STP cable for vehicle-mounted multimedia

Abstract

The utility model relates to a vehicle-mounted multimedia STP cable. The cable comprises two wire cores and two filling ropes which are mutually twisted, an aluminum foil, a drainage wire, a braided shielding layer, a film belt and a sheath layer from inside to outside, each wire core comprises a conductor and an insulating layer wrapping the conductor; each filling rope is formed by twisting a PP rope in a fine net shape; and the drainage wire is formed by twisting a plurality of aluminum coating basalt fibers. And the conductor is formed by twisting seven strands of fine copper-tin alloy wires with the diameter of 0.15-0.16 mm, the twisting direction is S, and the pitch diameter ratio is controlled to be 13-15. The insulation layer is made of PP materials, the structure of the insulation layer is skin-foam-skin, the inner layer of the insulation layer is foamed PP, the thickness of the insulation layer is controlled to be 0.17-0.20 mm, the insulation outer diameter is 1.8-1.9 mm, and the insulation concentricity is larger than 95%. The STP cable for the vehicle-mounted multimedia provided by the utility model has the advantages of high speed, high reliability and low loss.

Description

Technical Field

[0001] This utility model belongs to the technical field of cables, specifically referring to an STP cable for vehicle multimedia. Background Technology

[0002] With the rapid development of automotive electronics technology, the communication needs between various systems within a vehicle are increasing, and the operating environment for wiring is becoming more complex. Traditional automotive communication cables can no longer meet the demands for high-performance, high-speed, and high-reliability communication. Smart cockpits require support for multi-screen interaction and high-definition audio and video transmission, placing stringent requirements on signal integrity.

[0003] Traditional cables have the following defects: 1. They are prone to breakage when frequently bent (bending life < 30,000 times); 2. Traditional shielding structures cannot meet the protection requirements of strong electromagnetic interference (EMC) in vehicles (shielding effectiveness < 50dB); 3. The temperature resistance of the sheath material is insufficient (the working temperature of conventional PVC sheaths is ≤ 85℃).

[0004] The current market demand is that automobiles have a great need for STP cables that are flexible (bending resistance > 100,000 times), highly reliable (operating temperature -40℃ to 125℃), and highly resistant to interference (EMC > 50dB).

[0005] Therefore, developing a new high-composite STP cable for automobiles is of great significance for improving the performance and stability of in-vehicle communication systems. Utility Model Content

[0006] The technical problem to be solved by this utility model is to provide a high-speed, high-reliability, and low-loss STP cable for vehicle multimedia.

[0007] This utility model is implemented as follows:

[0008] An STP cable for vehicle multimedia includes, from the inside out: two twisted cores and two filler ropes, aluminum foil, drain wire, braided shielding layer, film tape, and sheath layer;

[0009] Each of the said wire cores includes: a conductor and an insulating layer wrapped around the conductor; the conductor is composed of 7 strands of fine copper-tin alloy wire with a diameter of 0.15-0.16mm twisted together, with the twisting direction S and the pitch ratio controlled at 13-15;

[0010] Each of the aforementioned filler ropes is a fine mesh twisted PP rope;

[0011] The drainage line is composed of 2964 strands of 10μm monofilament aluminum-coated basalt fibers twisted together, with an outer diameter of 0.65mm after twisting.

[0012] Furthermore, the insulating layer is made of PP material with a structure of skin-foam-skin, the inner layer is foamed PP, the thickness of the insulating layer is controlled at 0.17-0.20mm, the outer diameter of the insulating layer is 1.8-1.9mm, and the concentricity of the insulating layer is >95%.

[0013] Furthermore, the braided shielding layer is made of tin-plated copper metal.

[0014] Furthermore, the sheath layer is made of polyurethane (TPU) material, with a thickness controlled at 0.6-0.8 mm, an outer diameter of 5.6-6.0 mm, and a concentricity of >85%.

[0015] The advantages of this utility model are:

[0016] 1. Compared to traditional STP 100BASE-T1 cables, it has superior transmission performance and still maintains excellent transmission performance after high-strength composite torsional bending test (>100,000 times).

[0017] 2. The use of AluCoat aluminum-coated basalt fiber multi-strand stranded structure as the lead wire improves the transmission stability and flexibility of the cable. Compared with traditional copper conductors of the same cross-section, the weight is reduced by about 45%, and the cost is reduced by 90%.

[0018] 3. The cable's anti-electromagnetic interference capability is enhanced by using a double-layer aluminum foil + tin-plated copper metal braid + AluCoat aluminum-coated basalt fiber multi-strand strand structure as the drain wire.

[0019] 4. By adopting a PP tape insulation layer structure, the integrity and stability of the cable structure are effectively guaranteed, thereby ensuring the communication transmission capability of the cable and the stable operation of the vehicle.

