taut and flatly cover the copper foil layer, forming a robust outer shielding shell that effectively suppresses high-frequency electromagnetic interference.

[0048] S4. A slow-release layer 41 and a high-temperature resistant layer 43 are formed on the outside of the shielding layer 3 by double-layer co-extrusion. Using a multi-channel co-extruder, the inner slow-release layer 41 and the outer high-temperature resistant layer 43 are simultaneously formed on the outside of the shielding layer 3 through a single extrusion operation.

[0049] S5. Monitor the wire diameter using a laser diameter measuring device, detect shielding wrapping defects using a high-speed camera device, and feed back the detection results in a closed-loop manner to adjust the wrapping tension.

[0050] As an optional implementation, step S1 includes: S11. Select two copper wires of appropriate spacing as the substrate of the inner core conductor 1. A single copper wire is selected as the conductor to ensure high-speed and stable signal transmission. Before annealing, the surface of the copper wire is cleaned to remove oil and oxides.

[0051] S12. Anneal the substrate of the inner conductor 1 in an inert environment; Annealing treatment improves the tensile strength of the inner conductor.

[0052] S13. The substrate of the inner conductor 1 is electroplated with silver. A protective layer is formed on the surface of the inner conductor to prevent oxidation of the inner conductor.

[0053] As an optional implementation, step S3 includes: S31. Copper foil and aluminum foil are selected as shielding materials; S32. The copper foil and aluminum foil are subjected to surface activation treatment in sequence, including degreasing, micro-acid washing, deionized water rinsing and hot air drying. The copper and aluminum foils are passed through tanks containing alkaline cleaning agents to remove oil stains adhering to them during rolling and production. They are then gently etched through a tank containing dilute phosphoric acid or citric acid solution to remove an extremely thin oxide layer, exposing fresh metal atoms with high surface energy. Afterward, they are rinsed with high-purity deionized water in multiple stages to ensure that no ions remain. Finally, a highly efficient hot air drying system is used to ensure that the foil surface is completely dry and free of moisture.

[0054] S33. Perform a conversion coating treatment on the aluminum foil; After cleaning, a chromate or chromium-free conversion coating is applied to the surface of the aluminum foil through precision coating or spraying. This coating reacts chemically with the aluminum substrate to form a non-metallic, polar protective film. This enhances the corrosion resistance of the aluminum foil and, due to its polarity, provides more physical anchoring points for subsequent bonding with the outer sheath material.

[0055] S34. Apply wrapping tensions T1 and T2 to the copper foil and aluminum foil respectively using independent tension channels, such that T1 < T2, and wrap with an overlap angle of 10–30° and an overlap width of 0.2–0.8 mm to form a shielding layer 3.

[0056] The differential tension wrapping of copper foil layer 31 and aluminum foil layer 32 can effectively prevent electromagnetic leakage and foil wrinkling, while improving mechanical fatigue resistance and grounding conductivity stability.

[0057] As an optional implementation, step S4 includes: S41. A multi-channel coaxial co-extrusion die is used to coaxially form the sustained-release layer 41, the elastic balance layer 42, and the high-temperature resistant layer 43. The microstructure surface 44 on the sustained-release layer 41 is formed by passing through a pre-set die with a toothed cavity. Using a three-channel coaxial co-extrusion die, the materials of the slow-release layer 41, the elastic balance layer 42, and the high-temperature resistant layer 43 are melted and plasticized by three extruders and flow into their respective independent channels; the cavity section in the die used to form the slow-release layer 41 has a pre-set toothed or wavy structure on its inner wall, so that when the molten slow-release layer 41 material flows through, a periodic microstructure surface 44 can be formed on its inner and outer surfaces.

[0058] S42. Perform primary cooling at a set rate to stabilize the thickness and geometry of the outer layer 4. The extruded cable is immediately placed in a cooling water tank (set to 40-50°C) to fix the geometry of the outer sheath 4 and the microstructure, preventing stress freezing and shape distortion caused by sudden cooling.

[0059] S43. Hold at 60–120℃ for 10–60 min to release residual stress and stabilize the interlayer interface; Introducing the primary cooled cable into the hot air circulation drying tunnel and holding it at 80°C for 30 minutes can effectively eliminate the internal stress locked inside the material and at the interlayer interface during extrusion and cooling, promote the mutual diffusion and entanglement of the composite layers at the interface, and form a stronger bond.

