Flexible high frequency data cable

Abstract

The utility model discloses a flexible high frequency data cable, include: conductor, the extrusion of conductor has PE insulating layer and forms core, is provided with foamed layer on PE insulating layer, the thickness of foamed layer accounts for 75% of PE insulating layer total thickness, and the foaming rate of foamed layer is 60%~65%, and every two core wire pairs form a pair of double -twisted pair, and the twisting pitch of every pair of double -twisted pair is different, and the aluminium -plastic composite tape is wrapped on double -twisted pair, and four pairs of double -twisted pair with aluminium -plastic composite tape are twisted into cable core, and the overlap gap of aluminium -plastic composite tape on each double -twisted pair all faces outward, and the tinned copper wire braid is woven on cable core, and the tinned copper wire braid covers and presses on the overlap gap of aluminium -plastic composite tape, and the weaving density of tinned copper wire braid is 70%, and the tape is wrapped on tinned copper wire braid, and the sheath is extruded on tape. The utility model can prevent the signal crosstalk between double -twisted pair without heat sealing to aluminium -plastic composite tape, thereby protecting PE insulating layer from being damaged.

Description

Technical Field

[0001] This utility model relates to the field of cables, and more particularly to flexible high-frequency data cables. Background Technology

[0002] Data cables, with copper conductors at their core, are used for transmitting electrical signals. Compared to fiber optics, their advantage lies in their ability to directly connect to terminal devices without photoelectric conversion, making them a cost-effective solution for the "last 100 meters." With the speed leap driving standard iterations, Category 3 (16MHz) and Category 5 (100MHz) cables have been forcibly retired by the new specifications because they cannot meet the requirements of 5G / data centers. Category 6 (250MHz) and Cat.6A (500MHz) have become the mainstream for 5G base stations and enterprise networks. Among them, Cat.6A (Category 6 Augmented) cable is specifically designed for 10 Gigabit Ethernet (10GBASE-T), operating at frequencies up to 500MHz, and can stably support a transmission rate of 10Gbps over a distance of 100 meters.

[0003] The conventional structural design of Cat.6A cables aims to overcome crosstalk problems in high-frequency transmission and meet stringent performance standards. It typically uses a cross-shaped frame to isolate the four pairs of twisted wires. Cables with this frame have a larger outer diameter, are less flexible, require more space for wiring, and increase costs. To address this issue, manufacturers prefer to use aluminum-plastic tape for partial shielding combined with high-density braided overall shielding to ensure product performance. However, the aluminum-plastic tape has overlapping gaps facing the center of the wire pairs. High-frequency signals in the twisted pairs can easily leak through these gaps, causing crosstalk between the wire pairs. To prevent this, the aluminum-plastic tape is usually heat-sealed at high temperatures to seal the overlaps. However, under high temperatures, the foamed insulation layer is prone to decomposition, leading to deformation and collapse, affecting the cable's electrical performance. Utility Model Content

[0004] The purpose of this invention is to provide a flexible high-frequency data cable that can prevent signal crosstalk in twisted pairs without heat sealing the aluminum-plastic composite tape and without damaging the insulation layer.

[0005] To achieve the above objectives, the technical solution adopted by this utility model is as follows: a flexible high-frequency data cable, comprising: a conductor, a core wire formed by extruding a PE insulation layer on the conductor, a foam layer provided on the inner sidewall of the PE insulation layer in contact with the conductor, the thickness of the foam layer accounting for 75% of the total thickness of the PE insulation layer, the foaming rate of the foam layer being 60% to 65%, each pair of core wires being twisted together to form a pair of twisted wires, each pair of twisted wires having a different twisting pitch, an aluminum-plastic composite tape wrapped around the twisted wires, four pairs of twisted wires with aluminum-plastic composite tape being twisted together to form a cable core, the overlap seams of the aluminum-plastic composite tape on each pair of twisted wires facing outwards, a tinned copper wire braided tape woven on the cable core, the tinned copper wire braided tape covering and pressing against the overlap seams of the aluminum-plastic composite tape, the braiding density of the tinned copper wire braided tape being 70%, a wrapping tape wrapped around the tinned copper wire braided tape, and a sheath extruded on the wrapping tape.

