A flexible, abrasion-resistant, impact-resistant automotive sensor signal cable

Abstract

The utility model discloses a kind of bending-resistant, wear-resistant, impact-resistant automobile sensor signal cable, belong to cable technical field, it is characterized by: including at least one twisted wire core, the outer side of the twisted wire core is equipped with foamed inner sheath, the foamed inner sheath is wrapped the twisted wire core and forms strand, the strand is sequentially equipped with the shielding layer of covered strand, the foamed outer sheath with bubble volume fraction less than the foamed inner sheath and the outer sheath of covered foamed outer sheath from inside to outside. This cable not only improves the bending resistance of cable in dynamic wiring scene, but also enhances its impact resistance and mechanical protection ability in harsh use environment, suitable for flexible, stability and durability are all higher requirements in modern automobile sensor signal transmission scene.

Description

Technical Field

[0001] This utility model belongs to the field of cable technology, and in particular relates to a bend-resistant, wear-resistant, and impact-resistant automotive sensor signal cable. Background Technology

[0002] With the continuous improvement of automotive electronics and intelligence, cables, as a crucial medium for signal and power transmission in vehicle systems, directly impact the functional stability and operational safety of the entire vehicle. Especially in new energy vehicles and intelligent connected vehicles, the types of automotive cables are becoming increasingly diverse, encompassing power transmission lines, charging cables, high-speed data communication lines, and a wide variety of signal cables used for sensor signal acquisition and control execution. Compared to traditional industrial cables, automotive cables face much stricter requirements in terms of size, flexibility, environmental resistance, and mechanical strength.

[0003] However, existing automotive cables still face numerous technical bottlenecks and performance defects during use, making it difficult to fully meet the actual needs of complex vehicle operating conditions. Firstly, in critical areas such as the engine compartment, chassis, and wheel hubs, limited wiring space often necessitates cable installation with small bending radii. Traditional cables are prone to sheath cracking, insulation fatigue, and structural deformation after repeated bending or prolonged compression, affecting their service life and signal transmission stability. Secondly, in certain specific locations (such as near suspension arms and braking systems), to meet lightweight and concealed wiring requirements, additional physical protection structures are not permitted. This forces cables to directly face harsh conditions such as road debris, rainwater erosion, and oil contamination. Traditional sheath materials struggle to balance abrasion resistance and flexibility, making them highly susceptible to internal functional failure due to surface wear or impact damage. Furthermore, with the increasing number of onboard sensing systems, the conflict between the anti-interference capability, mechanical protection capability, and flexible structural design of signal cables is becoming increasingly prominent. Therefore, there is an urgent need for an automotive sensor signal cable structure that combines bending resistance, wear resistance, and impact resistance to effectively improve the reliability and service safety of the vehicle's electrical system. Utility Model Content

[0004] To address the problem that existing automotive sensor signal cables cannot effectively maintain stable signal transmission and cable structural integrity under complex working conditions such as bending, wear, and impact, this utility model provides a bending-resistant, wear-resistant, and impact-resistant automotive sensor signal cable.

[0005] This utility model is implemented as follows: a bend-resistant, wear-resistant, and impact-resistant automotive sensor signal cable, characterized in that: it includes at least one stranded core, the outer side of which is provided with a foamed inner sheath, the foamed inner sheath wraps around the stranded core to form a strand, and the strand is provided with a shielding layer covering the strand, a foamed outer sheath with a foamed cell volume fraction smaller than that of the foamed inner sheath, and an outer sheath covering the foamed outer sheath in sequence from the inside to the outside.

[0006] In the above technical solution, preferably, the cell volume fraction of the foamed inner protective layer is 50-60%; and the cell volume fraction of the foamed outer protective layer is 30-40%.

[0007] In the above technical solution, preferably, the stranded core includes a stranded conductor and an insulating protective sleeve covering the outside of the stranded conductor.

