Anti-interference environment-resistant high-reliability computer cable

Abstract

This invention relates to the field of wire and cable technology, and in particular to a high-reliability computer cable with anti-interference and environmental resistance. From the inside out, it comprises a conductor, an insulation layer, a composite inner shielding layer, a sub-shielding layer, a filling layer, a double-layer overall shielding layer, an isolation sleeve, and a sheath layer. The composite inner shielding layer is composed of a copper foil wrapping layer and a highly conductive non-woven fabric, heat-pressed together. The copper foil thickness is 0.02-0.05 mm, with a wrapping overlap rate ≥30%. A 0.03-0.06 mm layer of highly conductive non-woven fabric is bonded to the outside to compensate for high-frequency shielding failure due to gaps in the copper foil wrapping, achieving 100% continuity of the inner shielding conductivity. This invention overcomes the conventional bias in non-woven fabric applications through a composite inner shielding layer, compensating for high-frequency leakage from copper foil gaps. Combined with sub-shielding and double-layer overall shielding, it achieves crosstalk suppression capability ≥75 dB, effectively isolating EMI / RFI interference and core crosstalk; transmission delay ≤100 μs / 100 m, supporting transmission speeds above 40 Gbps, meeting real-time control requirements.

Description

Technical Field

[0001] This invention relates to the field of wire and cable technology, and in particular to a high-reliability computer cable that is resistant to interference and environmental conditions. Background Technology

[0002] Computer cables, as the core carrier of data transmission in electronic equipment and automated systems, are widely used in industrial control, data centers, rail transportation, precision instruments, and other fields. Their transmission performance and environmental adaptability directly determine the stability of system operation. With the development of Industry 4.0 and big data technologies, equipment places higher demands on cables for interference resistance, high and low temperature resistance, high bandwidth, and long lifespan. However, existing computer cables suffer from multiple technical defects, and the industry has two major technical biases, resulting in the inability to meet the needs of high-end scenarios: Existing cables mostly use single shielding or simple double shielding, which cannot effectively isolate EMI and RFI interference. The industry generally believes that conductive non-woven fabric is only a conventional isolation pad, without shielding compensation, and is only used as an auxiliary setting. At the same time, it is believed that high braid density shielding will reduce cable flexibility. Therefore, the shielding layer design is conservative, and the crosstalk suppression capability is only ≤60dB. It cannot solve the high-frequency shielding leakage problem caused by the gap of copper foil wrapping. Crosstalk is serious when digital / analog signals are mixed.

[0003] Traditional cables use ordinary polyethylene and polyvinyl chloride for insulation and sheathing, which can only withstand temperatures from -20℃ to 85℃. They are prone to brittleness at low temperatures and aging at high temperatures. It is generally believed in the industry that wide-temperature materials are incompatible with high-transmission materials. Waterproof, rodent-proof, flame-retardant, and corrosion-resistant properties are difficult to achieve simultaneously. They are easily damaged, damp, or eaten by rodents in humid, outdoor, underground, and oily environments, and have a service life of less than 8 years.

[0004] Ordinary copper wire has low conductivity and high resistance loss, resulting in a long-distance transmission rate of ≤25Gbps and a transmission delay of ≥200μs / 100m. The dielectric constant of the insulation layer is unstable, and high-frequency signals are severely attenuated, which cannot meet the requirements of 40Gbps high bandwidth and microsecond-level real-time control.

[0005] Poor interlayer bonding in cables makes the shielding layer prone to detachment under bending and vibration; poor flame retardancy results in toxic fumes during combustion; imported high-performance cables are expensive, while ordinary cables fail to meet performance standards, creating an industry problem of "high performance, high cost; low cost, low performance".

[0006] In summary, existing technologies only address single problems and do not form a systematic solution. They cannot simultaneously meet the collaborative requirements of anti-interference, environmental resistance, high transmission, high reliability, and low cost, thus becoming a technical bottleneck that urgently needs to be overcome in this field. Summary of the Invention

[0007] The purpose of this invention is to overcome the limitations of existing technologies that only address single problems without forming a systematic solution, and thus cannot simultaneously meet the collaborative requirements of anti-interference, environmental resistance, high transmission, high reliability, and low cost.