[0006] Furthermore, in the aforementioned flexible high-frequency data cable, the twist pitch ratio of the four pairs of twisted wires is 1:1.2:1.4:1.6.

[0007] Furthermore, in the aforementioned flexible high-frequency data cable, the foam pore size of the foam layer is ≤50μm.

[0008] Furthermore, in the aforementioned flexible high-frequency data cable, the overlap gap of the aluminum-plastic composite strip on the upper right twisted pair faces the 3 o'clock direction, the overlap gap of the aluminum-plastic composite strip on the lower right twisted pair faces the 6 o'clock direction, the overlap gap of the aluminum-plastic composite strip on the lower left twisted pair faces the 9 o'clock direction, and the overlap gap of the aluminum-plastic composite strip on the upper left twisted pair faces the 12 o'clock direction.

[0009] Furthermore, in the aforementioned flexible high-frequency data cable, the sheath is made of modified TPU material.

[0010] Furthermore, in the aforementioned flexible high-frequency data cable, the conductor is made of seven φ0.16mm copper wires twisted together in a 1+6 configuration.

[0011] Furthermore, in the aforementioned flexible high-frequency data cable, the width of the aluminum-plastic composite tape is 5 to 7 times the outer diameter of the twisted pair, and the wrapping angle of the aluminum-plastic composite tape is 35°±10°.

[0012] The advantages of this invention are as follows: A PE insulation layer is extruded onto the conductor to form the core wire; a foamed layer is provided on the inner wall where the PE insulation layer contacts the conductor; the thickness of the foamed layer accounts for 75% of the total thickness of the PE insulation layer, and the foaming rate of the foamed layer is 60%–65%. This ensures both the mechanical strength and excellent electrical performance of the core wire. Furthermore, the overlap seams of the aluminum-plastic composite tape wrapped around the four pairs of twisted wires all face outwards, preventing high-frequency signal leakage caused by the overlap seams of the aluminum-plastic composite tape on the four pairs of twisted wires facing towards the center of the wire pairs. To ensure crosstalk immunity between the four twisted pairs, high-temperature heat sealing of the aluminum-plastic composite tape is unnecessary to prevent signal crosstalk between the twisted pairs. This prevents damage to the PE insulation layer from high temperatures, thus ensuring its integrity and the electrical performance of the core wires. Controlling the braid density of the tinned copper wire braid to 70%, combined with the outward-facing overlap of the aluminum-plastic composite tape, provides excellent shielding performance. This reduces manufacturing costs and increases the flexibility of the tinned copper wire braid, ensuring the overall flexibility of the cable. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of the flexible high-frequency data cable described in this utility model.

[0014] Figure 2 This is a schematic diagram of the mold used for wrapping aluminum-plastic composite tape.

[0015] Figure 3 yes Figure 2 A schematic diagram of the axial cross-sectional structure of the central wrapping shaft.

[0016] Figure 4 yes Figure 2 A schematic diagram of the radial cross-sectional structure of the central wrapping shaft. Detailed Implementation

[0017] The technical solution of this utility model will be further described below with reference to the accompanying drawings and preferred embodiments.

