A low deflection flat cable and a method of manufacturing the same

Abstract

The application discloses a kind of low deflection flat cable and preparation method thereof, it is related to wire and cable technical field.The flat cable includes cable core, wrapping layer and outer sheath;Cable core includes a signal unit, two groups of second insulated wire core, two third insulated wire core and two parallelly arranged steel wire ropes;Signal unit is formed by two first insulated wire core pair-twisted and braided shielding layer;In width direction, steel wire rope, third insulated wire core, second insulated wire core group, signal unit, second insulated wire core group, third insulated wire core, steel wire rope are sequentially arranged;Steel wire rope surface is phosphorized and has the concave-convex grain formed by mechanical embossing.The application is phosphorized and mechanically embossed to steel wire rope, combined with the symmetrical arrangement of flat structure, significantly improve the bonding force of steel wire rope and outer sheath, effectively inhibit the lateral deflection of cable in dynamic bending process, and the anti-deflection performance is excellent.

Description

Technical Field

[0001] This invention belongs to the field of wire and cable technology, specifically relating to a low-deflection flat cable suitable for dynamic bending applications such as elevators, cranes, and robot cable chains, and its preparation method. Background Technology

[0002] In applications such as elevators, cranes, and robot cable carriers, cables need to withstand frequent reciprocating bending and torsion, as well as other mechanical stresses. Traditional round cables are prone to torsion and deflection when repeatedly bent, leading to cable misalignment, increased signal interference, and even insulation wear or conductor breakage, severely affecting the stability and safety of equipment operation.

[0003] To address the deflection issue during bending, flat cables are currently in use. Flat cables, by arranging the insulated cores side-by-side, limit the cable's bending freedom in the width direction to some extent, thus reducing torsional deflection. However, under actual dynamic bending conditions, the internal cores of current flat cables still experience relative misalignment during long-term dynamic bending, and the cable as a whole is prone to lateral warping or serpentine deflection, making it impossible to maintain the intended path. Therefore, the deflection performance still falls short of the requirements for high-frequency, large-angle reciprocating torsion applications. Summary of the Invention

[0004] The purpose of this application is to provide a low-deflection flat cable and its manufacturing method to solve the problem that existing flat cables are prone to lateral flipping and internal core misalignment during dynamic bending.

[0005] Firstly, the low-deflection flat cable provided in this application adopts the following technical solution: A low-deflection flat cable includes a cable core, a wrapping layer, and an outer sheath. The cable core includes a signal unit, two sets of second insulated cores, two third insulated cores, and two parallel steel wire ropes. The signal unit is formed by twisting two first insulated cores together, and a shielding layer is braided around the signal unit. In the width direction of the cable core, the components are arranged sequentially as follows: one steel wire rope, one third insulated core, one set of second insulated cores, the signal unit, another set of second insulated cores, another third insulated core, and another steel wire rope. The surface of the steel wire rope is phosphated and has a textured surface formed by mechanical embossing.

[0006] By adopting the above technical solution, steel wire ropes are symmetrically arranged in the cable core, and then subjected to phosphating and mechanical embossing treatments in sequence. Phosphating forms a phosphate film on the surface of the steel wire rope, while mechanical embossing further creates raised and recessed textures. Both processes increase the contact area and mechanical interlocking force between the steel wire rope and the surrounding sheath material. Simultaneously, the symmetrical arrangement of the steel wire ropes provides a stable bending-resistant skeleton for the cable, helping to suppress lateral deflection during dynamic bending.

[0007] Optionally, the raised or recessed texture formed by mechanical embossing can be either diamond knurling or straight knurling.

[0008] By adopting the above technical solution, diamond knurling or straight knurling can form regularly distributed indentations on the surface of the wire rope. These indentations form a mechanical locking structure with the extruded outer sheath material, further improving the bonding stability between the wire rope and the sheath.

[0009] Optionally, the upper and lower surfaces of the cable core are respectively provided with a first anti-deviation layer and a second anti-deviation layer. Both the first and second anti-deviation layers are thermoplastic elastomer layers, and the hardness of the first anti-deviation layer is higher than that of the second anti-deviation layer.

