UTP cable for vehicle sliding door

Abstract

The utility model provides a UTP cable of a vehicle sliding door. The UTP cable sequentially comprises twisted pair wire cores, a filling layer, a polyester belt and a sheath from inside to outside. Each wire core comprises a conductor and an insulating layer wrapping the periphery of the conductor; the conductor is formed by twisting 19 strands of wires; each strand of lead is formed by twisting seven aluminum coating basalt fibers with the diameter of 23 microns; the insulating layer is made of a PP material; and the sheath is made of a modified TPE-S material. And the filling layer is made of 500D NY (Nitrogen Yarn) wires or Kevlar (Kevlar). The diameter of the conductor is 0.13 mm < 2 >. The UTP cable provided by the utility model has the characteristics of high tensile strength, bending resistance and reciprocating motion resistance.

Description

Technical Field

[0001] This utility model belongs to the technical field of automotive cables, specifically referring to a UTP cable for automotive sliding doors. Background Technology

[0002] Automotive Ethernet is an in-vehicle communication network technology designed to meet the high bandwidth and low latency requirements of intelligent vehicles. It is gradually replacing traditional CAN / LIN buses and has been widely applied in complex scenarios such as autonomous driving, advanced driver assistance systems, smart cockpits, and OTA upgrades. In high-end new energy MPV models, such as the Denza D9, Dongfeng Voyah Dreamer, and Jihu Koala, more human-machine interaction and autonomous driving functions, such as LiDAR, cameras, and millimeter-wave radar, are embedded in the sliding doors.

[0003] When traditional vehicle-mounted UTP cables (unshielded twisted pair cables) are applied to the sliding door application scenario in high-end new energy MPV models, problems such as loss of lidar function, black screen on the sliding door display, loss of millimeter-wave radar function, and interruption of human-machine interaction occur after on-vehicle testing.

[0004] Traditional automotive Ethernet cable structures, such as Figure 1 and Figure 2 As shown, UTP cables for sliding doors consist of a conductor, insulation, twisted wire pairs, polyester tape, and an outer extruded sheath. They suffer from poor conductor flexibility, bending resistance, and durability. After hundreds of thousands or even millions of reciprocating cycles, the central conductor may break, causing the entire sliding door system to lose its functionality and posing a significant safety hazard to the driver and passengers. Therefore, UTP cables for sliding doors must not only meet the requirements of high bandwidth, low latency, and real-time control, but also withstand high and low temperature environments, while simultaneously meeting the special operating conditions of high durability, high strength torsion and bending, and repeated cable carrier operations. Utility Model Content

[0005] The technical problem to be solved by this utility model is to provide a UTP cable for automotive sliding doors and its manufacturing method. The UTP cable has the characteristics of high tensile strength, bending resistance and reciprocating motion resistance.

[0006] This utility model is implemented as follows:

[0007] A UTP cable for a vehicle sliding door comprises, from the inside out: twisted pair cores, filler layer, polyester tape, and sheath;

[0008] Each of the said wire cores includes: a conductor, and an insulating layer surrounding the conductor;

[0009] The conductor is made of aluminum-coated basalt fiber stranded together;

[0010] The insulating layer is made of PP material.

[0011] The sheath is made of modified TPE-S material.

[0012] Furthermore, the conductor is made of 19 strands of wire twisted together; each strand of the wire is made of 7 aluminum-coated basalt fibers with a diameter of 23μm twisted together.

[0013] Furthermore, the filling layer is made of 500D NY yarn or Kevlar.

[0014] Furthermore, the diameter of the conductor is 0.13 mm. 2 .

[0015] The advantages of this utility model are:

[0016] 1. Increase the stability of UTP in sliding doors: First, the design of the conductor material, structure and stranding method is improved, which greatly increases the flexibility and tensile strength of the wire after stranding, making the conductor more flexible and stronger overall, suitable for scenarios with reciprocating movement and bending.

[0017] 2. Improved Signal Transmission Quality: During the core twisting process, the twisting is first de-twisted to remove the reaction force between the cores. Simultaneously, high-strength 500DNY wire or Kevlar filler rope is added to both sides of the cores, making the twisted cores more rounded and enhancing their overall tensile strength. Even after millions of bends and reciprocating motions, it maintains good communication performance, thus ensuring signal transmission stability.

