A type of bend-resistant ABS sensor cable

Abstract

This utility model discloses a bend-resistant ABS sensor cable, comprising a core wire assembly, which includes several looped core wires. Each core wire includes a bare copper conductor and an elastomer insulation layer covering the bare copper conductor. A memory fiber filling layer is located at the center of the core wire assembly. From the inside out, the core wire assembly is surrounded by a polyester tape wrapping layer, a copper wire braided shielding layer, an aluminum foil shielding layer, and an elastomer sheath. A tinned copper lead wire is located between the polyester tape wrapping layer and the copper wire braided shielding layer. This bend-resistant ABS sensor cable significantly improves the cable's bend resistance, shape recovery ability, electromagnetic shielding effectiveness, and mechanical durability, making it particularly suitable for harsh environments such as vehicle ABS systems, characterized by high vibration, high-frequency bending, and strong electromagnetic interference.

Description

Technical Field

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

[0002] With the increasing sophistication of automotive electronic control systems, the reliability and accuracy of anti-lock braking systems (ABS) have become crucial. As a key component connecting sensors and control units, ABS sensor cables operate in extremely harsh environments, typically needing to be installed near the vehicle chassis, suspension, and steering knuckles, enduring long-term high-frequency vibrations, repeated small-radius bending, and the corrosive effects of oil, moisture, and chemical media. Traditional ABS sensor cables often use ordinary copper conductors and PVC insulation sheaths, which suffer from insufficient flexibility and poor fatigue resistance. Under dynamic stress, the conductors are prone to breakage, and the insulation sheath is prone to cracking, leading to signal transmission failure or interruption. Their shielding structure (such as simple aluminum foil wrapping) is easily damaged or its shielding effectiveness decreases after repeated bending, failing to effectively resist complex electromagnetic interference within the vehicle and affecting the accuracy of ABS signals. While solutions using elastomer materials to improve bending resistance exist, core issues such as internal stress dispersion, interlayer structural stability, and long-term dynamic durability have not been systematically addressed. Therefore, there is an urgent need for a comprehensive ABS sensor cable that combines excellent resistance to repeated bending, high shielding effectiveness, good environmental resistance, and long lifespan. Utility Model Content

[0003] The purpose of this invention is to provide a bend-resistant ABS sensor cable to solve the problems existing in the prior art.

[0004] The purpose of this utility model is achieved as follows: A bend-resistant ABS sensor cable includes a core wire assembly, which includes several looped core wires. Each core wire includes a bare copper conductor and an elastomer insulation layer covering the bare copper conductor. A memory fiber filling layer is provided at the center of the core wire assembly. From the inside to the outside, the core wire assembly is provided with a polyester tape wrapping layer, a copper wire braided shielding layer, an aluminum foil shielding layer, and an elastomer sheath. A tinned copper lead wire is provided between the polyester tape wrapping layer and the copper wire braided shielding layer.

[0005] This utility model of a bend-resistant ABS sensor cable, through the combination structure of a central memory fiber filling layer and a ring-shaped core wire, combined with double-layer shielding (copper wire braided layer and aluminum foil layer) and an elastomer sheath design, significantly improves the cable's bend resistance, shape recovery ability, electromagnetic shielding effectiveness and mechanical durability, and is especially suitable for harsh environments with high vibration, high frequency bending and strong electromagnetic interference, such as vehicle ABS systems.

[0006] As a further improvement of this invention, the bare copper conductor is a multi-strand stranded structure that has undergone annealing treatment. The annealing treatment and the multi-strand stranded structure significantly improve the conductor's flexibility, fatigue strength, and conductivity stability.

[0007] As a further improvement of this utility model, both the elastomer insulation layer and the elastomer sheath adopt a tubular structure made of thermoplastic polyester elastomer material. The thickness of the elastomer insulation layer is 0.3-0.5mm, and the thickness of the elastomer sheath is 0.6-0.8mm. While ensuring good insulation and protection, the bending resistance and durability of the cable are further enhanced.

[0008] As a further improvement of this utility model, the memory fiber filling layer is a columnar structure composed of multiple layers of highly elastic fibers and shape memory polymers that mimic the structure of muscle fibers. It can achieve dynamic stress absorption and self-repair function, enhance mechanical durability and signal fidelity, and significantly reduce the damage to the core wire assembly caused by bending.

[0009] As a further improvement of this utility model, the polyester tape wrapping layer is a continuous tubular structure formed by wrapping biaxially oriented polyester film tape with a wrapping rate of 20%~25%, which effectively improves the tightness and stability of the wrapping layer, provides more reliable protection for the internal core wires, and enhances the overall tensile and bending resistance of the cable.

[0010] As a further improvement of this utility model, the braided coverage of the copper wire braided shielding layer is not less than 85%. The high coverage copper wire braided layer has both excellent electromagnetic shielding and resistance to bending fatigue, which can enhance the overall structural stability.

[0011] As a further improvement of this utility model, the aluminum foil shielding layer is a single-sided aluminum foil Mylar wrapping shielding layer formed by a composite process of pure aluminum foil and Mylar substrate. While ensuring shielding performance, it reduces the weight of the cable and improves the flexibility and bending resistance of the cable.

