A high-durability RF coaxial test lead structure with anti-breaking skin and anti-breaking wire at both ends

Abstract

The application discloses a kind of two-end breakage-proof and wire-breaking-proof high-durability radio frequency coaxial test lead structures, including coaxial cable main body and the radio frequency connector being set to the both ends of coaxial cable main body, coaxial cable main body outside is provided with outer protective sheath, and the integrated gradual stress release buffer structure is arranged in the connecting root of radio frequency connector and coaxial cable main body.The joint end rigid fixed section, middle section conical gradual buffer section and cable end high-elasticity adhesion section of the application are integrally formed, and the three-section structure realizes the continuous stiffness transition from metal joint rigid structure to flexible cable, eliminates the right-angle stress concentration inflection point of joint root, prevents breakage and conductor fracture caused by repeated bending;From structural gradient transition, stress relief, non-damage process, material upgrading, internal buffer filling five dimensions solve radio frequency test line two-end root breakage, broken core, broken shield, parameter drift and other problems.

Description

Technical Field

[0001] This invention belongs to the field of radio frequency coaxial cable structure technology, specifically relating to a high-durability radio frequency coaxial test lead structure that is resistant to both ends of the insulation and breakage. Background Technology

[0002] RF coaxial test leads are core connection devices for RF communication testing, base station debugging, instrument calibration, microwave experiments, and 6G front-end testing. The most significant failure defects in commercially available RF test leads are concentrated at the root of the cable where it connects to the RF connector at both ends.

[0003] The main shortcomings of existing technologies are as follows: 1) Traditional structures are rigid metal connectors for cables. The connectors are rigid metal structures, while the cables are flexible structures. A rigid abrupt change in inflection point is formed at the junction. During testing, repeated bending, twisting, and plugging and unplugging cause stress to be highly concentrated at the root, which can easily cause the sheath to be torn and cracked. 2) Traditional production processes generally use metal crimping teeth to forcibly crimp and fix the shielding layer and outer sheath. The crimping teeth are prone to cutting into the shielding layer and insulation layer, generating hidden micro-cracks. After long-term use, the cracks expand, resulting in broken shields, broken cores, and poor contact. 3) Ordinary PVC sheaths have poor fatigue resistance, and after repeated bending, they age, crack, peel, and expose the threads; 4) Without stress relief transition structure, the bending radius is too small, which makes it very easy to produce dead bends, directly leading to fatigue fracture of internal conductors; 5) The end has no sealing and buffer structure, and water vapor and dust enter the root, which accelerates oxidation and wire breakage, resulting in deterioration of VSWR, abnormal insertion loss and test data drift.

[0004] Existing improvement solutions mostly involve adding simple spring sheaths and thickening the outer sheath, resulting in a simplistic structure that fails to address the root causes of wire breakage and sheath damage from four sources: stress transition, process damage, material fatigue, and structural abrupt changes. This leads to limited improvement in durability and fails to meet the demands of high-frequency, high-precision, and long-life industrial-grade RF testing. Summary of the Invention

[0005] To address the problems in the prior art, the present invention aims to provide a high-durability RF coaxial test lead structure with anti-breakage and anti-fracture properties at both ends, which is suitable for high-frequency precision testing scenarios.

[0006] To achieve the above objectives and technical effects, the technical solution adopted by this invention is as follows: A high-durability radio frequency coaxial test lead structure with anti-penetration and anti-breakage protection at both ends includes a coaxial cable body and radio frequency connectors disposed at both ends of the coaxial cable body. The coaxial cable body is provided with an outer protective sheath, and the root of the connection between the radio frequency connector and the coaxial cable body is provided with an integrated gradient stress release buffer structure.

[0007] Furthermore, the integrated gradient stress relief buffer structure includes a rigid fixing section at the connector end, a tapered gradient buffer section in the middle section, and a high-elasticity bonding section at the cable end arranged in sequence, and the rigid fixing section at the connector end, the tapered gradient buffer section in the middle section, and the high-elasticity bonding section at the cable end are integrally formed.

[0008] Furthermore, the middle section of the tapered gradient buffer segment is provided with a longitudinal wave-like flexible pleated structure that is evenly distributed along the axial direction, and can adapt to bending deformation of ±180°.

[0009] Furthermore, the axial length of the middle section tapered gradient buffer segment is 14-18 mm.

[0010] Furthermore, the axial length of the middle section tapered gradient buffer segment is 15mm.

[0011] Furthermore, the internal cavity of the middle tapered gradient buffer section is filled with flexible silicone-based buffer sealant.

[0012] Furthermore, the coaxial cable body includes a conductor, a shielding layer, and an insulation layer arranged sequentially from the inside out. The conductor is a multi-strand ultra-fine stranded soft copper conductor, and the shielding layer is a high-density flexible braided copper mesh.

[0013] Furthermore, the outer protective sleeve is made of TPU high bending resistance sleeve with a Shore hardness of 85-92A.