[0018] 3. Improved cable structural stability: The TPE-S sheath protects the cable from physical damage and chemical corrosion, increasing its stability and reliability.

[0019] In summary, the UTP cable for vehicle sliding doors of this utility model overcomes the shortcomings of traditional sliding door UTP data cables by adjusting the original data transmission unit to a more flexible combination and using high tensile strength Kevlar and TPE-S sheaths. It also achieves advantages such as stable signal transmission and improved cable stability and reliability under reciprocating motion conditions. Attached Figure Description

[0020] The present invention will now be further described with reference to the accompanying drawings and embodiments.

[0021] Figure 1This is a schematic diagram of the existing UTP cable structure.

[0022] Figure 2 yes Figure 1 Cross-sectional view.

[0023] Figure 3 This is a cross-sectional view of the UTP cable of this utility model.

[0024] Figure 4 This is a cross-sectional view of the conductor in this utility model.

[0025] Figure 5 This is a comparison chart of the characteristic impedance of a conventional UTP cable and the automotive UTP cable of this invention in a high-frequency test report after a cyclic bending test (the left side is the conventional UTP cable, and the right side is the UTP cable of this invention).

[0026] Figure 6 This is a comparison chart of return loss in high-frequency test reports after cyclic bending tests of conventional UTP cables and the automotive UTP cables of this invention (the left side is the conventional UTP cable, and the right side is the UTP cable of this invention).

[0027] Figure 7 This is a comparison chart of the longitudinal transmission loss (LCL) in the high-frequency test report after the cyclic bending test of conventional UTP cable and the UTP cable for vehicles of this utility model (the left side is the conventional UTP cable, and the right side is the UTP cable of this utility model).

[0028] Figure 8 This is a comparison chart of the longitudinal transmission conversion loss (LCTL) in the high-frequency test report after the cyclic bending test of conventional UTP cable and the automotive UTP cable of this utility model (the left side is the conventional UTP cable, and the right side is the UTP cable of this utility model).

[0029] Figure 9 This is a comparison chart of attenuation in high-frequency test reports after cyclic bending tests of conventional UTP cables and the UTP cables for vehicles of this invention (the left side is the conventional UTP cable, and the right side is the UTP cable of this invention).

[0030] Figure label:

[0031] 1-Core wire, 11-Conductor, 12-Insulation layer, 2-Filling layer, 3-Polyester tape, 4-Sheath. Detailed Implementation

[0032] The technical solution of the present invention will now be clearly and completely described in conjunction with the accompanying drawings and specific embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0033] A UTP cable for automotive sliding doors, such as Figure 3 As shown, from the inside out, it includes: twisted pair core 1, filler layer 2, polyester tape 3, and sheath 4.

[0034] The wire core 1 includes: a conductor 11 and an insulating layer 12 surrounding the conductor 11;

[0035] Conductor 11, such as Figure 4 As shown, it is composed of 19 strands of wire twisted together in a 1+6+12 arrangement; each strand of wire is composed of 7 aluminum-coated basalt fibers with a diameter of 23μm twisted together; conductor 11 has a diameter of 0.13mm. 2 (This is one embodiment. In practice, other parameter combinations can be used to prepare the conductor as needed. As long as it is an aluminum-coated basalt fiber stranded conductor, it falls within the scope of protection of this utility model.)

[0036] The insulating layer 12 is made of low dielectric constant PP material, which has a certain tensile strength and must meet the requirements of communication transmission performance.

[0037] The filler layer 2 uses a high tensile strength filler material, such as 500D NY wire or Kvilar, to increase the overall tensile strength of the cable.

[0038] Polyester tape 3, with specifications of 0.02*10mm, has an overlap rate of 25% to 30%.

[0039] Sheath 4 is made of flame-retardant TPE-S material with low dielectric constant, which is an elastomer material with high flexibility, low temperature flexibility and wear resistance.