[0010] By employing the above technical solution, anti-deflection layers of different hardness are set on the upper and lower surfaces of the cable core. When the cable is bent, the tensile and compressive stresses on the upper and lower surfaces are distributed differently. The anti-deflection layer with higher hardness provides greater resistance to deformation, while the anti-deflection layer with lower hardness provides better flexibility. The combination of the two helps to balance the asymmetrical stress during the bending process.

[0011] Optionally, the first anti-deviation layer comprises the following components by weight: 100 parts polyvinyl chloride resin, 25-35 parts dioctyl phthalate, 5-10 parts trioctyl trimellitate, 5-8 parts calcium-zinc composite stabilizer, 10-15 parts calcium carbonate, 0.5-1.0 parts calcium stearate, and 0.5-1.0 parts polyethylene wax. The second anti-deviation layer comprises the following components by weight: 100 parts polyvinyl chloride resin, 50-65 parts dioctyl phthalate, 5-10 parts epoxidized soybean oil, 5-8 parts calcium-zinc composite stabilizer, 5-10 parts calcium carbonate, 0.5-1.0 parts calcium stearate, and 0.5-1.0 parts paraffin wax.

[0012] By adopting the above technical solution, the above proportions respectively endow the first anti-deviation layer with higher hardness and the second anti-deviation layer with lower hardness, thereby achieving different mechanical properties on the upper and lower surfaces.

[0013] Optionally, the insulation material of the first insulated conductor comprises the following components by weight: 100 parts high-density polyethylene, 15-25 parts low-density polyethylene, 5-10 parts ethylene-vinyl acetate copolymer, 5-8 parts carbon black masterbatch, 0.2-0.5 parts antioxidant 1076, 0.2-0.5 parts antioxidant DLPT, and 0.5-1.0 parts polyethylene wax; The insulation material of the second insulated core comprises the following components by weight: 100 parts PVC resin, 40-60 parts dioctyl phthalate, 10-20 parts trioctyl trimellitate, 5-8 parts tribasic lead sulfate, 3-5 parts dibasic lead phosphite, 15-25 parts calcium carbonate, 8-12 parts calcined kaolin, 0.5-1.5 parts calcium stearate, 0.5-1.0 parts polyethylene wax, 0.3-0.8 parts antioxidant 1010; The insulation material of the third insulated core comprises the following components by weight: 100 parts polyvinyl chloride resin, 30-50 parts dioctyl adipate, 5-10 parts epoxidized soybean oil, 6-10 parts calcium-zinc composite stabilizer, 10-20 parts hydrotalcite, 5-8 parts antimony trioxide, 20-30 parts aluminum hydroxide, 1-2 parts calcium stearate, and 0.5-1.5 parts paraffin wax.

[0014] By adopting the above technical solution, the first insulated core uses a high-density polyethylene-based formula, which has high insulation resistance and mechanical strength; the second insulated core uses a polyvinyl chloride plasticizing system, which has good flexibility; and the third insulated core contains flame retardants, giving it flame-retardant properties. These formulas respectively meet the different functional requirements of signal transmission, power transmission, and flame-retardant protection.

[0015] Optionally, the phosphating solution used in the phosphating treatment contains, by weight: 50-80 parts phosphoric acid, 30-50 parts zinc dihydrogen phosphate, 5-10 parts nickel nitrate, 10-20 parts calcium nitrate, 2-5 parts citric acid, 1-3 parts accelerator, and 800-1000 parts water.

[0016] By adopting the above technical solution, the phosphating solution can form a dense phosphate conversion film on the surface of the wire rope. This film has a certain roughness and chemical activity, which is beneficial for subsequent mechanical embossing and bonding with the outer sheath material.