[0008] The technical solution adopted by this invention to solve its technical problem is: an anti-interference, environmentally resistant, and highly reliable computer cable, which, from the inside out, includes a conductor, an insulation layer, a composite inner shielding layer, a sub-shielding layer, a filling layer, a double-layer total shielding layer, an isolation sleeve, and a sheath layer. The composite inner shielding layer is composed of a copper foil wrapping layer and a highly conductive non-woven fabric hot-pressed together. The copper foil thickness is 0.02-0.05mm, the wrapping overlap rate is ≥30%, and the outer side is bonded with 0.03-0.06mm of highly conductive non-woven fabric to compensate for the high-frequency shielding failure of the copper foil wrapping gaps, achieving 100% conductivity continuity of the inner shielding. The conductor is made of high-purity annealed copper wire with a purity of ≥99.99% stranded together, with a conductivity of ≥102% IACS. The stranding pitch is 10-12 times the outer diameter of the conductor. The surface is coated with a compound antioxidant with a thickness of 0.01-0.03mm. The antioxidant is a compound of benzotriazole and magnesium stearate in a weight ratio of 1:0.3-0.5. The insulating layer is formed in one step using a three-layer co-extrusion process with nano-modified polyolefin material, and has a thickness of 0.5-1.2 mm and a dielectric constant fluctuation of ≤ ±0.05. The sub-shielding layer is woven from tin-plated copper wire with a weaving density of ≥90% and a weaving pitch of 8-10 times the outer diameter of the sub-shielding layer. The double-layer total shielding layer is a double-layer structure consisting of an inner aluminum-plastic composite tape wrapping and an outer silver-plated copper wire braiding. The aluminum-plastic composite tape wrapping overlap rate is ≥40%, and the silver-plated copper wire braiding density is ≥95%. The composite inner shielding layer, the sub-shielding layer, and the double-layer total shielding layer form a four-layer collaborative shielding structure with a crosstalk suppression capability of ≥75dB. The filling layer is a flame-retardant and waterproof filling rope woven from glass fiber and nitrogen-phosphorus flame retardant, with a filling density of ≥95%, and the surface is coated with a compound waterproofing agent with a thickness of 0.02-0.04mm. The waterproofing agent is a compound of polysiloxane and zeolite powder in a weight ratio of 1:0.8-1.2. The isolation sleeve is made of cross-linked polyethylene material with 0.5-1.0% anti-aging agent and 0.3-0.6% UV stabilizer added, and has a thickness of 0.8-1.5 mm; The sheath layer is made of nano-ceramic composite flame-retardant material with a thickness of 1.0-1.8mm, and is tightly bonded to the isolation sleeve through a low-temperature plasma treatment process; The cable as a whole achieves stable operation at -40℃ to +125℃, transmission delay ≤100μs / 100m, transmission rate ≥40Gbps, and service life ≥15 years.

[0009] The copper foil of the composite inner shielding layer is bonded to the highly conductive nonwoven fabric using a hot-pressing process, with a peel strength ≥5N / cm, to prevent the nonwoven fabric from loosening and causing shielding failure.

[0010] The stranding pitch of the conductor is a customized design for digital / analog mixed transmission scenarios, which can reduce crosstalk between wire pairs by more than 40%.

[0011] The four-layer collaborative shielding structure can simultaneously isolate external EMI / RFI interference and signal crosstalk between wire cores, making it suitable for industrial high-interference scenarios.

[0012] The nano-modified polyolefin material of the insulating layer comprises, by weight: 160-180 parts of polyethylene, 20-45 parts of polyisobutylene, 22-30 parts of polyvinylidene fluoride-vinylidene fluoride copolymer, 12-18 parts of modified vinyl chloride-vinyl acetate copolymer, and 20-31 parts of modified glass fiber.

[0013] The anti-aging agent of the isolation sleeve is 2,2'-methylenebis, and the anti-ultraviolet agent is 2-hydroxy-4-methoxybenzophenone.

[0014] The nano-ceramic composite flame-retardant material of the sheath layer comprises, by weight: 150-170 parts of polyethylene, 15-25 parts of nano-ceramic powder, 10-18 parts of flame retardant compounded with nitrogen-phosphorus flame retardant and magnesium hydroxide in a 2:1 ratio, 3-5 parts of rodent repellent, and 2-4 parts of termite repellent.

