Cable for intelligent system control signal

Abstract

The utility model relates to the technical field of cables, and provides a cable for intelligent system control signals. The problems of signal distortion, easy damage of a sheath and environmental hidden dangers of halogen-containing materials of a traditional cable in a complex electromagnetic environment are solved. According to the main scheme, the cable comprises at least two twisted-pair groups, and each twisted-pair group is formed by twisting two cable cores in pairs; each wire core comprises a superfine bare copper wire conductor (1), a 125 DEG C cross-linked polyolefin insulating layer (2) wrapping the conductor, and a PET wrapping tape (3) wrapping the insulating layer; a braided copper wire shielding layer (4) and a wrapping PET layer (5) are sequentially wrapped outside each twisted pair group; the two groups are twisted to form a cable, then the cable is filled with a flame-retardant halogen-free material (6), and an aluminum-plastic composite belt shielding layer (7) and a PUR sheath (8) are sequentially coated on the outer layer.

Description

Technical Field

[0001] This utility model relates to the field of cable technology and provides a cable for control signals in intelligent systems. Background Technology

[0002] With the rapid development of industrial automation, smart homes, intelligent transportation, aerospace, and new energy, intelligent systems are placing higher demands on the reliability, speed, anti-interference capabilities, and data integrity of signal transmission. Especially in complex electromagnetic environments, high-frequency data transmission, and long-distance transmission scenarios, the shortcomings of traditional signal cables in terms of corrosion resistance, flexibility, and anti-interference performance are becoming increasingly apparent, becoming a key bottleneck restricting the improvement of intelligent system performance.

[0003] Currently, the research and development of control signal cables for intelligent systems both domestically and internationally mainly focuses on material improvement and structural optimization. Advanced foreign technologies, through high-speed data transmission cables, high-shielding effectiveness designs, and materials adapted to special environments, have to some extent met the high-performance requirements. For example, while cross-linked polyethylene (XLPE) as the insulation layer possesses excellent electrical properties and heat resistance, its sheath material has poor abrasion resistance, oil resistance, and acid and alkali corrosion resistance, making it difficult to cope with humid, low-temperature, or corrosive environments. Furthermore, traditional cables often employ a single-layer metal shielding structure (such as steel wire or steel tape), which is prone to signal distortion and attenuation in environments with strong electromagnetic interference or high-frequency noise. Additionally, rigid sheath materials (such as PVC) result in insufficient cable flexibility, easily leading to sheath cracking and core damage during installation or frequent bending.

[0004] Although domestic technology has made some progress in cable conductor materials and manufacturing processes, the following technical shortcomings still exist:

[0005] (1) Traditional XLPE sheathed cables have insufficient weather resistance and are prone to aging when exposed to harsh environments for a long time, resulting in a decline in insulation performance;

[0006] (2) The single-layer shielding structure and rigid core design make it difficult to balance anti-interference performance and flexibility, especially in narrow spaces or dynamic cable laying scenarios, which can easily lead to unstable signal transmission.

[0007] (3) Halogen-containing sheath materials release toxic gases when burned, posing environmental and safety hazards. These problems severely limit the application of cables in high-end intelligent equipment, new energy equipment and other fields.

[0008] To address the aforementioned issues, existing technologies attempt to optimize the cable by improving sheath materials or increasing the number of shielding layers. However, this often leads to increased cable weight, higher costs, or increased processing complexity. For example, while multi-layered metal braided shielding can improve anti-interference capabilities, it significantly reduces cable flexibility. Conversely, introducing high-performance sheath materials such as fluoroplastics improves corrosion resistance, but their high cost and complex molding processes make them unsuitable for large-scale production. Therefore, there is an urgent need for a cable structure design that combines high flexibility, multi-layered shielding effectiveness, environmental corrosion resistance, and environmental friendliness to meet the high standards of signal transmission required by intelligent systems.

[0009] Based on the aforementioned technical pain points, this patent proposes a novel cable for intelligent system control signals through innovative material combinations and structural design, aiming to break through the limitations of traditional technologies and provide efficient and reliable basic component support for intelligent equipment manufacturing. Utility Model Content

[0010] The present invention aims to provide an environmentally friendly intelligent system control signal cable that combines high flexibility, corrosion resistance, wear resistance and double-layer electromagnetic shielding structure, in order to solve the problems of signal distortion, sheath damage and environmental hazards of halogen-containing materials in traditional cables in complex electromagnetic environments.

[0011] To achieve the above objectives, the present invention employs the following technical means:

[0012] This utility model provides a cable for control signals in an intelligent system, comprising:

[0013] At least two sets of twisted pairs, each set of twisted pairs is formed by twisting two wire cores together;

[0014] Each of the wire cores includes an ultra-fine bare copper wire conductor, a 125°C cross-linked polyolefin insulation layer covering the conductor, and a PET wrapping tape covering the insulation layer;

[0015] Each pair of twisted pairs is sequentially covered with a braided copper wire shielding layer and a PET wrapping layer;

[0016] After the two sets of twisted pairs are formed into a cable, they are filled with flame-retardant halogen-free material, and the outer layer is successively covered with an aluminum-plastic composite tape shielding layer and a PUR sheath.

