A small outer diameter digital communication transmission cable

Abstract

This utility model provides a small-diameter digital communication transmission cable, comprising: multiple pairs of twisted wires, wherein the twisted wires are arranged on both sides of a "I"-shaped filler and twisted together to form a cable core, and the outer side of the cable core is provided with a wrapping layer, a metal foil and plastic composite layer and an outer sheath from the inside to the outside; it solves the technical problems of traditional cables being unable to achieve small outer diameter, high bandwidth, strong anti-interference, long-distance transmission and high durability, and can optimize the cable core structure to improve anti-interference performance and signal transmission bandwidth while ensuring small outer diameter and high flexibility of the cable, and takes into account electromagnetic protection and mechanical strength through composite shielding design, thereby meeting the requirements of high-speed, long-distance and high-reliability communication.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, specifically to a small-diameter digital communication transmission cable. Background Technology

[0002] With the rapid development of digital communication technology, high-speed data transmission places higher demands on the transmission performance, anti-interference ability, and structural compactness of communication cables. Traditional digital communication cables typically employ a stranded cable structure, maintaining the core shape through filler. However, traditional digital communication cables have the following limitations:

[0003] First, while conventional fillers (such as circular or large-section fillers) can fix the position of wire pairs, they significantly increase the outer diameter of the cable, which is not conducive to wiring in confined spaces and high-density installation requirements. At the same time, the wire pair spacing is limited by the volume of the filler; too small a spacing can easily cause crosstalk between wire pairs, especially in high-frequency signal transmission, which severely restricts bandwidth and transmission rate.

[0004] Secondly, traditional shielding layers often use metal braided layers or single thick metal layers. Although they can provide electromagnetic shielding, they can lead to a decrease in bending performance and insufficient impact resistance. Furthermore, under complex working conditions, the shielding layer is easily damaged by lateral pressure or bending, affecting long-term reliability.

[0005] In addition, the existing stranded structure design of the cable core has limited effect on interference suppression. When multiple wire pairs are stranded, uneven distribution of wire pairs is easily caused by structural asymmetry or insufficient filling support, which weakens the interference cancellation effect, aggravates signal attenuation, and thus shortens the effective transmission distance.

[0006] The above background information is provided only to assist in understanding the utility model concept and technical solution of this utility model. It does not necessarily belong to the prior art of this patent application, nor does it necessarily provide technical teaching. In the absence of clear evidence that the above information was disclosed before the filing date of this patent application, the above background information should not be used to evaluate the novelty and inventiveness of this application. Utility Model Content

[0007] To address the technical challenges of traditional cables in achieving small outer diameter, high bandwidth, strong anti-interference capabilities, long-distance transmission, and high durability, this invention proposes a small outer diameter digital communication transmission cable. This cable solves these problems by optimizing the core structure to enhance anti-interference performance and signal transmission bandwidth while maintaining a small outer diameter and high flexibility. Furthermore, a composite shielding design balances electromagnetic protection and mechanical strength, thus meeting the demands for high-speed, long-distance, and high-reliability communication.

[0008] To achieve the above objectives, the technical solution of this utility model is as follows:

[0009] On the one hand, this utility model provides a small outer diameter digital communication transmission cable, including: multiple pairs of twisted wires, the twisted wires are arranged on both sides of a "I"-shaped filler and twisted into a cable to form a cable core, and the outer side of the cable core is provided with a wrapping layer, a metal foil and plastic composite layer and an outer sheath from the inside to the outside.

[0010] This utility model proposes a small-diameter digital communication transmission cable, which solves the technical problems of traditional cables being unable to achieve small outer diameter, high bandwidth, strong anti-interference, long-distance transmission and high durability. Under the premise of ensuring small outer diameter and high flexibility of the cable, the core structure is optimized to improve anti-interference performance and signal transmission bandwidth. The composite shielding design takes into account both electromagnetic protection and mechanical strength, thereby meeting the needs of high-speed, long-distance and high-reliability communication.

