High-performance vehicle-mounted Ethernet cable

Abstract

The utility model discloses a high-performance vehicle-mounted Ethernet cable, which comprises a conductor, the conductor is formed by twisting a plurality of monofilaments, each monofilament is of a sandwich structure, the sandwich structure comprises a core layer, a transition layer and an outer cladding, the core layer is made of copper-graphene eutectic composite materials, the transition layer is made of copper / graphene nanosheets, and the outer cladding is made of copper; the insulating layer coats the outer layer of the conductor to form a wire core, and the insulating layer is made of a modified PTFE material; the two wire cores are twisted to form a twisted wire; the outer layer of the stranded wire is sequentially coated with a shielding layer and a sheath layer; the shielding layer is graphene aerogel, the thickness is 1 mm, and the width is 10 mm; the sheath layer is made of a polyurethane material, the outer diameter is 3.6-4.0 mm, and the concentricity is greater than 85%. The communication performance of the communication cable can exceed that of a traditional STP communication cable, and the communication cable has good electrical performance and mechanical performance.

Description

Technical Field

[0001] This utility model relates to the field of cable manufacturing, specifically to a high-performance vehicle Ethernet cable. Background Technology

[0002] Currently widely used Ethernet cables (such as the Cat 5e to Cat 8 series) are gradually revealing multi-dimensional technical bottlenecks when supporting high-speed data transmission and complex application scenarios. Specifically, these bottlenecks manifest in the following core issues: First, due to the skin effect, when the operating frequency exceeds 6 GHz, the skin depth of the current shrinks drastically to only 1 micrometer. This characteristic directly leads to a significant increase in transmission loss. Experimental data shows that at an operating frequency of 10 GHz, the signal loss exceeds 8 dB / m, severely affecting the reliable transmission of high-frequency signals. Second, under vibration conditions, relative slippage easily occurs at grain boundaries within the conductor material. Tests according to the ISO 16750-3 standard show that this change in microstructure causes significant fluctuations in conductor resistance, with variations exceeding 5%, making it difficult to meet the stable electrical performance requirements of precision electronic equipment. Third, while current metal braided layers have good initial shielding effectiveness, their shielding performance will decrease by up to 30% during repeated bending and use (after 500 cycles); while flexible polymer shielding materials have excellent mechanical reliability, their electromagnetic shielding performance in the high-frequency band is difficult to meet the needs of practical applications, forming a technical dilemma. Summary of the Invention

[0003] The technical problem to be solved by this utility model is to provide a high-performance vehicle Ethernet cable.

[0004] This utility model is implemented as follows: A high-performance vehicle-mounted Ethernet cable includes: a conductor, which is formed by twisting multiple monofilaments, each monofilament having a sandwich structure, the sandwich structure including a core layer, a transition layer, and an outer sheath layer, wherein the core layer is a copper-graphene eutectic composite material, the transition layer is a copper / graphene nanosheet, and the outer sheath layer is copper; an insulation layer, which covers the outer layer of the conductor and forms a wire core, and the insulation layer is a modified PTFE material; two wire cores are twisted together to form a stranded wire; the stranded wire is sequentially covered with a shielding layer and a sheath layer; the shielding layer is graphene aerogel with a thickness of 1 mm and a width of 10 mm; the sheath layer is polyurethane material with an outer diameter of 3.6-4.0 mm and a concentricity greater than 85%.

[0005] Furthermore, the conductor is composed of seven strands of 0.15-0.16 mm diameter monofilaments twisted together, with a wire diameter of 0.25 mm. The thickness of the transition layer is 2-5 μm, and the thickness of the outer cladding layer is 10 μm.

[0006] Furthermore, the insulating layer is a foamed insulating layer with a "skin-foam-skin" structure and a thickness of 0.35-0.41 mm.

[0007] The advantages of this invention are as follows: it achieves ultra-low high-frequency loss, with an attenuation value of only 2.8 dB / m at 10 GHz, a 44% reduction compared to the industry standard (≤5 dB / m); it possesses excellent vibration resistance, with a vibration test ΔR of 0.8%, only 27% of the industry limit (≤3%), and exhibits ultra-stable electrical characteristics under 50 Hz vibration conditions; it has strong mechanical durability, with a bending life exceeding 105,000 cycles, far exceeding the industry requirement of more than 30,000 cycles. This invention significantly surpasses industry standards in all key performance indicators, possessing high performance, high stability, and high durability, and can meet the needs of various complex and demanding application scenarios. Attached Figure Description

[0008] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0009] Figure 1 This is a diagram of the internal structure of this utility model;

[0010] Figure 2 This is a schematic diagram of the cross-sectional structure of this utility model.