[0017] Secondly, the method for manufacturing the low-deflection flat cable as described in the first aspect, as used in this application, includes the following steps: (1) Prepare insulating layer materials for the first insulating core, the second insulating core, and the third insulating core according to the weight ratio of the first insulating layer material; (2) The corresponding insulating layer material obtained in step (1) is extruded over each conductor bundle to form the first insulating core, the second insulating core and the third insulating core; (3) The wire rope is immersed in phosphating solution for phosphating treatment, and after drying, the wire rope is mechanically embossed to form a textured surface on the wire rope. (4) Twist the two first insulated wire cores together to form a signal pair, and braid a shielding layer on the outside of the signal to obtain a signal unit; (5) The first insulated wire core, the second insulated wire core, the third insulated wire core obtained in step (2) and the steel wire rope obtained in step (3) are arranged in the layout described in the first aspect to form a cable core; (6) Prepare a cladding layer on the outside of the cable core; (7) An outer sheath is extruded outside the wrapping layer, and when the anti-deflection cable includes a first anti-deflection layer and a second anti-deflection layer, the first anti-deflection layer and the second anti-deflection layer are extruded simultaneously on the upper and lower surfaces of the cable core, and cooled and shaped to obtain a low-deflection flat cable.

[0018] By adopting the above technical solution, this preparation method first prepares each insulated wire core according to the insulation layer material formula described in the first aspect. Then, the steel wire rope is subjected to phosphating and mechanical embossing treatment in sequence to form a phosphating film and textured surface. Next, two first insulated wire cores are twisted together and a shielding layer is braided to form a signal unit. Finally, the components are arranged into cable cores according to the cable width direction, and a wrapping layer, outer sheath, and optional anti-deflection layer are sequentially set. The above steps are logically sequenced and clearly defined, enabling the stable production of low-deflection flat cables.

[0019] In summary, this application includes at least one of the following beneficial technical effects: 1. By symmetrically arranging the wire ropes in the cable core and performing phosphate treatment and mechanical embossing on the surface of the wire ropes, the bonding force between the wire ropes and the outer sheath is significantly improved, avoiding relative slippage during repeated torsion. The cable has low horizontal offset after dynamic bending and excellent anti-deflection performance. 2. By setting anti-deviation layers of different hardness on the upper and lower surfaces of the cable core, the asymmetrical stress during bending can be effectively balanced, further suppressing the lateral warping of the cable and improving the stability of long-term dynamic use. 3. The preparation method is mature and the operation is controllable. The resulting cable maintains good flexibility while also maintaining good electrical properties such as insulation resistance and voltage withstand capability. Detailed Implementation

[0020] The present application will be further described in detail below with reference to specific preparation examples and embodiments. Unless otherwise specified, the raw materials used in each embodiment and comparative example are all commercially available conventional materials.

[0021] Preparation Example 1: Preparation of Insulating Core Material The first insulating core material comprises the following components by weight: 100 parts high-density polyethylene, 20 parts low-density polyethylene, 8 parts ethylene-vinyl acetate copolymer, 6 parts carbon black masterbatch, 0.3 parts antioxidant 1076, 0.3 parts antioxidant DLPT, and 0.8 parts polyethylene wax; The above components are put into a high-speed mixer and mixed evenly. The mixture is then melt-blended and granulated by a twin-screw extruder at 165°C to obtain the first insulating material.

[0022] The second insulating core material comprises the following components by weight: 100 parts PVC resin, 50 parts dioctyl phthalate, 15 parts trioctyl trimellitate, 6 parts tribasic lead sulfate, 4 parts dibasic lead phosphite, 20 parts calcium carbonate, 10 parts calcined kaolin, 1.0 part calcium stearate, 0.8 parts polyethylene wax, and 0.5 parts antioxidant 1010. The above components are mixed in a high-speed mixer, then plasticized in an internal mixer, and granulated by twin-screw extrusion to obtain the second insulating material.

[0023] The third insulating core material comprises the following components by weight: 100 parts polyvinyl chloride resin, 40 parts dioctyl adipate, 8 parts epoxidized soybean oil, 8 parts calcium-zinc composite stabilizer, 15 parts hydrotalcite, 6 parts antimony trioxide, 25 parts aluminum hydroxide, 1.5 parts calcium stearate, and 1.0 part paraffin wax; the mixing and granulation method is the same as that for the second insulating material.

