A highly flexible and lightweight data cable

Abstract

This utility model belongs to the field of data cable structure technology, specifically relating to a highly flexible and lightweight data cable. It includes a core layer, a main shielding layer, and an outer sheath layer, arranged sequentially from the inside out. The core layer includes a coaxial signal unit and a power unit, with flexible fiber filaments filling the gaps between the coaxial signal unit and the power unit. The coaxial signal unit includes multiple coaxial core wires, an insulation layer, a low-frequency shielding layer, a high-frequency shielding layer, and a smooth sheathing layer, arranged sequentially from the inside out. The data cable structure provided by this utility model, through optimized layout and the combination of sheathing layers, fills the spaces between the core wires with flexible and tensile-resistant fiber filaments, resulting in a smaller cable diameter and weight. This makes it suitable for the lightweight and thin requirements of portable devices and prevents conductor breakage after bending, making it suitable for dynamic cabling in confined spaces.

Description

Technical Field

[0001] This utility model relates to the field of data cable structure technology, and more specifically, to a highly flexible and lightweight data cable. Background Technology

[0002] With the widespread use of USB cables in charging and data transmission of consumer electronic devices, portable electronic instruments, industrial automation equipment connections, and smart home device interactions, especially in dynamic scenarios (such as device movement, repeated bending and pulling of cables), the twisted structure is easily deformed by external forces, and external interference can easily couple into the signal circuit due to complex electromagnetic environments, thus facing problems of structural stability and signal integrity.

[0003] The existing data cable structure, as shown in the patent document with patent number CN202122180308.7 and title "A Bending-Resistant USB Optoelectronic Composite Cable", includes an optical fiber unit, a cable unit, an outer aluminum foil layer, a braided shielding layer, and a sheath layer. A filler sleeve is provided outside the optical fiber unit and inside the outer aluminum foil layer. The filler sleeve is integrally formed with a spacer strip, and a buffer sleeve is integrally formed at the end of the spacer strip away from the filler sleeve. The buffer sleeve is sleeved with the filler sleeve. The buffer sleeve is integrally formed with a buffer tube. The longitudinal cross section of the buffer tube is semi-circular. The wire cores in the cable unit and the buffer tube are distributed in a ring-shaped staggered manner.

[0004] The aforementioned data cable structure claims to form a flexible internal skeleton through filler sleeves, spacers, buffer sleeves, and buffer sheaths, separating the optical fiber and cable unit. The buffer sheath provides elastic cushioning, improves overall flexibility, and prevents the wire cores from shifting.

[0005] However, this solution uses an elastic skeleton composed of filler sleeves, spacers, and buffer sleeves, which only achieves "separating optical fibers from cable units and preventing core misalignment," without optimizing stress distribution during dynamic bending. In daily use, bending can easily lead to skeleton structure deformation (such as spacer breakage or buffer sleeve misalignment), affecting the long-term stability of the cable. Furthermore, the large gap between the optical fiber unit and the filler sleeve means that during dynamic bending, the lack of continuous support in the optical fiber can easily cause micro-bending loss, reducing signal integrity. While the four-level shielding ("aluminum foil layer for signal lines + aluminum foil layer for control lines + outer aluminum foil layer + braided shielding layer") enhances electromagnetic protection, the precise alignment of the aluminum foil layers increases production difficulty and cost. Moreover, the multi-layered metal shielding reduces cable flexibility, which does not match the "bending resistance" design goal, and also increases weight, leaving significant room for improvement. Utility Model Content

[0006] To address the issues of current data cable structures failing to balance signal transmission performance and bending flexibility, resulting in high production costs and difficulty in controlling weight, a highly flexible and lightweight data cable is provided.

[0007] A highly flexible and lightweight data cable includes a core layer, a main shielding layer, and an outer sheath layer, which are wrapped sequentially from the inside out. The core layer includes a coaxial signal unit and a power unit. The gap between the coaxial signal unit and the power unit is filled with flexible fiber filaments. The coaxial signal unit includes multiple coaxial core wires, an insulation layer, a low-frequency shielding layer, a high-frequency shielding layer, and a smooth wrapping layer, which are wrapped sequentially from the inside out.

[0008] Furthermore, the flexible fiber filaments are interwoven layers of Kevlar fibers.

[0009] Furthermore, the insulating layer is a fluoropolymer layer.