[0008] In the above technical solution, preferably, the shielding layer is a composite structure of an aluminum-plastic composite tape winding layer and a tin-plated copper wire braided layer.

[0009] This invention presents a bend-resistant, wear-resistant, and impact-resistant automotive sensor signal cable. Addressing the high requirements for cable flexibility, resistance to mechanical damage, and signal stability in the complex working environment of automobiles, it employs a multi-layer composite structure design, significantly improving the cable's overall performance. The cable includes at least one stranded core with an outer foamed inner sheath to buffer external mechanical stress and maintain core shape stability. The foamed inner sheath has a high cell volume fraction, providing excellent compression buffering performance. When the cable is subjected to bending, stretching, or compression stress, it effectively absorbs deformation energy, reduces the deformation of the insulated core, maintains the core's roundness, thereby reducing the risk of electrical performance fluctuations and ensuring stable signal transmission. Simultaneously, the presence of the foamed inner sheath reduces disturbance to the shielding layer structure during bending, effectively suppressing shielding layer deformation caused by stranded core eccentricity or displacement, maintaining good geometric stability of the shielding layer under dynamic stress, and improving the overall electromagnetic shielding effect of the cable. This structure is particularly suitable for automotive sensor applications with high signal integrity requirements, helping to improve the anti-interference capability of the vehicle control system.

[0010] The outer layer consists of a shielding layer, a foamed outer sheath, and an outer jacket, arranged sequentially around the foamed inner sheath. The foamed outer sheath has a relatively low cell volume fraction, resulting in higher structural density and greater mechanical strength. Its primary function is to absorb energy through deformation when subjected to external impacts (such as sand or gravel splashes or object collisions), acting as an "energy-absorbing buffer layer." This effectively reduces the direct damage to the inner structure from impact forces, enhancing the overall impact resistance and abrasion resistance of the cable. Furthermore, the outer jacket material can be further selected from polymer materials with oil resistance, high and low temperature resistance, and aging resistance, thereby improving the cable's overall environmental adaptability and service life.

[0011] In summary, by rationally introducing a double-layer foamed sheath into the cable structure, this utility model not only improves the cable's bending resistance in dynamic wiring scenarios, but also enhances its impact resistance and mechanical protection capabilities in harsh operating environments. It is suitable for sensor signal transmission scenarios in modern automobiles where high flexibility, stability, and durability are required. Attached Figure Description

[0012] Figure 1 This is a schematic diagram of the structure of this utility model. Detailed Implementation

[0013] To make the objectives, technical solutions, and advantages of this utility model clearer, the following detailed description is provided in conjunction with embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this utility model.

[0014] To address the problem that existing automotive sensor signal cables cannot effectively maintain stable signal transmission and cable structural integrity under complex conditions such as bending, wear, and impact, this invention provides a bending-resistant, wear-resistant, and impact-resistant automotive sensor signal cable. To further illustrate the structure of this invention, a detailed description is provided below in conjunction with the accompanying drawings:

[0015] Please see Figure 1 A bend-resistant, wear-resistant, and impact-resistant automotive sensor signal cable includes at least one stranded core. The outer side of the stranded core is provided with a foamed inner sheath 3, which encloses the stranded core to form a strand. Specifically, in this embodiment, the stranded core includes a stranded conductor 1 and an insulating protective sleeve 2 covering the outside of the stranded conductor. Two stranded cores are enclosed by the foamed inner sheath to form a strand. Specifically, the stranded conductor is made of multiple strands of fine copper wire, possessing good flexibility and conductivity. The insulating protective sleeve is made of cross-linked polyethylene (XLPE), thermoplastic elastomer (TPE), or other materials with good insulation and heat resistance. The two stranded cores are jointly enclosed in the same foamed inner sheath, forming a structurally stable strand.