[0024] Preparation Example 2: Preparation of Anti-polarization Material Layer First anti-segregation layer material: 100 parts polyvinyl chloride resin, 30 parts dioctyl phthalate, 8 parts trioctyl trimellitate, 6 parts calcium-zinc composite stabilizer, 12 parts calcium carbonate, 0.8 parts calcium stearate, 0.8 parts polyethylene wax, mixed and granulated for later use. Second anti-segregation layer material: 100 parts polyvinyl chloride resin, 60 parts dioctyl phthalate, 8 parts epoxidized soybean oil, 6 parts calcium-zinc composite stabilizer, 8 parts calcium carbonate, 0.8 parts calcium stearate, 0.8 parts paraffin wax, mixed and granulated for later use.

[0025] Preparation Example 3: Preparation of Phosphating Solution 65 parts phosphoric acid, 40 parts zinc dihydrogen phosphate, 8 parts nickel nitrate, 15 parts calcium nitrate, 3 parts citric acid, 2 parts accelerator (model HANADD-131), and 900 parts water; Add 900 parts of water to the reaction vessel, turn on the stirrer, and control the speed at 400 rpm; Slowly add 65 parts of phosphoric acid while stirring, and continue stirring for 5 minutes to mix the solution evenly; Add 40 parts zinc dihydrogen phosphate, 8 parts nickel nitrate, and 15 parts calcium nitrate in sequence, then stir for 5 minutes to ensure complete dissolution; Add 3 parts of citric acid again, stir for 10 minutes, then add 2 parts of accelerator, and continue stirring for 15 minutes until all components are fully dissolved to obtain a phosphating solution. It then needs to be left to stand for 24 hours for later use.

[0026] Example 1: Preparation of conductor and insulated wire core 1. Prepare each insulated wire core First insulated wire core: Seven tinned copper wires with a diameter of 0.2 mm are twisted together to form a conductor bundle. The first insulating material obtained in Example 1 is extruded over the conductor bundle, and the insulation layer thickness is 0.8 mm, thus obtaining the first insulated wire core; Second insulated core: The conductor is made by twisting 19 copper wires with a diameter of 0.18 mm into a conductor bundle, extruding to prepare the second insulating material obtained in Example 1, with an insulation layer thickness of 1.0 mm, thus obtaining the second insulated core; Third Insulated Core: The conductor is made by twisting 30 copper wires with a diameter of 0.15 mm into a conductor bundle, extruding to prepare the third insulating material obtained in Example 1, with an insulation layer thickness of 1.2 mm, thus obtaining the third insulated core; 2. Twist the two first-insulated wire cores together with a twisting gap of 40mm to form a signal pair. Braid a layer of tinned copper wire shielding around the signal pair, with a braiding density ≥85%. 3. The galvanized steel wire rope was treated with the phosphating solution obtained in Preparation Example 3. The specific treatment method was to heat the phosphating solution to 55°C, immerse the steel wire rope in the solution for 10 minutes, take it out, rinse it with clean water, and dry it to form a phosphating film on its surface. 4. Arrange the following along the width of the cable: 1 steel wire rope obtained in step 3, the third insulating core obtained in step 1, two second insulating cores obtained in step 1 side by side, the first insulating core obtained in step 2, two second insulating cores obtained in step 1 side by side, the third insulating core obtained in step 1, and 1 steel wire rope obtained in step 3. 5. Wrap a layer of polyester tape around the cable cores arranged in step 4 to form a wrapping layer; 6. The outer sheath material, the first anti-deviation material obtained in Preparation Example 2, and the second anti-deviation material are respectively added to three extruders and extruded simultaneously through three co-extruded films. The outer sheath is wrapped around the wrapping layer and the thickness is controlled at 1.5 mm. The first anti-deviation layer is formed on the upper surface of the flat cable and the thickness is controlled at about 0.8 mm. The second anti-deviation layer is formed on the lower surface of the flat cable and the thickness is controlled at 0.8 mm. After extrusion, the cable is cooled and shaped in a water tank and the surface moisture is dried with compressed air to obtain a low-deflection flat cable.

[0027] Example 2

[0028] The difference between this embodiment and Embodiment 1 is that the steel wire rope with phosphate film obtained in step 3 is further subjected to mechanical embossing treatment. The specific steps are as follows: The phosphated wire rope is passed through a pair of rolling rollers at a linear speed of 5 m / min. The rolling rollers have diamond knurling on their surfaces, with a tooth depth of 0.2-0.3 mm and a tooth pitch of 0.5 mm. A radial pressure of 100 N is applied to form continuous diamond-shaped indentations on the surface of the wire rope.