[0060] The above-described embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A vehicle-mounted Ethernet high-speed communication cable, characterized in that, include: Inner core conductor (1), at least two inner core conductors (1) are provided, and adjacent inner core conductors (1) are arranged in parallel; An insulating layer (2) is extruded and formed on the outside of the inner core conductor (1) and encloses the inner core conductor (1); A shielding layer (3) is wrapped around the outside of the insulating layer (2). The shielding layer (3) includes a copper foil layer (31) and an aluminum foil layer (32) that are wrapped around and covered on the outside of the insulating layer (2) in sequence. The outer sheath (4) has at least a high-temperature resistant layer (43).

2. The vehicle-mounted Ethernet high-speed communication cable according to claim 1, characterized in that, The outer coating layer (4) further includes a slow-release layer (41), which is co-extruded with the high-temperature resistant layer (43) and located inside the high-temperature resistant layer (43). The inner and outer surfaces of the slow-release layer (41) have periodically undulating and staggered microstructure surfaces (44).

3. The vehicle-mounted Ethernet high-speed communication cable according to claim 2, characterized in that, The microstructure surface (44) is one of a microwave texture structure, a micro-helical structure, or a microchannel structure.

4. The vehicle-mounted Ethernet high-speed communication cable according to claim 2, characterized in that, There is also an elastic balance layer (42) between the sustained-release layer (41) and the high-temperature resistant layer (43). The hardness of the elastic balance layer (42) increases radially, and the hardness of the inner side is less than that of the outer side.

5. The vehicle-mounted Ethernet high-speed communication cable according to claim 4, characterized in that, The sustained-release layer (41) and the elastic balance layer (42), as well as the sustained-release layer (41) and the shielding layer (3), are all bonded together by an interlayer adhesive layer, which has functional groups that are polarly compatible with adjacent layers.

6. The vehicle-mounted Ethernet high-speed communication cable according to claim 4, characterized in that, The inner surface of the high-temperature resistant layer (43) is provided with grooves (45) spaced apart on both sides symmetrically along the axis, and the outer surface of the elastic balance layer (42) is provided with grooves (46) spaced apart along the axis for the grooves (45) to be inserted.

7. A method for preparing a vehicle-mounted Ethernet high-speed communication cable as described in any one of claims 1-5, characterized in that, Includes the following steps: S1. Provide at least two inner core conductors (1); S2. The insulating layer (2) is extruded and wrapped around the outside of the two inner core conductors (1) by double spiral co-extrusion; S3. By wrapping with differential tension, the copper foil layer (31) and the aluminum foil layer (32) are wrapped around the outside of the insulating layer (2) in sequence; S4. A slow-release layer (41) and a high-temperature resistant layer (43) are formed on the outside of the shielding layer (3) by double-layer co-extrusion. S5. Monitor the wire diameter using a laser diameter measuring device, detect shielding wrapping defects using a high-speed camera device, and feed back the detection results in a closed-loop manner to adjust the wrapping tension.

8. The cable manufacturing method according to claim 7, characterized in that, Step S1 includes: S11. Select two copper wires with appropriate spacing as the inner core conductor (1) substrate; S12. Anneal the inner conductor (1) substrate in an inert environment; S13. The inner conductor (1) substrate is electroplated with silver.

9. The cable manufacturing method according to claim 7, characterized in that, Step S3 includes: S31. Copper foil and aluminum foil are selected as shielding materials; S32. The copper foil and aluminum foil are subjected to surface activation treatment in sequence, including degreasing, micro-acid washing, deionized water rinsing and hot air drying. S33. Perform a conversion coating treatment on the aluminum foil; S34. Apply wrapping tensions T1 and T2 to the copper foil and aluminum foil respectively using independent tension channels, so that T1 < T2, and wrap with an overlap angle of 10–30° and an overlap width of 0.2–0.8 mm to form a shielding layer (3).

10. The cable manufacturing method according to claim 9, characterized in that, Step S4 includes: S41. A multi-channel coaxial co-extrusion die is used to coaxially form the slow-release layer (41), the elastic balance layer (42) and the high-temperature resistant layer (43). The microstructure surface (44) on the slow-release layer (41) is formed by using a pre-set die with a toothed cavity. S42. Perform primary cooling at a set rate to stabilize the thickness and geometry of the outer coating layer (4); S43. Hold at 60–120℃ for 10–60 min to release residual stress and stabilize the interlayer interface.

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