[0011] As a preferred technical solution, the pitch of the multiple pairs of twisted wires twisted into a cable is 60mm to 140mm.

[0012] As a preferred technical solution, the pitch of the multiple pairs of twisted wires twisted into a cable is randomly and dynamically varied around a preset center value by an offset of ±10% to 20% to reduce electromagnetic signal interference between wire pairs.

[0013] As a preferred technical solution, the metal foil and plastic composite layer includes: at least one metal foil layer and at least one plastic layer bonded thereto.

[0014] As a preferred technical solution, a ground wire is provided between the wrapping layer and the metal foil and plastic composite layer, and the ground wire is connected to the metal foil layer.

[0015] As a preferred technical solution, the twisted pair cable includes: at least two single-core wires, each pair of single-core wires being twisted together to form a twisted pair cable, and the twist pitch of each pair of single-core wires being 7 to 20 mm.

[0016] As a preferred technical solution, the single-core wire includes: a low resistivity conductor and an insulating layer disposed on the outside of the low resistivity conductor.

[0017] As a preferred technical solution, the twisted pair is arranged correspondingly on both sides of the "I"-shaped filler.

[0018] The small-diameter digital communication transmission cable provided by this utility model has the following beneficial effects:

[0019] 1) This utility model proposes a small outer diameter digital communication transmission cable, which solves the technical problems that traditional cables cannot achieve small outer diameter, high bandwidth, strong anti-interference, long distance transmission and high durability. Under the premise of ensuring small outer diameter and high flexibility of the cable, the core structure is optimized to improve anti-interference performance and signal transmission bandwidth. The composite shielding design takes into account both electromagnetic protection and mechanical strength, thereby meeting the needs of high-speed, long distance and high reliability communication.

[0020] 2) This utility model proposes a small-diameter digital communication transmission cable, which uses a "I"-shaped sheet filler to replace the traditional circular / large-section filler. Twisted pairs are symmetrically arranged on both sides and twisted into a cable. The "I"-shaped sheet filler significantly reduces the volume of the filler, avoiding the diameter expansion caused by the excessive space occupied by the traditional filler. The lateral extension of the "I"-shaped sheet filler allows the twisted pairs on both sides to maintain a large spacing, reducing inter-pair capacitive coupling and electromagnetic crosstalk, and improving bandwidth. The twisted pairs are symmetrically distributed on both sides of the "I"-shaped sheet filler, forming a geometrically symmetrical structure when twisted. This causes external interference signals to generate common-mode noise in the twisted pairs, which is canceled out by differential signal transmission, suppressing signal attenuation and achieving synergistic optimization of small outer diameter and anti-interference performance.

[0021] The twisted-pair cable's twist pitch, combined with the support of the "I"-shaped filler, reduces impedance fluctuations caused by uneven pair distribution, lowers signal reflection and attenuation, and extends transmission distance. The high conductivity of the metal foil layer forms a continuous electromagnetic shield, blocking external interference and internal signal leakage. The composite of the plastic layer and metal foil enhances the mechanical strength of the shielding layer, preventing magnetic leakage due to gaps caused by bending, ensuring shielding integrity. The highly efficient protection of the metal foil and plastic composite layer reduces the superimposed effects of external electromagnetic interference on the signal. Combined with the inherent anti-interference properties of the twisted pair, this reduces the attenuation rate of high-frequency signals, supporting stable transmission over longer distances and achieving high bandwidth and long-distance transmission.