[0029] The subsequent preparation method is the same as steps 4-6 in Example 1.

[0030] Example 3

[0031] The difference between this embodiment and Embodiment 1 is that the steel wire rope with phosphate film obtained in step 3 is further subjected to mechanical embossing treatment. The specific steps are as follows: The phosphated wire rope is passed through a pair of rolling rollers at a linear speed of 5 m / min. The rolling rollers have straight knurled surfaces with a tooth depth of 0.2-0.3 mm and a tooth pitch of 0.5 mm. A radial pressure of 150 N is applied to form continuous annular indentations on the surface of the wire rope.

[0032] The subsequent preparation method is the same as steps 4-6 in Example 1.

[0033] Example 4

[0034] The difference between this embodiment and Embodiment 2 is that the thickness of the anti-deviation layer is different. The thickness of the first anti-deviation layer is 1.0 mm, and the thickness of the second anti-deviation layer is 0.5 mm.

[0035] Comparative Example 1 The difference between this comparative example and Example 1 is that the first and second anti-deviation layers in step 6 are omitted, and only the outer sheath is extruded. The remaining steps are the same as in Example 1.

[0036] Comparative Example 2 The difference between this comparative example and Example 1 is that the wire rope in step 3 is not phosphated, and untreated galvanized wire rope is used directly. The remaining steps are the same as in Example 1.

[0037] Comparative Example 3 This comparative example adopts a conventional circular structure: the cable core is made up of three insulated wire cores twisted together. The specifications of the insulated wire cores are the same as those of the first, second, and third insulated wire cores in Example 1. There is no steel wire rope, no anti-deviation layer, and the outer sheath is a circular extrusion.

[0038] Performance testing 1. Deflection resistance test A 1m long cable sample was placed horizontally and fixed at both ends to a torsion testing machine with a fixing point spacing of 800mm. A reciprocating torsion of ±90° was applied at a torsion frequency of 10 times / minute for 1000 consecutive torsion cycles. After the test, the horizontal offset of the cable centerline relative to the original centerline was measured. Three sets of samples were tested for each example / comparative example, and the average value was taken.

[0039] 2. Peel strength test For the interface between the wire rope and the outer sheath, the wire rope was removed from the finished cable and tested according to GB / T 2790-1995 "Test Method for 180° Peel Strength of Adhesives". The sample width was 10 mm, the peeling speed was 100 mm / min, and the maximum peel force (N) was recorded. The peel strength (N / mm) was obtained by dividing the maximum peel force by the sample width. Each sample was tested 5 times, and the average value was taken.

[0040] 3. Insulation resistance test According to GB / T 5023.2-2008, after immersing in water at 20℃ for 1 hour, apply a DC voltage of 500V and measure the insulation resistance (MΩ·km).

[0041] 4. Withstand voltage test According to GB / T 5023.2-2008, the cable is qualified if it does not break down when immersed in water at 20℃ and an AC voltage of 3kV is applied between the conductor and the water for 5 minutes.

[0042]

[0043] The cable in Example 1 used phosphated steel wire rope and an anti-deflection layer of equal thickness on both sides. Test results showed that the anti-deflection offset was significantly less than that of Comparative Examples 1-3, indicating that the phosphated treatment combined with the anti-deflection layer provided good anti-deflection performance. The peel strength was significantly higher than that of the untreated steel wire rope, indicating that the phosphated film effectively enhanced the bond between the steel wire rope and the outer sheath. Furthermore, the insulation resistance and withstand voltage tests both met the standard requirements, demonstrating that the electrical performance of the cable foundation was not affected in any way.

[0044] Example 2, based on Example 1, further applied a diamond-shaped knurling mechanical embossing treatment to the phosphated wire rope. Compared to Example 1, its resistance to deflection was further reduced, indicating that the mechanical interlocking effect provided by the diamond-shaped indentations enhanced the integrity of the wire rope and the sheath, thus more effectively resisting torsional deflection, without affecting the electrical performance.