[0017] The cable forms a double-layer electromagnetic shielding structure through the braided copper wire shielding layer and the aluminum-plastic composite tape shielding layer, and achieves corrosion resistance, wear resistance and high flexibility through the PUR sheath.

[0018] In the above scheme, the ultra-fine bare copper wire conductor adopts the Class 5 copper conductor standard, the conductor diameter ranges from 0.08mm to 0.15mm, and the conductor stranding pitch is no more than 8-12 times the conductor diameter.

[0019] In the above scheme, the braided copper wire shielding layer (4) has a braiding density of ≥85% and a copper wire diameter of ≤0.10mm; the aluminum layer thickness of the aluminum-plastic composite tape shielding layer is 6-12μm and the PET layer thickness is 25-50μm.

[0020] To address the shortcomings of the aforementioned traditional technologies, this patent achieves the following technical benefits: wear and corrosion resistance, high flexibility, multi-layer shielding, and environmental friendliness (halogen-free).

[0021] 1. Compared with conventional XLPE sheathed power cables, this patent achieves a long cable life and improves oil resistance, abrasion resistance and corrosion resistance in low temperature and harsh environments.

[0022] 2. Using PUR material as the sheath increases the cable's relative flexibility, solving the problem that traditional cables are difficult to bend or twist in limited situations.

[0023] 3. The cable employs a double-layer shielding system consisting of one layer of braided copper wire shielding and one layer of aluminum-plastic composite tape shielding, which greatly enhances the cable's anti-interference capability and makes it more stable in transmitting electrical signals. Attached Figure Description

[0024] Figure 1 This is a structural diagram of the present utility model. Detailed Implementation

[0025] The embodiments of this utility model will be described in detail below. Although this utility model will be described and illustrated in conjunction with some specific embodiments, it should be noted that this utility model is not limited to these embodiments. On the contrary, any modifications or equivalent substitutions made to this utility model should be covered within the scope of the claims of this utility model.

[0026] Furthermore, to better illustrate this invention, numerous specific details are provided in the following detailed embodiments. Those skilled in the art will understand that this invention can be implemented without these specific details.

[0027] Example 1: Implementation of the basic structure

[0028] like Figure 1 As shown, this embodiment provides a cable for control signals in an intelligent system, and its specific structure includes the following components in order from the inside out:

[0029] 1. Core structure:

[0030] Each conductor consists of an ultra-fine bare copper wire conductor 1, which conforms to the Class 5 copper conductor standard, with a conductor diameter of 0.10 mm and a stranding pitch controlled to be 10 times the conductor diameter (i.e., 1.0 mm). The conductor surface is covered with a 125℃ cross-linked polyolefin insulation layer 2, with an insulation layer thickness of 0.6 mm, to ensure electrical insulation performance.

[0031] A PET strap 3 with a thickness of 0.05mm is tightly wrapped around the outside of the insulation layer to fix the insulation layer and initially enhance the anti-interference ability.

[0032] 2. Twisted pair structure:

[0033] Twist the two aforementioned wire cores together with a twist pitch of 8 times the wire core diameter to form a twisted pair.

[0034] The following structures are sequentially wrapped around the outer layer of the twisted pair:

[0035] Braided copper wire shielding layer 4: Braided with tin-plated copper wire with a diameter of 0.08mm and a braiding density of 88%, forming the first layer of electromagnetic shielding.

[0036] PET wrapping layer 5: 0.08mm thick, used to fix the shielding layer and isolate subsequent structures.

[0037] 3. Cable-making structure:

[0038] Two sets of twisted pairs are concentrically twisted into a cable with a twisting pitch 14 times the outer diameter of the cable. The gaps between the cables are filled with flame-retardant halogen-free material 6, which is a magnesium hydroxide / aluminum hydroxide composite material with a filling density ≥95%, ensuring flame retardancy and environmental friendliness.

[0039] After cabling is completed, the outer layers are wrapped sequentially:

[0040] Aluminum-plastic composite tape shielding layer 7: The aluminum layer is 8μm thick and the PET layer is 30μm thick. The second shielding layer is formed by longitudinal overlapping (overlap rate ≥25%).

[0041] PUR sheath (8): 1.2mm thick, made of thermoplastic polyurethane (Shore hardness 85A), coated by extrusion process, giving the cable oil resistance, wear resistance and high flexibility.

[0042] Example 2: Parameter Optimization Implementation

[0043] Based on Example 1, the key parameters of this utility model have been optimized:

[0044] Conductor design: The diameter of the ultra-fine bare copper wire conductor 1 is adjusted to 0.15mm, and the stranding pitch is 8 times the conductor diameter (i.e. 1.2mm), further improving flexibility.