[0014] Compared with the prior art, the beneficial effects of the present invention are as follows: The present invention integrates three sections: a rigid fixing section at the connector end, a tapered gradient buffer section in the middle, and a high-elasticity bonding section at the cable end. The three-section structure achieves a continuous stiffness transition from the rigid structure of the metal connector to the flexible cable, eliminates the right-angle stress concentration inflection point at the root of the connector, and prevents the insulation and conductor breakage caused by repeated bending. It solves problems such as insulation breakage, core breakage, shielding breakage, and parameter drift at the root of both ends of the RF test line from five dimensions: structural gradient transition, stress relief, non-destructive process, material upgrade, and internal buffer filling. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the structure of the present invention; Figure 2 This is a schematic diagram of the integrated gradual stress relief buffer structure of the present invention. Detailed Implementation

[0016] The present invention will now be described in detail so that its advantages and features can be more easily understood by those skilled in the art, thereby providing a clearer and more explicit definition of the scope of protection of the present invention.

[0017] The following provides a brief overview of one or more aspects to offer a basic understanding of them. This overview is not an exhaustive summary of all conceived aspects, nor is it intended to identify key or decisive elements of all aspects, nor to define the scope of any or all aspects. Its sole purpose is to present some concepts of one or more aspects in a simplified form to prepare for the more detailed descriptions that follow.

[0018] like Figure 1-2 As shown, this invention discloses a high-durability RF coaxial test lead structure that is resistant to both ends of the wire and prevents breakage. It solves problems such as wire breakage, core breakage, shielding breakage, and parameter drift at the root of the RF test lead from five dimensions: structural gradient transition, stress relief, non-destructive process, material upgrade, and internal buffer filling. This high-durability RF coaxial test lead structure, which is resistant to both ends of the cable and is protected against breakage, includes a coaxial cable body 1 and RF connectors 2 located at both ends of the coaxial cable body 1. The coaxial cable body 1 is equipped with an outer protective sheath 3. The root of the RF connector 2 connected to the coaxial cable body 1 is equipped with an integrated gradient stress relief buffer structure. The integrated gradient stress relief buffer structure includes a rigid fixing section 4 at the connector end, a tapered gradient buffer section 5 in the middle, and a high-elasticity fitting section 6 at the cable end. The three sections are integrally formed, and the three sections achieve a continuous stiffness transition from the rigid structure of the metal connector to the flexible cable, eliminating the right-angle stress concentration inflection point at the root of the connector and preventing the insulation from being damaged and the conductor from breaking due to repeated bending.

[0019] In some embodiments, the coaxial cable body 1 includes a conductor, a shielding layer, and an insulation layer arranged sequentially from the inside out. The conductor is a multi-strand ultra-fine stranded soft copper conductor, and the shielding layer is a high-density flexible braided copper mesh, suitable for high-frequency repeated bending conditions and improving fatigue fracture resistance.

[0020] In some implementations, the RF connector 2 is made using a metal-free crimping tooth integrated injection molding encapsulation process, abandoning the traditional metal rigid crimping fixing method. The shielding layer, insulation layer and conductor joint of the coaxial cable body 1 are wrapped with flexible hot melt plastic, eliminating the hidden cracks caused by compression and preventing the risk of wire breakage and insulation damage caused by the crimping process.

[0021] In some implementations, the outer protective sleeve 3 uses a TPU high-bending-resistance sleeve instead of a traditional PVC sleeve, with a Shore hardness of 85-92A, and has fatigue resistance, abrasion resistance, and low-temperature crack resistance, and the surface is not easily damaged or cracked.

[0022] In some implementations, the middle tapered gradual buffer section 5 is provided with a longitudinal wave-like flexible pleated structure that is evenly distributed along the axial direction. It can adapt to positive and negative 180° bending deformation, forcibly increase the minimum bending radius of the cable, and eliminate dead bend damage.

[0023] In some implementations, the axial length of the middle tapered gradient buffer section 5 is set to 14-18mm, preferably 15mm, which is compatible with all SMA, BNC, N-type, and SMP series RF test connectors.

[0024] In some embodiments, the internal cavity of the middle tapered gradual buffer section 5 is filled with flexible silicone-based buffer sealant, which serves to prevent shock, buffer bending stress, provide waterproof sealing, and prevent fatigue fracture of the internal conductor.

[0025] In some embodiments, the high-durability RF coaxial test lead structure with anti-penetration and anti-breakage at both ends disclosed in this invention requires a pre-stress release process after the finished product is assembled. This process involves repeatedly bending the lead 20 times in both directions to eliminate the pre-stress and prevent short-term natural cracking failure after leaving the factory.

[0026] Example 1

[0027] like Figure 1-2 As shown, a high-durability RF coaxial test lead structure with anti-damage and anti-breakage protection at both ends is proposed. It solves problems such as root damage, core breakage, shield breakage, and parameter drift at both ends of the RF test lead from five dimensions: structural gradient transition, stress relief, non-destructive process, material upgrade, and internal buffer filling. This high-durability RF coaxial test lead structure, which is resistant to both insulation damage and breakage, includes a coaxial cable body 1 and RF connectors 2 located at both ends of the coaxial cable body 1. The coaxial cable body 1 is equipped with an outer protective sheath 3. The RF connectors 2 and the coaxial cable body 1 are connected at their root points with an integrated gradient stress relief buffer structure. The integrated gradient stress relief buffer structure includes a rigid fixing section 4 at the connector end, a tapered gradient buffer section 5 in the middle, and a high-elasticity fitting section 6 at the cable end. The three sections are integrally formed, achieving a continuous stiffness transition from the rigid structure of the metal connector to the flexible cable, eliminating the right-angle stress concentration inflection point at the connector root, and preventing insulation damage and conductor breakage caused by repeated bending.