[0015] The ant repellent is a compound of lorividide, tricyclazole, and acetamiprid in a weight ratio of 1:1.6:0.22; the rodent repellent is a compound of lorividide, vanillin nonanoic acid, acetamiprid, and dextrorotatory trans-cypermethrin in a weight ratio of 1:0.2:0.15:0.3.

[0016] The signal attenuation of the cable is ≤5% within 200 meters, and the bending radius is not less than 6 times the outer diameter of the cable.

[0017] The cable's flame retardant performance meets the EN45545-2 standard, its waterproof rating reaches IP68, and its combustion smoke toxicity is 1 / 5 of the national standard.

[0018] The beneficial effects of this invention are: (1) The present invention breaks through the conventional non-woven fabric application bias by using a composite inner shielding layer to compensate for high frequency leakage in copper foil gaps. Combined with sub-shielding and double-layer total shielding, the crosstalk suppression capability is ≥75dB, effectively isolating EMI / RFI interference and wire core crosstalk; the transmission delay is ≤100μs / 100m, supporting transmission above 40Gbps, and meeting the real-time control requirements.

[0019] (2) Nano-modified insulation + anti-aging isolation sleeve + ceramic flame-retardant sheath, achieving stable operation over a wide temperature range of -40℃ to +125℃, solving the problems of low-temperature brittleness and high-temperature aging of traditional cables; waterproof rating IP68, with rodent and ant protection, corrosion resistance and wear resistance, suitable for humid, outdoor, underground and oily complex environments.

[0020] (3) The conductor stranding pitch, shielding density and material ratio are all customized designs for high-end scenarios, rather than conventional choices in this field; long-distance signal attenuation ≤5%, stable characteristic impedance, solving the problems of high attenuation and low bandwidth of traditional cables.

[0021] (4) Three-layer co-extrusion + low-temperature plasma process, with tight interlayer bonding, bending radius ≥ 6 times outer diameter, and shielding layer does not fall off under vibration conditions; meets EN45545-2 fire protection standard, service life ≥ 15 years; conventional raw materials, simple process, cost is reduced by more than 40% compared with imported similar products, and large-scale production is highly feasible.

[0022] (5) This invention is not a feature stacking, but rather overcomes industry technical biases through the systematic synergy of structure, materials and processes, and solves the industry problem that it is impossible to simultaneously achieve anti-interference, environmental resistance, high transmission, high reliability and low cost, thus demonstrating significant technological progress. Attached Figure Description

[0023] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0024] Figure 1 This is a schematic diagram of the cross-sectional structure of a computer cable in an embodiment of the present invention.

[0025] In the diagram: 1-Conductor, 2-Insulation layer, 3-Inner shielding layer, 4-Sub-shielding layer, 5-Filling layer, 6-Total shielding layer, 7-Isolation sleeve, 8-Sheath layer. Detailed Implementation

[0026] The present invention will now be described in further detail with reference to the accompanying drawings. These drawings are simplified schematic diagrams, illustrating only the basic structure of the invention, and therefore only show the components relevant to the invention.

[0027] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "connected" and "linked" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0028] Example 1, such as Figure 1As shown, the cable consists of conductor 1, insulation layer 2, composite inner shielding layer 3, sub-shielding layer 4, filling layer 5, double-layer total shielding layer 6, isolation sleeve 7, and sheath layer 8 from the inside out.

[0029] Conductor 1: 99.99% pure annealed copper wire, conductivity 102% IACS, stranding pitch is 10 times the conductor outer diameter, surface coated with 0.01mm compound antioxidant (benzotriazole: magnesium stearate = 1:0.3).

[0030] Insulation layer 2: Nano-modified polyolefin three-layer co-extrusion, thickness 0.5mm, dielectric constant fluctuation ≤±0.05.

[0031] Composite inner shielding layer 3: 0.02mm copper foil wrapping (overlap rate 30%) + 0.03mm highly conductive non-woven fabric to compensate for shielding gaps.

[0032] Sub-shielding layer 4: tin-plated copper wire braid, density 90%, pitch is 8 times the outer diameter of the sub-shielding layer.

[0033] Double-layer total shielding layer 6: Aluminum-plastic composite tape wrapping (overlap rate 40%) + silver-plated copper wire braiding (density 95%).

[0034] Filler layer 5: Flame-retardant and waterproof filler rope, with a filling density of 95%, and a 0.02mm thick compound waterproofing agent (polysiloxane: zeolite powder = 1:0.8) on the surface.