[0045] Shielding layer collaborative design:

[0046] The braided copper wire shielding layer uses copper wires with a diameter of 0.06mm and a braiding density of 90%, which enhances the shielding effectiveness against high-frequency interference.

[0047] The aluminum-plastic composite tape shielding layer 7 has an increased aluminum layer thickness of 12μm and a PET layer thickness of 50μm, which improves the shielding effect of low-frequency electric fields.

[0048] The beneficial effects of this utility model are reflected in its multi-dimensional improvements addressing the shortcomings of existing technologies, and in achieving performance enhancement through material combination and structural innovation:

[0049] 1. Significantly enhanced corrosion resistance and wear resistance

[0050] Compared to traditional XLPE sheathed cables, which are susceptible to oil, acid and alkali corrosion, and mechanical wear, this invention uses a PUR (polyurethane) sheath layer. Its molecular structure gives the cable excellent chemical corrosion resistance and surface abrasion resistance, making it particularly suitable for harsh environments such as damp and oily conditions. It also avoids the safety hazards of releasing toxic gases when traditional halogen-containing materials burn. 14 .

[0051] 2. High flexibility while meeting dynamic cable deployment requirements

[0052] By optimizing the design of ultra-fine bare copper wire conductors and stranding pitch, combined with the high elasticity of the PUR sheath, the overall flexibility of the cable is significantly improved, solving the problem of easy cracking of traditional rigid sheaths in confined spaces or frequent bending scenarios. It is particularly suitable for dynamic wiring scenarios such as robotic arms and mobile devices.

[0053] 3. Double-layer shielding collaborative anti-interference mechanism

[0054] The dual composite structure of braided copper wire shielding layer and aluminum-plastic composite tape shielding layer is adopted. Through the synergistic effect of electromagnetic induction shielding (copper wire braiding layer) and electric field shielding (aluminum-plastic layer), the shielding effectiveness of single-layer shielding under high-frequency electromagnetic interference is overcome, ensuring the integrity of signal transmission in complex electromagnetic environments.

[0055] 4. Comprehensive improvement in environmental protection and safety performance

[0056] The combined design of flame-retardant halogen-free filler material and full-structure halogen-free material not only meets the flame-retardant requirements, but also completely eliminates the toxic gases produced by the combustion of halogen-containing materials, which meets green and environmental protection standards and solves the problem of secondary hazards of traditional cables in fire scenarios.

[0057] 5. Flexible design of the shielding layer

[0058] The braided copper wire shielding layer uses fine copper wires with a diameter ≤0.10mm and controls the braiding density to ≥85%. The fine diameter copper wires significantly reduce the rigidity of the shielding layer while ensuring conductivity, while the high-density braiding prevents the copper wires from loosening and shifting through tight twisting, thereby maintaining structural stability when bending.

[0059] The aluminum layer of the aluminum-plastic composite tape shielding layer is only 6-12μm thick. Combined with the flexibility of the PET layer (25-50μm), it significantly reduces the thickness and rigidity compared to traditional steel tape shielding, allowing the layer to bend synchronously with the sheath after cabling.

[0060] 6. Structural layout optimization

[0061] The double-layer shielding acts separately on the outer layer of the twisted pair (braided copper wire layer) and the outer layer after cabling (aluminum-plastic composite tape layer), reducing the thickness of a single layer through layered shielding. This design avoids the rigid superposition effect between layers in traditional multi-layer shielding, allowing each shielding layer to deform independently when the cable bends, reducing structural resistance.

Claims

1. An intelligent system control signal cable, characterized by, The application relates to a cable, which comprises: at least two groups of paired-strands, each group of paired-strands being formed by two wire cores in a paired-strand mode; each wire core comprising a superfine bare copper wire conductor (1), a 125 DEG C cross-linked polyolefin insulation layer (2) covering the conductor, and a PET tape (3) covering the insulation layer; a braided copper wire shielding layer (4) and a wrapped PET layer (5) are sequentially covered outside each group of paired-strands; after two groups of paired-strands are combined into a cable, a flame-retardant halogen-free material (6) is filled, and an aluminum-plastic composite tape shielding layer (7) and a PUR sheath (8) are sequentially covered outside.

2. The intelligent system control signal cable according to claim 1, characterized in that: The superfine bare copper wire conductor (1) adopts a 5-class copper conductor standard, the conductor diameter ranges from 0.08 mm to 0.15 mm, and the conductor stranding pitch is not greater than 8-12 times of the conductor diameter.

3. The cable of claim 1, wherein, The braided copper wire shielding layer (4) has a braiding density of greater than or equal to 85% and a copper wire diameter of less than or equal to 0.10 mm; the aluminum-plastic composite tape shielding layer (7) has an aluminum layer thickness of 6-12 mu m and a PET layer thickness of 25-50 mu m.

4. The intelligent system control signal cable of claim 1, wherein: The 125 DEG C cross-linked polyolefin insulation layer (2) has a thickness of 0.6 mm.

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