[0045] Example 3 also involved mechanical embossing after phosphating, using straight-line knurling and applying greater radial pressure. Its deflection resistance and peel strength were similar to those of Example 2, indicating that both diamond and straight-line embossing effectively improve deflection resistance, and that different patterns have practical value without affecting electrical performance.

[0046] Example 4, based on Example 2, altered the thickness distribution of the anti-deflection layer, thickening the upper surface anti-deflection layer and thinning the lower surface. This resulted in the smallest anti-deflection offset among the tested samples, while achieving the highest peel strength. This demonstrates that the asymmetric anti-deflection structure can further suppress deflection tendencies during bending. Through the asymmetric anti-deflection structure and mechanical embossing, the cable's anti-deflection performance reached the optimal level in all examples, without affecting its basic electrical performance.

[0047] The difference between Comparative Example 1 and Example 1 is that the anti-deflection layer was omitted. Test results show that although the wire rope is still phosphated, its anti-deflection offset is much greater than that of Example 1, and its peel strength is close to that of Example 1, but its anti-deflection effect is affected. This indicates that the combination of the wire rope and the sheath alone is insufficient to effectively suppress deflection, and the presence of the anti-deflection layer is crucial.

[0048] The wire rope used in Comparative Example 2 was not subjected to any surface treatment, retaining only the anti-deflection layer. Its resistance to deflection was second only to Comparative Example 3 among all samples, and its peel strength was extremely low, far less than that of Example 1. Comparing Example 1 and Comparative Example 2, it can be seen that the untreated wire rope has almost no bonding force with the sheath, and even with the presence of the anti-deflection layer, it cannot effectively resist torsion.

[0049] Comparative Example 3 employs a traditional circular cable structure without steel wire rope or anti-deflection layer. It exhibits the highest resistance to deflection, far exceeding all other embodiments and comparative examples. Conventional surface structures are prone to significant deflection under repeated torsion, failing to meet low deflection requirements. This comparative example serves as a baseline reference, illustrating that the flat, symmetrical arrangement, steel wire rope reinforcement, and synergistic effect of the anti-deflection layer described in the technical solution all contribute to resistance to deflection.

[0050] In summary, this invention, through the symmetrical arrangement of steel wire ropes in the cable core, phosphate treatment of the steel wire rope surface, mechanical embossing, and the application of anti-deflection layers of different hardness or thickness on the upper and lower surfaces, enables the cable to maintain a low deflection under repeated torsion conditions, while simultaneously achieving high peel strength between the steel wire ropes and the outer sheath. All embodiments demonstrate stable and reliable anti-deflection performance, and the basic electrical performance indicators remain unaffected. The described technical solution incorporates multiple anti-deflection mechanisms from the inside out, providing a practical low-deflection solution for flat cables in dynamic application scenarios.

[0051] This specific embodiment is merely an explanation of this application and is not intended to limit it. After reading this specification, those skilled in the art can make modifications to this embodiment without contributing any inventive step, but such modifications are protected by patent law as long as they fall within the scope of the claims of this application.

Claims

1. A low-deflection flat cable, comprising a cable core, a sheath, and an outer sheath, characterized in that, The cable core includes a signal unit, two sets of second insulated wire cores, two third insulated wire cores, and two parallel steel wire ropes. The signal unit is formed by twisting two first insulated wire cores together, and a shielding layer is woven around the outside of the signal unit; In the width direction of the cable core, the components are arranged in sequence as follows: one steel wire rope, one third insulated wire core, a group of second insulated wire cores, the signal unit, another group of second insulated wire cores, another third insulated wire core, and another steel wire rope; The surface of the steel wire rope is phosphated and has a textured surface formed by mechanical embossing.

2. The low-deflection flat cable according to claim 1, characterized in that, The raised and recessed patterns formed by the mechanical embossing are either diamond-shaped knurling or straight knurling.

3. The low-deflection flat cable according to claim 1, characterized in that, The upper and lower surfaces of the cable core are respectively provided with a first anti-deviation layer and a second anti-deviation layer. Both the first anti-deviation layer and the second anti-deviation layer are thermoplastic elastomer layers, and the hardness of the first anti-deviation layer is higher than that of the second anti-deviation layer.