[0020] 5. By using flame-retardant and weather-resistant TPU material as the sheath layer, it can operate normally in a high-temperature environment of 125 degrees Celsius, and protect the cable from external environmental damage, thereby improving the cable's service life and safety, and enhancing the safety and reliability of the vehicle. Attached Figure Description

[0021] The present invention will now be further described with reference to the accompanying drawings and embodiments.

[0022] Figure 1 This is a cross-sectional view of the cable of this utility model.

[0023] Figure 2 This is a cross-sectional view of the mold used in the weaving process of this utility model.

[0024] Figure 3 This is an EMC comparison diagram of a conventional STP cable and the STP cable of this invention (the left side is the conventional STP cable, and the right side is the STP cable of this invention).

[0025] Figure 4 This is a comparison chart of the attenuation performance of the STP cable before and after the bending test (the left side shows the attenuation performance before bending, and the right side shows the attenuation performance after bending).

[0026] Figure 5 This is a comparison chart of the EMC performance of the STP cable before and after the bending test (the left side shows the EMC performance before bending, and the right side shows the EMC performance after bending). Attached image description:

[0028] 1-Wire core, 11-Conductor, 12-Insulation layer, 3-Aluminum foil, 4-Drain wire, 5-Braided shielding layer, 6-Sheath layer, 100-Braiding mold, 101-Cylindrical channel. Detailed Implementation

[0029] like Figure 1 As shown, an STP cable for vehicle multimedia includes, from the inside out: two twisted cores 1 and two filler ropes 2, aluminum foil 3, drain wire 4, braided shielding layer 5, film tape (not shown), and sheath layer 6.

[0030] Each wire core 1 includes: a conductor 11 and an insulation layer 12 wrapped around the conductor 11; the conductor 11 is made of 7 strands of fine copper-tin alloy wire with a diameter of 0.15-0.16mm twisted together, and the insulation layer 12 is made of PP material with a structure of skin-foam-skin, the inner layer being foamed PP, the insulation layer thickness being controlled at 0.17-0.20mm, the insulation outer diameter being 1.8-1.9mm, and the insulation concentricity being >95%;

[0031] Each filler rope has 2 strands, which are PP ropes with a fine mesh twist;

[0032] Aluminum foil 3 is a double-layer aluminum foil processed by wrapping, with a width of 14mm and a thickness of 0.04mm;

[0033] Drainage line 4 is composed of 2964 strands of 10μm monofilament aluminum-coated basalt fibers twisted together, with an outer diameter of 0.65mm after twisting.

[0034] The braided shielding layer 5 is made by adding multiple stranded basalt fiber guide wires 4 with aluminum coating during the braiding process. The guide wires 4 are added by using an external wire feeding frame of the braiding machine to ensure that the guide wires 4 are located between the aluminum foil 3 and the braided shielding layer 5.

[0035] A single-sided adhesive film strip made of PP material is used to cover the braided shielding layer 5, with the adhesive side facing outwards. When the sheath is extruded, the adhesive will melt and cause the film strip to stick to the sheath. In this embodiment, the film strip is made of PP polypropylene, but it can also be made of polyester.

[0036] Sheath layer 6 is made of polyurethane (TPU) material, with a thickness controlled at 0.6-0.8 mm, an outer diameter of 5.6-6.0 mm, and a concentricity of >85%.

[0037] The above-mentioned method for manufacturing an STP cable for vehicle multimedia includes the following steps:

[0038] Conductor 11 is formed by twisting together 7 fine copper-tin alloy wires with a diameter of 0.15-0.16mm, with the twisting direction being S and the pitch ratio controlled at 13-15.

[0039] An insulating layer 12 is extruded over the conductor 11 to form the wire core 1;

[0040] Two wire cores 1 and two PP filler ropes 2 are twisted together. The PP filler ropes are fine mesh twisted and the outer diameter is controlled at 1.5mm. The twisting direction is S and the twisting pitch ratio is 7-10.

[0041] Double-layer aluminum foil 3 is processed by wrapping. The aluminum foil 3 has a width of 14mm and a thickness of 0.04mm.

[0042] Tin-plated copper braid: A 16 / 9 / 0.1mm structure with a pitch of 20±0.5mm is used. During the braiding process, multiple strands of aluminum-coated basalt fiber are added as guide wires 4. Guide wire 4 consists of 2964 strands of 10μm monofilaments, with an outer diameter of 0.65mm. The guide wires are added using an external feeding frame on the braiding machine to ensure the guide layer is located between the aluminum foil 3 and the braided shielding layer 5. During processing, due to the large difference in tensile strength between the wire core and the AluCoat aluminum-coated basalt fiber, it is difficult to process and shape using the same wire-passing method, and the wire core structure is not easily stable. Therefore, the process mold 100 needs to be optimized and improved by adding a cylindrical channel 101 for the guide wires to ensure the wire core is stable and round, maintaining stable performance under bending and environmental electromagnetic interference. During processing, the guide wires 4 must be placed and passed through the cylindrical channel 101. The mold is as follows... Figure 2 As shown;

[0043] A single-sided adhesive PP film tape is used to cover the braided shielding layer 5, with the adhesive side facing outwards. The required dimensions are: thickness: 0.020-0.023mm, width: 20mm, and wrapping pitch: 16. The PP tape is too large for the conductor and is difficult to process and shape. Wrapping can effectively cover the conductor core.