[0010] Furthermore, the low-frequency shielding layer comprises an oxygen-free copper wire mesh.

[0011] Furthermore, the high-frequency shielding layer includes a single-sided conductive aluminum foil layer.

[0012] Furthermore, the smooth coating layer is a PET film layer.

[0013] Furthermore, the power unit includes multiple stranded power cores, each of which is coated with a fluorine-containing coating.

[0014] Furthermore, the main shielding layer includes a copper wire braided layer, on which a tin-plated layer is wrapped.

[0015] Furthermore, the outer sheath layer comprises a thermoplastic elastomer.

[0016] The advantages of this utility model are: 1. The multi-level shielding structure (copper wire mesh, aluminum foil, PET) can shield a wide frequency range, ensuring stable signal transmission even in complex industrial electromagnetic environments.

[0017] 2. The gaps between the core wire layers are filled with soft and tensile-resistant fiber filaments, which helps to reduce the size and weight of the data cable, improve its flexibility, and adapt to the needs of dynamic cabling in confined spaces and the thinness and lightness of portable devices.

[0018] 3. The smooth PET film layer and the fluorine-containing layer with an extremely low coefficient of friction on the core wire surface can reduce friction and wear between the internal wires under dynamic conditions, thereby improving the dynamic bending life of the core wire. 4. The internal stress dispersion design, which combines multiple coaxial core wires, multiple stranded power core wires, and flexible fiber filaments, significantly improves the bending resistance of the wire. Attached Figure Description

[0019] To more clearly illustrate the technical solutions in the embodiments of this utility model or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this utility model. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 A schematic diagram of the structure of a highly flexible and lightweight data cable; Figure 2 This is a schematic diagram of the coaxial signal unit.

[0021] Attached image labels: 1. Coaxial signal unit; 101. Coaxial core wire; 102. Insulation layer; 103. Low-frequency shielding layer; 104. High-frequency shielding layer; 105. Smooth wrapping layer; 2. Power unit; 3. Main shielding layer; 4. Outer sheath layer; 5. Flexible fiber filament. Detailed Implementation

[0022] To address the issues of current data cable structures failing to balance signal transmission performance and bending flexibility, resulting in high production costs and difficulty in controlling weight, a highly flexible and lightweight data cable is provided.

[0023] To make the objectives, technical solutions, and advantages of the embodiments of this utility model clearer, the technical solutions of the embodiments of this utility model will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0024] It should be noted that the terms such as "inner", "middle" and "one" used in this specification are only for clarity of description and are not intended to limit the scope of implementation of this utility model. Any changes or adjustments to their relative relationships, without substantially altering the technical content, should also be considered as part of the scope of implementation of this utility model, as stated above.

[0025] In the description of this utility model, it should be understood that the terms "upper," "lower," "front," "rear," "left," "right," "vertical," and "horizontal," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are used only for the convenience of describing this utility model and for simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model. Furthermore, the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Thus, features defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature. In the description of this utility model, it should be noted that unless otherwise explicitly specified and limited, the terms "installed," "connected," and "joined" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components. For those skilled in the art, the specific meaning of the above terms in this utility model can be understood through specific circumstances.

[0026] like Figure 1 and 2 As shown, this embodiment provides a highly flexible and lightweight data cable, including a core layer, a main shielding layer 3, and an outer sheath layer 4 wrapped sequentially from the inside out. The core layer includes a coaxial signal unit 1 and a power unit 2. The gap between the coaxial signal unit 1 and the power unit 2 is filled with flexible fiber filaments 5. The coaxial signal unit 1 includes multiple coaxial core wires 101 wrapped sequentially from the inside out, an insulation layer 102, a low-frequency shielding layer 103, a high-frequency shielding layer 104, and a smooth wrapping layer 105.

[0027] In this embodiment, the number of coaxial signal units 1 is seven, corresponding to the seven unit lines of USB 3.0: D-, D+, SSTX±, SSRX±, and GND_DRAIN; the power unit 2 consists of two unit lines: VBUS and GND.

[0028] The flexible fiber filaments 5 are interwoven Kevlar fiber layers. The interwoven flexible fiber filaments 5 form a three-dimensional network, which can ensure the structural stability of the cable, prevent the core wires of the coaxial signal unit 1 and the power unit 2 from shifting or deforming, and ensure the consistency of electrical performance.