[0016] The foamed inner sheath uses a closed-cell foam material, preferably foamed polyolefin or foamed polyurethane, with a cell volume fraction of 50%-60%. This foamed inner sheath is soft and has a certain degree of elasticity, which can buffer deformation when the cable is subjected to external forces such as bending, compression or twisting, effectively reducing the deformation of the inner core wires, maintaining their rounded alignment, and reducing structural disturbances in the shielding layer, thereby ensuring the stability of signal transmission and the electromagnetic shielding effect.

[0017] The strands are provided with, from the inside out, a shielding layer 4 covering the strands, an outer foamed sheath 5 with a cell volume fraction smaller than that of the inner foamed sheath, and an outer sheath 6 covering the outer foamed sheath.

[0018] The shielding layer can be a tinned copper wire braided layer, an aluminum-plastic composite tape winding layer, or a composite shielding structure of braiding and winding, used to suppress external electromagnetic interference and prevent signal leakage.

[0019] The foamed outer sheath also uses closed-cell foamed materials, preferably foamed polyethylene, foamed TPV, etc., with a cell volume fraction of 30%-40%. Compared with the foamed inner sheath, this outer sheath has a denser structure, lower foaming ratio, and higher mechanical strength, and is mainly used to absorb external impact loads and reduce the risk of mechanical damage.

[0020] The outer sheath is made of materials with excellent abrasion resistance, oil resistance, and heat aging resistance, such as polyurethane (PU), polyamide (PA), and thermoplastic polyolefin (TPO), to provide final environmental protection for the entire cable.

[0021] Because the shielding layer is sandwiched between two layers of flexible foam material, forming a structure similar to a "cushion support," the mechanical stress it experiences is significantly buffered during the entire dynamic bending process of the cable. Unlike traditional shielding layers attached between the core or sheath, this design reduces strain concentration in the shielding layer during repeated bending, effectively reducing the risk of fatigue fracture of the metal wires or braided layers, thereby significantly improving the durability and reliability of the shielding structure. Under dynamic automotive conditions (engine vibration, road impact, etc.), cables often face micro-amplitude high-frequency resonant excitation. The inner and outer layers of this double-layer foam design have different hardness and damping characteristics, with a metal shielding layer sandwiched in between, effectively forming a structural damping and vibration isolation system. This effectively isolates high-frequency mechanical disturbances transmitted from the outer sheath, preventing them from directly affecting the inner sheath and core, thus improving dynamic stability and user comfort. The high foam density of the inner layer provides soft cushioning, while the low foam density of the outer layer provides rigid support, forming a double-layer composite structure similar to "soft inside, hard outside." This structure exhibits a smoother yielding process and lower peak stress when subjected to compression or impact. In other words, compared to a single foam or solid structure, this gradient foam design is more likely to absorb energy before structural damage occurs, delaying the failure process and improving the overall "toughness" of the cable.

[0022] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present utility model should be included within the protection scope of the present utility model.

Claims

1. A flexible, abrasion resistant, impact resistant automotive sensor signal cable characterized by: It includes at least one stranded core, the outer side of which is provided with a foamed inner sheath, the foamed inner sheath wraps around the stranded core to form a strand, and the strand is provided with a shielding layer covering the strand, a foamed outer sheath with a cell volume fraction smaller than that of the foamed inner sheath, and an outer sheath covering the foamed outer sheath in sequence from the inside to the outside.

2. The flexible, abrasion-resistant, impact-resistant automotive sensor signal cable of claim 1, wherein: The foamed inner protective layer has a cell volume fraction of 50-60%; the foamed outer protective layer has a cell volume fraction of 30-40%.

3. The bend-resistant, wear-resistant, and impact-resistant automotive sensor signal cable according to claim 2, characterized in that: The stranded core includes a stranded conductor and an insulating protective sleeve covering the outside of the stranded conductor.

4. The bend-resistant, wear-resistant, and impact-resistant automotive sensor signal cable according to claim 2, characterized in that: The shielding layer is a composite structure consisting of an aluminum-plastic composite tape winding layer and a tin-plated copper wire braided layer.

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