4. A low-deflection flat cable according to claim 3, characterized in that, The first anti-deviation layer comprises the following components by weight: 100 parts polyvinyl chloride resin, 25-35 parts dioctyl phthalate, 5-10 parts trioctyl trimellitate, 5-8 parts calcium-zinc composite stabilizer, 10-15 parts calcium carbonate, 0.5-1.0 parts calcium stearate, and 0.5-1.0 parts polyethylene wax. The second anti-deviation layer comprises the following components by weight: 100 parts polyvinyl chloride resin, 50-65 parts dioctyl phthalate, 5-10 parts epoxidized soybean oil, 5-8 parts calcium-zinc composite stabilizer, 5-10 parts calcium carbonate, 0.5-1.0 parts calcium stearate, and 0.5-1.0 parts paraffin wax.

5. A low-deflection flat cable according to claim 1, characterized in that, The first insulated core, the second insulated core, and the third insulated core each include a conductor and an insulating layer extruded over the conductor.

6. A low-deflection flat cable according to claim 5, characterized in that, The insulation layer material of the first insulated wire core comprises the following components by weight: 100 parts high-density polyethylene, 15-25 parts low-density polyethylene, 5-10 parts ethylene-vinyl acetate copolymer, 5-8 parts carbon black masterbatch, 0.2-0.5 parts antioxidant 1076, 0.2-0.5 parts antioxidant DLPT, and 0.5-1.0 parts polyethylene wax.

7. A low-deflection flat cable according to claim 5, characterized in that, The insulation layer material of the second insulated wire core comprises the following components by weight: 100 parts PVC resin, 40-60 parts dioctyl phthalate, 10-20 parts trioctyl trimellitate, 5-8 parts tribasic lead sulfate, 3-5 parts dibasic lead phosphite, 15-25 parts calcium carbonate, 8-12 parts calcined kaolin, 0.5-1.5 parts calcium stearate, 0.5-1.0 parts polyethylene wax, and 0.3-0.8 parts antioxidant 1010.

8. A low-deflection flat cable according to claim 5, characterized in that, The insulation layer material of the third insulated wire core comprises the following components by weight: 100 parts polyvinyl chloride resin, 30-50 parts dioctyl adipate, 5-10 parts epoxidized soybean oil, 6-10 parts calcium-zinc composite stabilizer, 10-20 parts hydrotalcite, 5-8 parts antimony trioxide, 20-30 parts aluminum hydroxide, 1-2 parts calcium stearate, and 0.5-1.5 parts paraffin wax.

9. A low-deflection flat cable according to claim 1, characterized in that, The phosphating solution used in the phosphating treatment contains, by weight: 50-80 parts phosphoric acid, 30-50 parts zinc dihydrogen phosphate, 5-10 parts nickel nitrate, 10-20 parts calcium nitrate, 2-5 parts citric acid, 1-3 parts accelerator, and 800-1000 parts water.

10. A method for manufacturing a low-deflection flat cable according to any one of claims 1-9, characterized in that, Includes the following steps: (1) Prepare insulating layer materials for the first insulated wire core, the second insulated wire core, and the third insulated wire core according to the weight ratios described in claims 6-8; (2) The corresponding insulating layer material obtained in step (1) is extruded over each conductor bundle to form the first insulating core, the second insulating core and the third insulating core; (3) The wire rope is immersed in phosphating solution for phosphating treatment, and after drying, the wire rope is mechanically embossed to form a textured surface on the wire rope. (4) Twist the two first insulated wire cores together to form a signal pair, and braid a shielding layer on the outside of the signal to obtain the signal unit; (5) The first insulated wire core, the second insulated wire core, the third insulated wire core obtained in step (2) and the steel wire rope obtained in step (3) are arranged in the layout described in claim 1 to form a cable core; (6) Prepare a cladding layer outside the cable core; (7) An outer sheath is extruded outside the wrapping layer, and when the low deflection flat cable includes a first anti-deflection layer and a second anti-deflection layer, the first anti-deflection layer and the second anti-deflection layer are extruded simultaneously on the upper and lower surfaces of the cable core, and the low deflection flat cable is obtained by cooling and shaping.

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