[0040] The UTP structure for a vehicle sliding door of this utility model has a thickness of 0.13mm. 2 Conductor 11 is made of AluCoat aluminum-coated basalt fiber stranded using a parallel stranding process, ensuring that each aluminum-coated basalt fiber conductor experiences consistent stress, forming a stable structure. Insulation layer 12 uses low-dielectric-constant PP material for its core, providing sufficient tensile strength while meeting communication transmission performance requirements. The core pairs are twisted using a pre-untwisted twisting machine, with high-tensile-strength filler material, such as 500D NY wire or Kvilar, added during twisting, and then stranded with a small pitch. Sheath 4 uses low-dielectric-constant flame-retardant TPE-S material, an elastomer material with high flexibility, low-temperature flexibility, and abrasion resistance. This material possesses characteristics such as low-temperature flexibility, low dielectric constant, and flame retardancy, effectively protecting the cable.

[0041] The conductor of this invention adopts an AluCoat aluminum-coated basalt fiber multi-strand stranded structure, possessing excellent conductivity. This material has a high tensile strength of 480 MPa and exhibits characteristics such as bending resistance, abrasion resistance, and reciprocating motion resistance. The insulation material uses PP with a high dielectric constant, and the sheath material uses TPE-S sheath material with a low dielectric constant and high flexibility, and Kevlar filler rope material is used, which can withstand more than 5 million reciprocating motions of car door opening and closing. During the core wire stranding process, a small twisting pitch is used, and multiple high tensile strength nylon filaments are added to increase the overall tensile strength of the wire and the roundness of the stranded core wire, giving the entire cable high flexibility and tensile strength. It meets the characteristics of automotive cables such as high and low temperature resistance, flame retardancy, vibration, and high-intensity reciprocating motion resistance. This structure takes into account the communication requirements of UTP cables while possessing high reliability, and can adapt to the bending and mechanical stress caused by repeated opening and closing of sliding doors, reducing cable wear and even failure caused by long-term movement.

[0042] Table 1 compares the technologies of aluminum-coated basalt fiber (simplified as AluCoat in the table) and traditional copper foil:

[0043] Comparison Dimensions AluCoat Traditional copper foil Density (g / cm3) 2.7 8.9 Shielding effectiveness (dB) 80 60 Cost (€ / kg) 5-15 80-120 Processability Woven, injection molded, 3D printed Planar machining only Corrosion resistance Aluminum oxide film provides heat protection against corrosion. Easily oxidized and discolored

[0044] Table 2 shows the key performance characteristics of aluminum-coated basalt fiber:

[0045]

[0046] Table 3 is a comparison table of the results of conventional UTP cables and the UTP cables for vehicles of this utility model after cyclic bending tests.

[0047]

[0048] Figures 5 to 9 The graph shows a comparison of high-frequency tests of conventional UTP cables and the UTP cable of this invention after a cyclic bending test. It can be seen that after the conventional UTP cable undergoes cyclic bending, the time domain impedance, return loss, longitudinal transmission loss (LCL) & longitudinal transmission conversion loss (LCTL), and attenuation all show abnormal graphs, failing to meet the communication performance requirements.

[0049] This utility model of a UTP cable for vehicle sliding doors overcomes the shortcomings of traditional sliding door UTP data cables by adjusting the original data transmission unit to a more flexible combination and using high tensile strength Kevlar and TPE-S sheaths. It also achieves advantages such as stable signal transmission and improved cable stability and reliability under reciprocating motion conditions.

[0050] 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. A UTP cable for a sliding door of a vehicle, characterized in that: From inside to outside, it includes twisted cores, a filling layer, a polyester tape and a sheath in sequence; Each of the cores comprises a conductor and an insulating layer wrapped around the conductor; The conductor is twisted by aluminum-coated basalt fibers; The insulating layer is made of PP material; The sheath is made of modified TPE-S material.

2. A UTP cable for a sliding door of a vehicle as defined in claim 1, characterized in that: The conductor is twisted by 19 wires; each of the wires is twisted by 7 aluminum-coated basalt fibers with a diameter of 23 μm.

3. A UTP cable for a sliding door of a vehicle as defined in claim 1, characterized in that: The filling layer is made of 500D NY yarn or Kevlar.

4. A UTP cable for a sliding door of a vehicle as defined in claim 1, characterized in that: The diameter of the conductor is 0.13 mm 2 .

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