[0018] like Figure 1As shown, the flexible high-frequency data cable of this utility model includes: a conductor 1, which is formed by twisting seven φ0.16mm copper wires in a 1+6 structure to ensure the roundness of the conductor 1; a PE insulation layer 2 is extruded on the conductor 1 to form the core wire; a foaming layer is provided on the inner sidewall of the PE insulation layer 2 in contact with the conductor 1; the foaming layer can reduce signal attenuation; the thickness of the foaming layer accounts for 75% of the total thickness of the PE insulation layer 2; the foaming rate of the foaming layer is 60% to 65%; and the foaming pore size of the foaming layer is ≤50μm, which can better suppress high-frequency skin effect damage and improve electrical performance while ensuring mechanical strength; each pair of core wires is twisted to form a pair of twisted wires; the twisting pitch of each pair of twisted wires is different; an aluminum-plastic composite tape 3 is wrapped around the twisted wires; and four pairs of twisted wires with aluminum-plastic composite tape 3 are twisted to form the cable core. In this embodiment, the twisting pitch ratio of the four pairs of twisted wires is 1:1.2:1.4:1.6. This pitch design randomizes the electromagnetic coupling point positions between adjacent twisted pairs, causing interference signals to cancel each other out due to phase misalignment. Simultaneously, it reduces external noise coupling and improves EMI immunity by over 15%. The overlap gaps 31 of the aluminum-plastic composite strips 3 on all four twisted pairs face outwards. The overlap gap 31 of the aluminum-plastic composite strip 3 on the upper right twisted pair faces the 3 o'clock direction; the overlap gap 31 of the aluminum-plastic composite strip 3 on the lower right twisted pair faces the 6 o'clock direction; the overlap gap 31 of the aluminum-plastic composite strip 3 on the lower left twisted pair faces the 9 o'clock direction; and the overlap gap 31 of the aluminum-plastic composite strip 3 on the upper left... The overlap gap 31 of the aluminum-plastic composite tape 3 on the twisted pair is oriented towards the 12 o'clock direction to avoid high-frequency signal leakage caused by the overlap gap 31 of the aluminum-plastic composite tape 3 on the four twisted pairs being oriented towards the center of the wire pair. This ensures the anti-crosstalk performance between the four twisted pairs. Therefore, it is not necessary to use high-temperature heat sealing to bond the aluminum-plastic composite tape 3 to avoid signal crosstalk between the twisted pairs. The PE insulation layer 2 will not be damaged by high temperature, thus ensuring the integrity of the PE insulation layer 2 and the electrical performance of the core wire. A tinned copper wire braided tape 4 is woven on the cable core, and the tinned copper wire braided tape 4 directly covers... The tin-plated copper wire braided tape 4 covers and presses against the overlap seam 31 of the aluminum-plastic composite tape 3, forming double protection. Furthermore, the tin-plated copper wire braided tape 4, after covering and pressing against the overlap seam 31 of the aluminum-plastic composite tape 3, prevents the aluminum-plastic composite tape 3 from loosening. The braiding density of the tin-plated copper wire braided tape 4 is 70%, lower than the conventional braiding density (85%). This reduces manufacturing costs and improves the flexibility of the tin-plated copper wire braided tape 4, thus ensuring the flexibility of the entire cable. The 70% braiding density of the tin-plated copper wire braided tape 4, combined with the aluminum-plastic composite tape 3 with the overlap seam 31 facing outwards, provides good shielding performance. A wrapping tape 5 is wrapped around the braided tape 4, and a sheath 6 is extruded onto the wrapping tape 5. The sheath 6 is made of modified TPU material. Modified TPU not only retains its original excellent properties, such as good mechanical strength, abrasion resistance, oil resistance, and low-temperature resistance, but also significantly improves flexibility and elasticity, making the cable more suitable for applications requiring high flexibility and elasticity. To prevent excessive pressure during sheath 6 extrusion from affecting product performance, a reduced-pressure extrusion process is used to lower the extrusion pressure. Simultaneously, the wrapping tape 5 prevents adhesion between the sheath 6 and the tinned copper wire braided tape 4, protecting the integrity of the sheath 6.