[0044] Extruded sheath layer 6, thickness controlled at 0.6-0.8mm, outer diameter 5.6-6.0mm, concentricity >85%; the adhesive melts during sheath extrusion, causing the strapping tape to stick to the sheath.

[0045] This utility model discloses a high-composite flexible STP communication cable for automobiles. By optimizing the structure and materials of the conductor, insulation layer, filler layer, shielding layer, current-guiding layer, isolation layer, and sheath layer, it achieves high-speed, high-reliability, and low-loss communication performance. Simultaneously, the cable also possesses excellent flexibility, abrasion resistance, and high-temperature resistance, enabling it to adapt to the complex working environment and varied installation conditions inside automobiles.

[0046] Table 1 shows a technical comparison between aluminum-coated basalt fiber material (referred to as AluCoat in the table) and traditional copper wire:

[0047] Table 1:

[0048]

[0049] The key properties of aluminum-coated basalt fiber materials are shown in Table 2:

[0050] Table 2:

[0051]

[0052] It is evident that using aluminum-coated basalt fiber as the drainage wire has significant advantages over traditional copper wire.

[0053] like Figure 3 As shown, the conventional STP 100BASE-T1 communication cable has an EMC of approximately 45dB, while this high-performance STP 100BASE-T1 communication cable has an EMC of approximately 60dB.

[0054] Figure 4 and Figure 5 The test data shown demonstrates that the high-performance STP communication cable of this invention has superior transmission performance compared to the traditional STP 100BASE-T1 cable, and still maintains excellent transmission performance after a high-strength composite torsional bending test (>100,000 times).

[0055] This utility model's high-performance STP communication cable improves transmission stability and flexibility by using high-foaming, low-dielectric-constant PP material as insulation, double PP rope filling, and AluCoat aluminum-coated basalt fiber multi-strand stranded structure as the lead wire.

[0056] AluCoat aluminum-coated basalt fiber stranded conductor leads are approximately 45% lighter and 90% cheaper than traditional copper conductors of the same cross-section.

[0057] The double-layer aluminum foil + tin-plated copper braid + AluCoat aluminum-coated basalt fiber multi-strand stranded conductor conductor enhances the cable's resistance to electromagnetic interference.

[0058] By adopting a PP tape insulation layer structure, the integrity and stability of the cable structure are effectively guaranteed, thereby ensuring the communication transmission capability of the cable and the stable operation of the vehicle.

[0059] By using flame-retardant and weather-resistant TPU material as the sheath layer, the cable can operate normally in a high-temperature environment of 125 degrees Celsius, and protects the cable from external environmental damage, thereby improving the cable's service life and safety, and enhancing the safety and reliability of the vehicle.

[0060] The above embodiments and figures are not intended to limit the product form and style of this utility model. Any appropriate changes or modifications made by those skilled in the art should be considered as not departing from the patent scope of this utility model.

Claims

1. An STP cable for in-vehicle multimedia, characterized by: It comprises two twisted core wires and two filling ropes, aluminum foil, drainage wire, braided shielding layer, film tape and sheath layer from inside to outside. Each of the core wires comprises a conductor and an insulating layer wrapped outside the conductor; the conductor is composed of seven strands of fine copper-tin alloy wires with a diameter of 0.15-0.16 mm twisted together, the twisting direction S, and the pitch ratio control 13-15. Each of the filling ropes is a fine mesh twisted PP rope. The drainage wire is composed of 2964 strands of 10 μm monofilament bundle aluminum-coated basalt fibers twisted together, and the outer diameter of the bundle wire after twisting is 0.65 mm.

2. The STP cable for vehicle multimedia according to claim 1, characterized in that: The insulating layer is made of PP material, with a structure of skin-bubble-skin, the inner layer being foamed PP, the insulating layer thickness being controlled within 0.17-0.20 mm, the insulating outer diameter being 1.8-1.9 mm, and the insulating concentricity being > 95%.

3. The STP cable for vehicle multimedia as described in claim 1, characterized in that: The braided shielding layer is made of tin-plated copper metal.

4. The STP cable for vehicle multimedia of claim 1, wherein: The sheath layer is made of polyurethane TPU material, with a thickness controlled within 0.6-0.8 mm, an outer diameter of 5.6-6.0 mm, and a concentricity of > 85%.

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