[0022] The cable uses a metal foil and plastic composite layer instead of traditional metal braiding / thick metal shielding. Combined with an outer sheath, the thin metal foil layer in the composite layer results in minimal plastic deformation during bending, significantly improving cable flexibility and adapting to wiring in confined spaces. The plastic layer in the composite layer provides cushioning, enhancing resistance to lateral pressure and preventing cracking of the composite layer during bending or compression. The outer sheath protects the internal structure from mechanical damage and, together with the wrapping layer, maintains the stability of the cable core shape, preventing performance degradation caused by structural deformation during long-term use. This achieves a balance between high durability and flexibility. Attached Figure Description

[0023] Figure 1 A schematic diagram of the structure of a small-diameter digital communication transmission cable provided by this utility model;

[0024] Among them, 1-outer sheath; 2-composite layer of metal foil and plastic; 3-wrapping layer; 4-"I"-shaped filler; 5-ground wire; 6-insulation layer; 7-low resistivity conductor; 8-twisted pair; 9-single core wire. Detailed Implementation

[0025] The preferred embodiments of this utility model are described in detail below with reference to the accompanying drawings.

[0026] like Figure 1 As shown, this utility model provides a small outer diameter digital communication transmission cable, including: multiple pairs of twisted wires 8, the twisted wires 8 are disposed on both sides of the "I"-shaped filler 4 and twisted into a cable to form a cable core, and the outer side of the cable core is provided with a wrapping layer 3, a metal foil and plastic composite layer 2 and an outer sheath 1 from the inside to the outside.

[0027] This utility model proposes a small-diameter digital communication transmission cable, which solves the technical problems of traditional cables being unable to achieve small outer diameter, high bandwidth, strong anti-interference, long-distance transmission and high durability. Under the premise of ensuring small outer diameter and high flexibility of the cable, the core structure is optimized to improve anti-interference performance and signal transmission bandwidth. The composite shielding design takes into account both electromagnetic protection and mechanical strength, thereby meeting the needs of high-speed, long-distance and high-reliability communication.

[0028] The “I”-shaped filler 4 serves to increase the distance between wire pairs, reduce electromagnetic signal interference between wire pairs, and increase signal transmission bandwidth.

[0029] The wrapping layer 3 is preferably a PE wrapping layer, a PP wrapping layer, or a PET wrapping layer. The wrapping layer 3 can serve as an additional insulation layer, providing electrical isolation and reducing the outer diameter of the insulation in the data cable. The wrapping layer 3 can form a buffer layer between the metal foil and the plastic composite layer 2 and other cable components, reducing physical damage caused by bending, stretching, or external pressure. This buffering effect helps extend the overall service life of the cable. In addition, during the manufacturing process, the wrapping layer 3 helps maintain the flatness and consistency of the cable structure, making subsequent processes such as the application of the metal foil and plastic composite layer 2 smoother and flatter. This helps ensure the quality and performance of the finished cable, and grounding enhances the electromagnetic compatibility (EMC) performance of the cable.

[0030] The shielding effect of the metal foil and plastic composite layer 2 ensures the quality of high-speed data transmission and avoids electromagnetic interference. High-quality audio and video signal transmission requires extremely low interference levels. In factory automation systems, reducing electromagnetic interference is crucial to ensuring the accurate operation of the control system. The application of the metal foil and plastic composite layer 2 in cables is mainly to improve their electromagnetic compatibility (EMC), ensure the quality of signal transmission, and enhance the durability and reliability of the cables to a certain extent.

[0031] The outer sheath 1 serves the following functions:

[0032] 1) The outer sheath 1 The conductor, insulation layer and shielding layer (if present) inside the cable provide the first line of defense against mechanical damage such as scratches, abrasions and damage to the cable caused by external pressure;

[0033] 2) The outer sheath 1 can resist the erosion of water, oil, chemicals and other corrosive media, thereby extending the service life of the cable, which is especially important for cables that need to be buried or exposed to harsh environments.

[0034] 3) Although the main electrical isolation function is provided by the internal insulation layer 6, the outer sheath 1 also provides a certain degree of additional isolation to prevent short circuits or other electrical faults caused by direct contact between cables or between cables and other metal parts;

[0035] 4) Many applications require cables to have certain fire resistance. Therefore, the outer sheath material often has good flame retardant properties, which can slow down the spread of fire when a fire occurs, and buy valuable time for personnel evacuation and fire fighting.