[0019] In this embodiment, in order to ensure that the overlap gap 31 of the aluminum-plastic composite tape 3 on the twisted pair faces outward, an aluminum-plastic composite tape 3 with a width of 5 to 7 times the outer diameter of the twisted pair is used. Then, it is wrapped at a wrapping angle of 35° ± 10°, achieved by using a specific mold 7, such as... Figures 2-4As shown, it includes: a fixing plate 71 and a wrapping shaft 72. Four mounting holes are evenly distributed around the circumference of the fixing plate 71. The wrapping shaft 72 passes through the mounting holes. A set bolt 73 is threaded onto the fixing plate 71 and fastened to the wrapping shaft 72. A wrapping hole 721 is provided in the wrapping shaft 72. A spirally extending, interconnected folding groove 722 extends from the wrapping hole 721. The aluminum-plastic composite tape 3 is pre-wound onto the twisted pair at a wrapping angle of 35°±10°. Then, the twisted pair with the aluminum-plastic composite tape 3 is inserted into the wrapping hole 721, and the aluminum-plastic composite tape 3 is inserted into the folding groove 722. During cabling... Four pairs of twisted wires are simultaneously wrapped around the aluminum-plastic composite tape 3 and then directly twisted into a cable core. Then, tin-plated copper wire braided tape 4 is woven on the cable core. During the entire cabling process, the twisted wires need to be rotated to achieve 100% untwisting. When the twisted wires rotate, they will drive the aluminum-plastic composite tape 3 to wrap. When the aluminum-plastic composite tape 3 is wrapped, the wrapping cutting direction of the aluminum-plastic composite tape 3 is controlled by the folding groove 722, thereby controlling the orientation of the overlap gap 31 of the aluminum-plastic composite tape 3. At the same time, by increasing the width of the aluminum-plastic composite tape 3 and decreasing the wrapping angle of the aluminum-plastic composite tape 3, the overlap length is increased, thereby reducing the overlap gap 31. Since the folding groove 722 controls the orientation of the overlap gap 31 of the aluminum-plastic composite tape 3, when the four wrapping shafts 72 are fixed in their respective mounting holes, it is necessary to determine the orientation of the folding groove 722. The folding groove 722 of the wrapping shaft 72 located at the upper right faces the 3 o'clock direction, the folding groove 722 of the wrapping shaft 72 located at the lower right faces the 6 o'clock direction, the folding groove 722 of the wrapping shaft 72 located at the lower left faces the 9 o'clock direction, and the folding groove 722 of the wrapping shaft 72 located at the upper left faces the 12 o'clock direction. This ensures that the wrapping cutting direction of the aluminum-plastic composite tape 3 on the four pairs of twisted wires faces the 3 / 6 / 9 / 12 o'clock directions respectively.

[0020] Finally, it should be noted that the above embodiments are only used to illustrate the technical solution of this utility model and not to limit it. Although the utility model has been described in detail with reference to the above embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the specific implementation of this utility model. Any modifications or equivalent substitutions that do not depart from the spirit and scope of this utility model should be covered within the protection scope of the claims of this utility model.

Claims

1. A flexible high-frequency data cable, characterized in that: include: The conductor has a PE insulation layer extruded onto it to form a core wire. A foam layer is provided on the inner wall where the PE insulation layer contacts the conductor. The thickness of the foam layer accounts for 75% of the total thickness of the PE insulation layer, and the foaming rate of the foam layer is 60% to 65%. Every two core wires are twisted together to form a pair of twisted wires. The twisting pitch of each pair of twisted wires is different. An aluminum-plastic composite tape is wrapped around the twisted wires. Four pairs of twisted wires with aluminum-plastic composite tape are twisted together to form a cable core. The overlap gaps of the aluminum-plastic composite tape on each pair of twisted wires face outwards. A tinned copper wire braided tape is woven on the cable core. The tinned copper wire braided tape covers and presses against the overlap gaps of the aluminum-plastic composite tape. The braiding density of the tinned copper wire braided tape is 70%. A wrapping tape is wrapped around the tinned copper wire braided tape, and a sheath is extruded on the wrapping tape.

2. The flexible high-frequency data cable according to claim 1, characterized in that: The twist pitch ratio of the four twisted pairs is 1:1.2:1.4:1.

6.

3. The flexible high-frequency data cable according to claim 1, characterized in that: The pore size of the foamed layer is ≤50μm.

4. The flexible high-frequency data cable according to claim 1, characterized in that: The overlap of the aluminum-plastic composite tape on the upper right twisted pair faces the 3 o'clock direction, the overlap of the aluminum-plastic composite tape on the lower right twisted pair faces the 6 o'clock direction, the overlap of the aluminum-plastic composite tape on the lower left twisted pair faces the 9 o'clock direction, and the overlap of the aluminum-plastic composite tape on the upper left twisted pair faces the 12 o'clock direction.

5. The flexible high-frequency data cable according to claim 1, characterized in that: The sheath is made of modified TPU material.

6. The flexible high-frequency data cable according to claim 1, characterized in that: The conductor is made of seven φ0.16mm copper wires twisted together in a 1+6 configuration.

7. The flexible high-frequency data cable according to claim 1, characterized in that: The width of the aluminum-plastic composite tape is 5 to 7 times the outer diameter of the twisted pair, and the wrapping angle of the aluminum-plastic composite tape is 35°±10°.

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