[0028] The main body 1 of the coaxial cable is a 50Ω high-frequency coaxial cable, comprising a conductor, a shielding layer, and an insulation layer arranged sequentially from the inside out. The conductor uses multi-strand ultra-fine stranded soft copper conductors, and the shielding layer uses a high-density flexible braided copper mesh, suitable for high-frequency repeated bending conditions and improving fatigue fracture resistance.

[0029] The RF connector 2 uses a metal-free crimping tooth integrated injection molding encapsulation process, abandoning the traditional metal rigid crimping fixing method. The shielding layer, insulation layer and conductor joint of the coaxial cable body 1 are wrapped with flexible hot melt plastic, eliminating the hidden cracks caused by compression and eliminating the risk of wire breakage and insulation damage caused by crimping process.

[0030] The outer protective sleeve 3 uses a TPU high-bending sleeve to replace the traditional PVC sleeve. It has a Shore hardness of 90A and has fatigue resistance, abrasion resistance, and low-temperature crack resistance. The surface is not easily damaged or cracked.

[0031] The middle tapered gradient buffer section 5 has six sets of longitudinal wave-like flexible pleated structures evenly distributed along the axial direction, which can adapt to bending deformation of ±180°, forcibly increasing the minimum bending radius of the cable and eliminating dead bend damage. The internal cavity of the middle tapered gradient buffer section 5 is filled with flexible silicone-based buffer sealant.

[0032] The axial length of the 5-section tapered buffer section is 15mm, which is compatible with all SMA, BNC, N-type and SMP series RF test connectors.

[0033] The high-durability RF coaxial test lead structure disclosed in this embodiment, which is resistant to both ends of the insulation and breakage, requires a pre-stress release process after the finished product is assembled. This process involves repeatedly bending the lead 20 times in both directions to eliminate the pre-stress and prevent short-term natural cracking failure after leaving the factory.

[0034] Any parts or structures not specifically described in this invention can be made using existing technologies or products, and will not be elaborated upon here.

[0035] The above description is merely an embodiment of the present invention and does not limit the patent scope of the present invention. Any equivalent structural or procedural transformations made based on the content of the present invention specification, or direct or indirect applications in other related technical fields, are similarly included within the patent protection scope of the present invention.

Claims

1. A high-durability RF coaxial test lead structure with both ends protected against puncture and breakage, characterized in that, It includes a coaxial cable body and radio frequency connectors disposed at both ends of the coaxial cable body. The coaxial cable body is provided with an outer protective sleeve, and the root of the radio frequency connector connected to the coaxial cable body is provided with an integrated gradient stress release buffer structure.

2. The high-durability RF coaxial test lead structure with anti-penetration and anti-breakage protection at both ends as described in claim 1, characterized in that, The integrated gradient stress relief buffer structure includes a rigid fixing section at the connector end, a tapered gradient buffer section in the middle section, and a high-elasticity bonding section at the cable end, arranged in sequence. The rigid fixing section at the connector end, the tapered gradient buffer section in the middle section, and the high-elasticity bonding section at the cable end are integrally formed.

3. The high-durability RF coaxial test lead structure with anti-penetration and anti-breakage protection at both ends as described in claim 2, characterized in that, The middle section of the tapered gradient buffer section is equipped with a longitudinal wave-like flexible pleated structure that is evenly distributed along the axial direction, and can adapt to bending deformation of ±180°.

4. The high-durability RF coaxial test lead structure with anti-penetration and anti-breakage protection at both ends as described in claim 2, characterized in that, The axial length of the middle section tapered gradient buffer segment is 14-18mm.

5. The high-durability RF coaxial test lead structure with anti-penetration and anti-breakage protection at both ends as described in claim 4, characterized in that, The axial length of the middle section tapered gradient buffer segment is 15mm.

6. The high-durability RF coaxial test lead structure with anti-penetration and anti-breakage protection at both ends as described in claim 1, characterized in that, The internal cavity of the middle tapered gradient buffer section is filled with flexible silicone-based buffer sealant.

7. The high-durability RF coaxial test lead structure with anti-penetration and anti-breakage protection at both ends as described in claim 1, characterized in that, The coaxial cable body includes a conductor, an insulation layer, and a shielding layer arranged sequentially from the inside out. The conductor is a multi-strand ultra-fine stranded soft copper conductor, and the shielding layer is a high-density flexible braided copper mesh.

8. The high-durability RF coaxial test lead structure with anti-penetration and anti-breakage protection at both ends as described in claim 1, characterized in that, The outer protective sleeve is made of TPU high bending resistance sleeve with a Shore hardness of 85-92A.

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