[0036] 5) The outer sheath 1 is usually also printed with important parameters such as manufacturer information, model, specifications, and voltage rating to facilitate identification during installation and use. In addition, in some special purpose cables, the color of the outer sheath 1 is also used to distinguish different functions or uses.

[0037] 6) For cables that are outdoors or exposed to natural conditions, the outer sheath 1 must have excellent weather resistance and be able to resist the effects of ultraviolet rays, extreme temperature changes and other factors to ensure the long-term stable operation of the cable.

[0038] Preferably, such as Figure 1 As shown, the pitch of the multiple pairs of twisted wires 8 twisted into a cable is 60mm to 140mm. The preferred pitches are 60mm, 100mm, and 140mm. Due to space limitations and for the sake of brevity, this invention will not exhaustively list the specific values ​​included in the range. The lower limit of the pitch (60mm) is to avoid the wire pairs being too tightly twisted due to the twist pitch being too small, and to prevent the resistance of the low resistivity conductor 7 and signal attenuation due to excessive bending of the conductor (especially significantly affecting high-frequency signals). The upper limit of the pitch (140mm) is to avoid the wire pairs being loosely twisted due to the twist pitch being too large, thereby losing the ability of the twisted wires 8 to cancel common-mode noise through periodic twisting, and ensuring that the noise generated by external electromagnetic interference on the two conductors of the twisted wires 8 remains in phase, which is convenient for the differential circuit to eliminate interference.

[0039] Preferably, such as Figure 1As shown, the pitch of the multiple pairs of twisted 8-stranded composite cables is randomly and dynamically varied around a preset center value by an offset of ±10% to 20% to reduce electromagnetic signal interference between wire pairs. Preferably, for wire pairs with a preset center value of 100mm, the actual pitch fluctuates randomly between 80mm and 120mm. This technology breaks the interference superposition law by randomly changing the dynamic pitch, optimizes impedance matching to reduce signal attenuation, and works in conjunction with the differential transmission mechanism to suppress common-mode noise, ultimately achieving high bandwidth, low interference, and long-distance transmission of high-frequency signals.

[0040] Preferably, such as Figure 1 As shown, the metal foil and plastic composite layer 2 includes: at least one metal foil layer (not shown) and at least one plastic layer (not shown) bonded thereto. The metal foil (not shown) is preferably copper foil or aluminum foil to form a continuous shielding layer, effectively blocking the interference of external electromagnetic fields on the cable core signal, while suppressing the outward radiation of internal signals from the cable, reducing the risk of information leakage. The metal foil layer (not shown) is connected to the ground wire 5, which can quickly conduct external induced current or internal leakage current to the ground, avoiding voltage breakdown or equipment damage caused by charge accumulation. The plastic layer (not shown) and the metal foil layer (not shown) are bonded together to form the metal foil and plastic composite layer 2, which enhances its mechanical stability, ensures the continuity of the grounding path, and prevents the metal foil from losing its grounding function due to bending and breakage.

[0041] Preferably, such as Figure 1 As shown, a ground wire 5 is provided between the wrapping layer 3 and the metal foil and plastic composite layer 2. The ground wire 5 is connected to the metal foil layer (not shown). The ground wire 5 is usually connected to the shielding layer (such as metal foil) inside the cable to help guide external electromagnetic interference to the ground, thereby reducing the impact on data transmission. This grounding method can effectively reduce the interference of electromagnetic noise on signal quality and improve the accuracy and stability of data transmission. The direct connection between the ground wire 5 and the metal foil layer (not shown) can lock the potential of the shielding layer to the grounding system reference voltage, avoiding partial discharge or arc breakdown caused by static electricity accumulation on the metal foil (not shown). At the same time, it reduces the potential difference between different sections of the metal foil and the plastic composite layer 2, suppressing the generation of common-mode interference signals. The ground wire 5 provides a unified potential reference point for the entire system, which is very important for ensuring correct communication between different devices, especially in data networks involving multiple devices. A shared ground can help avoid communication errors or damage caused by potential differences.