[0011] Among them: 100, cable; 1, conductor; 2, insulation layer; 3, shielding layer; 4, sheath layer. Detailed Implementation

[0012] Please see Figure 1 and Figure 2As shown, a high-performance automotive Ethernet cable 100 includes: a conductor 1, which is composed of seven strands of 0.15-0.16 mm diameter monofilaments twisted together. Each monofilament has a sandwich structure, comprising a core layer, a transition layer, and an outer sheath. The core layer is a copper-graphene eutectic composite material, which is formed into grains smaller than 100 nm through spark plasma sintering (SPS) to suppress high-frequency grain boundary scattering. The transition layer consists of gradient-distributed copper / graphene nanosheets with a thickness of 2-5 μm. The outer sheath is made of copper with a laser-processed microgroove array on its surface, having a depth-to-width ratio of 1:3 to release bending stress. The outer sheath is 10 μm thick. The conductor 1 has a wire diameter of 0.25 mm. An insulation layer 2 is also included, which covers the conductor. 1. An outer layer forms the wire core, and the insulation layer 2 is made of modified PTFE material with a "skin-foam-skin" structure. The core layer is foamed, the insulation layer thickness is controlled at 0.35-0.41mm, the foaming degree is about 20%, and the insulation concentricity is greater than 95%. Graphene quantum dot arrays (spacing λ / 4, where λ is the target frequency wavelength) can also be embedded in the modified PTFE. In the 10-40GHz frequency range, the characteristic impedance fluctuation can be controlled within ±2Ω, significantly improving performance compared to the ±5Ω fluctuation range of traditional technologies. Two wire cores are twisted together to form a stranded wire with a twist ratio of 7-10. The outer layer of the stranded wire is successively covered with a shielding layer 3 and a sheath layer 4. The shielding layer 3 is graphene aerogel with a density of 0.05-0.1g / cm³. 3 Furthermore, the pores are filled with a thermally responsive silicone oil / carbon nanotube mixture, which can restore more than 95% of the shielding effectiveness after bending damage and heating at 80°C for 10 minutes (test frequency: 26.5GHz); in addition, when the compression ratio reaches 20%, its surface resistivity exhibits excellent performance, with a value as low as ≤0.5Ω / sq, and the shielding layer has a thickness of 1mm and a width of 10mm; the sheath layer 4 is made of polyurethane material, with an outer diameter of 3.6-4.0mm and a concentricity of >85%.

[0013] The advantages of this invention are as follows: it achieves ultra-low high-frequency loss, with an attenuation value of only 2.8 dB / m at 10 GHz, a 44% reduction compared to the industry standard (≤5 dB / m); it possesses excellent vibration resistance, with a vibration test ΔR of 0.8%, only 27% of the industry limit (≤3%), and exhibits ultra-stable electrical characteristics under 50 Hz vibration conditions; it has strong mechanical durability, with a bending life exceeding 105,000 cycles, far exceeding the industry requirement of more than 30,000 cycles. This invention significantly surpasses industry standards in all key performance indicators, possessing high performance, high stability, and high durability, and can meet the needs of various complex and demanding application scenarios.

[0014] While specific embodiments of the present invention have been described above, those skilled in the art should understand that the specific embodiments described are merely illustrative and not intended to limit the scope of the present invention. Equivalent modifications and variations made by those skilled in the art in accordance with the spirit of the present invention should be covered within the scope of protection of the claims of the present invention.

Claims

1. A high-performance automotive Ethernet cable, characterized in that: include: A conductor, wherein the conductor is formed by twisting together multiple monofilaments, each monofilament having a sandwich structure, the sandwich structure comprising a core layer, a transition layer and an outer cladding layer, the core layer being a copper-graphene eutectic composite material, the transition layer being a copper / graphene nanosheet, and the outer cladding layer being copper; An insulating layer, which covers the outer layer of the conductor and forms a wire core, wherein the insulating layer is a modified PTFE material; The two core wires are twisted together to form a stranded wire; The outer layer of the stranded wire is sequentially covered with a shielding layer and a sheath layer; The shielding layer is graphene aerogel, and the thickness of the shielding layer is 1 mm and the width is 10 mm. The sheath layer is made of polyurethane material, with an outer diameter of 3.6-4.0 mm and a concentricity greater than 85%.

2. The high-performance automotive Ethernet cable as described in claim 1, characterized in that: The conductor is made of seven strands of 0.15-0.16 mm diameter monofilaments twisted together, with a wire diameter of 0.25 mm. The thickness of the transition layer is 2-5 μm, and the thickness of the outer cladding layer is 10 μm.

3. The high-performance automotive Ethernet cable as described in claim 1, characterized in that: The insulation layer is a foamed insulation layer with a structure of "skin-foam-skin" and a thickness of 0.35-0.41 mm.

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