[0035] Isolation sleeve 7: Cross-linked polyethylene, 0.8mm thick, with 0.5% anti-aging agent and 0.3% UV stabilizer added.

[0036] Sheath layer 8: Nano-ceramic composite flame retardant material, 1.0mm thick, combined with low-temperature plasma process and isolation sleeve.

[0037] Example 2, Conductor 1: 99.99% pure annealed copper wire, conductivity 103% IACS, stranding pitch 11 times outer diameter, antioxidant thickness 0.02mm (ratio 1:0.4).

[0038] Insulation layer 2: 0.8mm thick, three-layer co-extruded.

[0039] Composite inner shielding layer 3: 0.035mm copper foil + 0.045mm non-woven fabric, with an overlap rate of 35%.

[0040] Shielding layer 4: Weaving density 92%, pitch 9 times outer diameter.

[0041] Double-layer total shielding layer 6: wrapping overlap rate 45%, braiding density 97%.

[0042] Filler layer 5: Filler density 97%, waterproofing agent thickness 0.03mm (mixing ratio 1:1.0).

[0043] Isolation sleeve 7: 1.2mm thick, 0.8% anti-aging agent, 0.45% UV protectant.

[0044] Sheath layer 8: 1.4mm thick, 20 parts of nano-ceramic powder.

[0045] Example 3, Conductor 1: 99.99% pure annealed copper wire, conductivity 104% IACS, stranding pitch 12 times outer diameter, antioxidant thickness 0.03mm (ratio 1:0.5).

[0046] Insulation layer 2: 1.2mm thick, three layers co-extruded.

[0047] Composite inner shielding layer 3: 0.05mm copper foil + 0.06mm non-woven fabric, with an overlap rate of 40%.

[0048] Shielding layer 4: Weaving density 95%, pitch 10 times outer diameter.

[0049] Double-layer total shielding layer 6: wrapping overlap rate 50%, braiding density 98%.

[0050] Filler layer 5: Filler density 98%, waterproofing agent thickness 0.04mm (mixing ratio 1:1.2).

[0051] Isolation sleeve 7: 1.5mm thick, 1.0% anti-aging agent, 0.6% UV protectant.

[0052] Sheath layer 8: 1.8mm thick, 25 parts of nano-ceramic powder.

[0053] Performance testing and comparative experiments (demonstrating unexpected technical effects) The test results of Embodiment 2 of the present invention, compared with conventional computer cables and high-end imported cables in the industry, are as follows: .

[0054] Test conclusion: This invention, through systematic innovation of four-layer synergistic shielding, customized material modification, and integrated process, produces unexpected technical effects. Its performance is superior to that of conventional cables, and its cost is far lower than that of imported products. It overcomes industry technical biases and has outstanding substantive features and significant progress.

[0055] It should be noted that the proportions of raw materials and process parameters in this invention can be appropriately adjusted according to actual usage requirements. As long as the technical effects of this invention can be achieved, they fall within the scope of protection of this invention. Furthermore, this invention does not involve improvements to software or methods, but only to the structure and materials of the cable, thus meeting the protection requirements of an invention patent.

Claims

1. A high-reliability computer cable with anti-interference and environmental resistance, comprising, from the inside out, a conductor (1), an insulation layer (2), a composite inner shielding layer (3), a sub-shielding layer (4), a filling layer (5), a double-layer overall shielding layer (6), an isolation sleeve (7), and a sheath layer (8), characterized in that: The composite inner shielding layer (3) is composed of a copper foil wrapping layer and a high-conductivity nonwoven fabric hot-pressed composite. The copper foil thickness is 0.02-0.05mm and the wrapping overlap rate is ≥30%. The outer side is bonded with 0.03-0.06mm of high-conductivity nonwoven fabric to compensate for the high-frequency shielding failure of the copper foil wrapping gap and achieve 100% conductivity continuity of the inner shielding. The conductor (1) is made of high-purity annealed copper wire with a purity of ≥99.99% stranded together, with a conductivity of ≥102% IACS. The stranding pitch is 10-12 times the outer diameter of the conductor. The surface is coated with a compound antioxidant with a thickness of 0.01-0.03mm. The antioxidant is a compound of benzotriazole and magnesium stearate in a weight ratio of 1:0.3-0.