[0042] Preferably, such as Figure 1As shown, the twisted pair 8 includes at least two single-core wires 9, with each pair of single-core wires 9 twisted together to form the twisted pair 8. The twist pitch of each pair of single-core wires 9 is 7 to 20 mm, preferably 7 mm, 13 mm, and 20 mm. Due to space limitations and for the sake of brevity, this invention will not exhaustively list the specific values ​​included in the range. The twist pitch achieves a multi-objective balance of low-frequency anti-interference, high-frequency low attenuation, and long-cycle reliability through electromagnetic field cancellation, impedance balance optimization, and mechanical strength adaptation.

[0043] A “I”-shaped filler 4 is used to maintain the shape of the cable core, avoiding the use of excessive filler to increase the cable diameter. The metal foil and plastic composite layer 2 uses a thin metal foil shield, which provides the necessary electromagnetic interference protection without increasing the thickness too much. The metal foil and plastic composite layer 2 is combined with the ground wire 5 to enhance the grounding effect without significantly increasing the cable size. The twist pitch of each pair of twisted wires 8 is adjusted to minimize signal crosstalk while arranging the positions of each pair of twisted wires 8 as compactly as possible, reducing additional space occupation and making the overall layout more compact.

[0044] Preferably, such as Figure 1 As shown, the single-core wire 9 includes: a low-resistivity conductor 7 and an insulating layer 6 disposed on the outside of the low-resistivity conductor 7; the combination of the low-resistivity conductor 7 and the insulating layer 6 achieves efficient power transmission, precise signal isolation and reliable shielding function through resistance minimization, dielectric performance optimization and mechanical compatibility improvement.

[0045] The low resistivity conductor 7 is preferably a high-purity copper conductor or a silver-plated copper conductor, which has a low resistivity. This can reduce energy loss during signal transmission and ensure that data can reach the receiving end accurately. The most basic function of the low resistivity conductor 7 is to act as a medium to transmit electrical signals. Whether it is a digital signal or an analog signal, the transmission from one point to another is achieved through the flow of electrons inside the low resistivity conductor 7.

[0046] Insulation layer 6 isolates the low-resistivity conductor 7 from other low-resistivity conductors 7 and the external environment, avoiding unnecessary current paths and thus preventing short circuits. In multi-core cables, good insulation helps reduce crosstalk between different signal lines, which is particularly important for maintaining data integrity. Insulation layer 6 also provides a certain degree of physical protection for the internal low-resistivity conductor 7, preventing mechanical damage such as scratches and abrasions. Insulation layer 6 is also resistant to chemical corrosion, allowing the cable to be used in environments containing corrosive substances. It isolates the low-resistivity conductor 7 from air to prevent oxidation and deterioration, maintaining signal transmission stability. High-quality insulation layer 6 can minimize energy loss (attenuation) of the signal during transmission, ensuring that the signal remains clear and discernible during long-distance transmission. For high-speed data transmission, precise control of the cable's characteristic impedance is crucial, and insulation layer 6 can also help maintain stable impedance matching, reducing reflection and return losses.

[0047] Preferably, such as Figure 1 As shown, the twisted pair 8 is correspondingly arranged on both sides of the "I"-shaped filler 4. The sheet-like structure of the "I"-shaped filler 4 provides fixed spacing support for the twisted pair 8, preventing the spacing of the wire pairs from changing due to external force or vibration, maintaining the symmetry required for differential signal transmission, and reducing common-mode noise coupling. The symmetrical layout on both sides makes the electromagnetic field distribution of adjacent twisted pairs 8 more uniform, and further reduces crosstalk between wire pairs by canceling phase difference. The symmetrically arranged twisted pairs 8 on both sides of the "I"-shaped filler 4 can balance the force on the cable cross section and prevent wire pair twisting or eccentricity caused by uneven twisting tension during cabling.