[0029] The insulating layer 102 is a fluoropolymer layer. The fluoropolymer layer (which can use commercially available designs such as perfluoroethylene propylene (FEP) or polytetrafluoroethylene (PTFE)) has a dielectric constant of less than 2.5, exhibiting low dielectric loss and high insulation strength. Combined with the multiple coaxial core wires 101 encased within the extruded structure, it provides a stable electrical environment for signal transmission.

[0030] The low-frequency shielding layer 103 includes an oxygen-free copper wire mesh. The oxygen-free copper wire mesh has high conductivity and can form a low-impedance shielding layer, effectively attenuating low-frequency interference (such as 50 / 60Hz power frequency interference and internal power supply noise of the equipment).

[0031] The high-frequency shielding layer 104 includes a single-sided conductive aluminum foil layer. This single-sided conductive aluminum foil layer, tightly bonded to the oxygen-free copper wire mesh, has reflective properties against high-frequency electromagnetic waves and can shield against high-frequency interference (such as 100MHz-3GHz wireless communication signals and radio frequency interference). Thus, the combination of low-frequency and high-frequency shielding effectively improves the anti-interference capability of the cable when transmitting signals.

[0032] The smooth wrapping layer 105 is a PET film layer. The smooth wrapping layer 105 can fix and tightly wrap the low-frequency shielding layer 103 and the high-frequency shielding layer 104, enhance the integrity of the shielding layer, and prevent the aluminum foil and copper wire mesh from loosening; while the smooth surface has a low coefficient of friction, and the friction and wear phenomenon with adjacent structures during dynamic bending is slight.

[0033] The power unit 2 comprises multiple stranded power cores, each coated with a fluorine-containing coating. The power unit 2 can employ a 3-strand strand (3C structure) to enhance tensile and bending resistance through geometric stability. The fluorine-containing coating has a very low coefficient of friction, meeting the requirements for low friction and wear resistance in dynamic scenarios, while the low dielectric constant of the fluorine-containing material (less than 2.1) ensures the integrity of auxiliary signal transmission.

[0034] The main shielding layer 3 includes a copper wire braided layer, which is wrapped with a tin-plated layer. The tin-plated layer can improve the corrosion resistance of the copper wire, thereby ensuring the dual function of electromagnetic shielding of the main shielding layer 3 and enhancing the tensile and tear resistance of the cable.

[0035] The outer sheath layer 4 comprises a thermoplastic elastomer. The thermoplastic elastomer of the outer sheath layer 4 can be an extruded TPE sheath that is already in use on the market, so as to tightly wrap all the internal cable structures while ensuring the thin and flexible performance of the cable outer sheath.

[0036] The above description is a further detailed explanation of the present utility model in conjunction with specific preferred embodiments. It should not be assumed that the specific implementation of the present utility model is limited to these descriptions. All equivalent changes and modifications made within the scope of this application should still fall within the scope of the present utility model.

Claims

1. A high-flexibility lightweight data cable, characterized by, It includes a core layer, a main shielding layer, and an outer sheath layer that are wrapped from the inside out. The core layer includes a coaxial signal unit and a power unit. The gap between the coaxial signal unit and the power unit is filled with flexible fiber filaments. The coaxial signal unit includes multiple coaxial core wires, an insulation layer, a low-frequency shielding layer, a high-frequency shielding layer, and a smooth wrapping layer that are wrapped from the inside out.

2. The high-flex, lightweight data cable of claim 1, wherein, The flexible fiber filaments are interwoven layers of Kevlar fibers.

3. The high-flex, lightweight data cable of claim 1, wherein, The insulating layer is a fluoropolymer layer.

4. The high-flex, lightweight data cable of claim 1, wherein, The low-frequency shielding layer includes an oxygen-free copper wire mesh.

5. The high-flex, lightweight data cable of claim 1, wherein, The high-frequency shielding layer includes a single-sided conductive aluminum foil layer.

6. The high-flex, lightweight data cable of claim 1, wherein, The smooth coating layer is a PET film layer.

7. The high-flex, lightweight data cable of claim 1, wherein, The power unit includes multiple stranded power cores, each with a fluorine-containing coating on its surface.

8. The high-flex, lightweight data cable of claim 1, wherein, The main shielding layer includes a copper wire braided layer, on which a tin-plated layer is wrapped.

9. The high-flex, lightweight data cable of claim 1, wherein, The outer sheath layer comprises a thermoplastic elastomer.

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