5. The insulating layer (2) is formed in one step using a three-layer co-extrusion process with nano-modified polyolefin material, with a thickness of 0.5-1.2 mm and a dielectric constant fluctuation of ≤ ±0.

05. The sub-shielding layer (4) is woven from tin-plated copper wire with a weaving density of ≥90% and a weaving pitch of 8-10 times the outer diameter of the sub-shielding layer. The double-layer total shielding layer (6) is a double-layer structure consisting of an inner aluminum-plastic composite tape wrapping and an outer silver-plated copper wire braiding. The aluminum-plastic composite tape wrapping overlap rate is ≥40%, and the silver-plated copper wire braiding density is ≥95%. The composite inner shielding layer (3), the sub-shielding layer (4), and the double-layer total shielding layer (6) form a four-layer cooperative shielding structure with a crosstalk suppression capability of ≥75dB. The filling layer (5) is a flame-retardant and waterproof filling rope woven from glass fiber and nitrogen-phosphorus flame retardant, with a filling density of ≥95%, and the surface is coated with a compound waterproofing agent with a thickness of 0.02-0.04mm. The waterproofing agent is a compound of polysiloxane and zeolite powder in a weight ratio of 1:0.8-1.

2. The isolation sleeve (7) is made of cross-linked polyethylene material with 0.5-1.0% anti-aging agent and 0.3-0.6% anti-ultraviolet agent added, and has a thickness of 0.8-1.5 mm; The sheath layer (8) is made of nano-ceramic composite flame retardant material with a thickness of 1.0-1.8 mm, and is tightly bonded to the isolation sleeve (7) through a low-temperature plasma treatment process; The cable as a whole achieves stable operation at -40℃ to +125℃, transmission delay ≤100μs / 100m, transmission rate ≥40Gbps, and service life ≥15 years.

2. The computer cable according to claim 1, characterized in that, The copper foil of the composite inner shielding layer (3) is bonded to the highly conductive nonwoven fabric using a hot-pressing bonding process, with a peel strength ≥5N / cm, to prevent the nonwoven fabric from becoming loose and causing shielding failure.

3. The computer cable according to claim 1, characterized in that, The stranding pitch of the conductor (1) is a customized design for digital / analog mixed transmission scenarios, which can reduce crosstalk between wire pairs by more than 40%.

4. The computer cable according to claim 1, characterized in that, The four-layer collaborative shielding structure can simultaneously isolate external EMI / RFI interference and signal crosstalk between wire cores, making it suitable for industrial high-interference scenarios.

5. The computer cable according to claim 1, characterized in that, The nano-modified polyolefin material of the insulating layer (2) includes, by weight: 160-180 parts of polyethylene, 20-45 parts of polyisobutylene, 22-30 parts of polyvinyl chloride-vinylidene fluoride copolymer, 12-18 parts of modified vinyl chloride-vinyl acetate copolymer, and 20-31 parts of modified glass fiber.

6. The computer cable according to claim 1, characterized in that, The anti-aging agent of the isolation sleeve (7) is 2,2'-methylenebis, and the anti-ultraviolet agent is 2-hydroxy-4-methoxybenzophenone.

7. The computer cable according to claim 1, characterized in that, The nano-ceramic composite flame retardant material of the sheath layer (8) includes, by weight: 150-170 parts of polyethylene, 15-25 parts of nano-ceramic powder, 10-18 parts of flame retardant compounded with nitrogen-phosphorus flame retardant and magnesium hydroxide in a ratio of 2:1, 3-5 parts of rodent repellent, and 2-4 parts of ant repellent.

8. The computer cable according to claim 7, characterized in that, The ant repellent is a compound of lorividide, tricyclazole, and acetamiprid in a weight ratio of 1:1.6:0.22; the rodent repellent is a compound of lorividide, vanillin nonanoic acid, acetamiprid, and dextrorotatory trans-cypermethrin in a weight ratio of 1:0.2:0.15:0.

3.

9. The computer cable according to claim 1, characterized in that, The signal attenuation of the cable is ≤5% within 200 meters, and the bending radius is not less than 6 times the outer diameter of the cable.

10. The computer cable according to claim 1, characterized in that, The cable's flame retardant performance meets the EN45545-2 standard, its waterproof rating reaches IP68, and its combustion smoke toxicity is 1 / 5 of the national standard.

Images