[0048] like Figure 1As shown, this utility model provides a small-diameter digital communication transmission cable, comprising: a single-core wire 9, wherein the single-core wire 9 includes: a low-resistivity conductor 7 and an insulation layer 6 disposed outside the low-resistivity conductor 7; every two single-core wires 9 are twisted together to form a twisted pair 8; the twist pitch of every two single-core wires 9 is 7-20mm; at least four pairs of twisted pairs 8 are correspondingly arranged on both sides of the "I"-shaped filler 4 and twisted together to form a cable core; the twist pitch of the four pairs of twisted pairs 8 is 60mm-140mm; the twist pitch of the four pairs of twisted pairs 8 is randomly and dynamically varied around a preset center value by an offset of ±10%-20% to reduce electromagnetic signal interference between wire pairs; the outer side of the cable core is arranged from the inside to the outside... The cable is further provided with a wrapping layer 3, a metal foil and plastic composite layer 2, and an outer sheath 1. A ground wire 5 is provided between the wrapping layer 3 and the metal foil and plastic composite layer 2. The metal foil and plastic composite layer 2 includes at least one metal foil layer (not shown) and at least one plastic layer (not shown) bonded to it. The ground wire 5 is connected to the metal foil layer (not shown). This design solves the technical problems of traditional cables in achieving small outer diameter, high bandwidth, strong anti-interference, long-distance transmission, and high durability. It can optimize the core structure to improve anti-interference performance and signal transmission bandwidth while ensuring small outer diameter and high flexibility. The composite shielding design takes into account both electromagnetic protection and mechanical strength, thereby meeting the requirements of high-speed, long-distance, and high-reliability communication.

[0049] It is understood that this utility model has been described through some embodiments, and those skilled in the art will recognize that various changes or equivalent substitutions can be made to these features and embodiments without departing from the spirit and scope of this utility model. Furthermore, under the teachings of this utility model, these features and embodiments can be modified to adapt to specific situations and materials without departing from the spirit and scope of this utility model. Therefore, this utility model is not limited to the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are protected by this utility model.

Claims

1. A small-diameter digital communication transmission cable, characterized in that, include: Multiple pairs of twisted wires are arranged on both sides of a "I"-shaped filler and twisted together to form a cable core. The outer side of the cable core is provided with a wrapping layer, a metal foil and plastic composite layer and an outer sheath from the inside to the outside.

2. The small-diameter digital communication transmission cable according to claim 1, characterized in that, The pitch of the multiple pairs of twisted wires twisted together to form a cable is 60mm to 140mm.

3. The small outside diameter digital communication transmission cable of claim 1 wherein, The pitch of the twisted pairs of wires is randomly and dynamically varied around a preset center value by an offset of ±10% to 20% to reduce electromagnetic signal interference between wire pairs.

4. The small outside diameter digital communication transmission cable of claim 1 wherein, The metal foil and plastic composite layer includes: at least one metal foil layer and at least one plastic layer bonded thereto.

5. The small outside diameter digital communication transmission cable of claim 4, wherein, A ground wire is provided between the wrapping layer and the metal foil and plastic composite layer, and the ground wire is connected to the metal foil layer.

6. The small outside diameter digital communication transmission cable of claim 1 wherein, The twisted pair cable includes at least two single-core wires, each pair of single-core wires being twisted together to form a twisted pair cable, wherein the twist pitch of each pair of single-core wires is 7 to 20 mm.

7. The small outside diameter digital communication transmission cable of claim 6 wherein, The single-core wire includes: a low-resistivity conductor and an insulating layer disposed on the outside of the low-resistivity conductor.

8. The small outside diameter digital communication transmission cable of claim 1 wherein, The twisted pair cables are respectively arranged on both sides of the "I"-shaped filler.

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