[0012] As a further improvement of this utility model, the core wire group includes 4 core wires, and the outer surfaces of the elastic insulation layers of adjacent core wires are in contact with each other, making the core wire group structure more compact, reducing the gaps inside the cable, improving the overall structural stability of the cable, and the four-core symmetrical contact layout is conducive to optimizing signal transmission consistency. Attached Figure Description

[0013] Figure 1 This is a schematic diagram of the structure of the bend-resistant ABS sensor cable of this utility model.

[0014] The components are: 1. bare copper conductor, 2. elastomeric insulation layer, 3. memory fiber filling layer, 4. polyester tape wrapping layer, 5. tinned copper lead wire, 6. copper wire braided shielding layer, 7. aluminum foil shielding layer, and 8. elastomeric sheath. Detailed Implementation

[0015] like Figure 1 The bending-resistant ABS sensor cable shown includes a core wire assembly, which comprises four looped core wires. Each core wire includes a bare copper conductor 1 and an elastomeric insulation layer 2 covering the bare copper conductor 1, with the outer surfaces of the elastomeric insulation layers 2 of adjacent core wires in contact with each other. A memory fiber filling layer 3 is located at the center of the core wire assembly. From the inside out, the core wire assembly is provided with a polyester tape wrapping layer 4, a copper wire braided shielding layer 6, an aluminum foil shielding layer 7, and an elastomeric sheath 8. A tinned copper lead wire 5 is located between the polyester tape wrapping layer 4 and the copper wire braided shielding layer 6.

[0016] Among them, bare copper conductor 1 is a high-purity bare copper conductor, which is treated with a precision annealing process. While maintaining excellent conductivity, it significantly enhances the material's flexibility and fatigue strength. Its multi-strand stranded structure not only ensures efficient transmission and accurate feedback of ABS sensor signals through low resistance characteristics, reducing signal attenuation and delay, but also gives the cable excellent bending resistance—it can withstand thousands of reciprocating bends without easily breaking. It is perfectly suited for working environments with high-frequency vibration and frequent deformation, such as automotive chassis, and constitutes the core elements of the bending-resistant ABS sensor cable for high efficiency, reliability, and long life.

[0017] Elastomer Insulation Layer 2: Utilizing high-performance thermoplastic polyester elastomer as the insulation material, with a thickness of 0.3-0.5mm, it maintains excellent flexibility and resilience over a wide temperature range, giving the cable superior resistance to repeated bending and torsion. This ensures that the insulation layer is less prone to cracking or fatigue failure during high-frequency vibrations, steering, and bumps in the vehicle chassis, effectively preventing wear, compression damage, and foreign object intrusion during installation or use. Simultaneously, the polyester elastomer insulation layer 2 possesses excellent resistance to oil, chemical corrosion, and weathering, resisting the erosion of oil, salt spray, and various chemical media in the automotive environment. It is one of the core guarantees for the high reliability and long service life of the bend-resistant ABS sensor cable.

[0018] The memory fiber filling layer 3 is composed of multiple layers of highly elastic fibers and shape memory polymers, mimicking the structure of muscle fibers in an alternating composite. When the cable is subjected to high-frequency, small-radius bending due to vehicle movement, the internal biomimetic elastic fiber network actively extends and retracts like a "muscle," efficiently absorbing and dispersing most of the dynamic mechanical stress and preventing stress concentration from impacting the internal conductors. Furthermore, under triggered conditions, the shape memory polymer fibers can undergo controllable phase transition recovery, generating continuous and directional contractile force to offset the internal shear stress caused by the difference in thermal expansion coefficients of different materials, repairing microcracks caused by frequent deformation, forming an intelligent, adaptive dynamic stress compensation and self-healing mechanism. This provides mechanical durability and signal fidelity for the bend-resistant ABS sensor cable.

[0019] The fourth layer, a polyester tape wrapping layer, uses high-strength biaxially oriented polyester film tape tightly wrapped around the cable core wires at a 20%~25% overlap rate, constructing a robust load-bearing and structurally stable layer. This layer, leveraging the extremely high tensile strength and modulus of polyester, effectively binds and integrates the multiple internal insulated core wires, preventing relative displacement or torsion during repeated bending, thereby offsetting radial stress and suppressing core wire deformation. Simultaneously, the excellent heat resistance of the polyester tape ensures its dimensional stability and performance without degradation in high-temperature engine compartment environments, a key design feature guaranteeing the structural integrity and long-term reliability of the bend-resistant ABS sensor cable under dynamic operating conditions.

[0020] Tinned copper lead wire 5, as a key component of the shielding layer, plays a crucial role in constructing a low-impedance, highly reliable discharge path. When the shielding layer inevitably develops minute gaps or fluctuations in contact resistance due to dynamic bending of the cable, the tinned copper lead wire 5, with its excellent conductivity and flexibility, greatly eliminates the risk of signal distortion or false alarms caused by shielding failure.

[0021] The copper wire braided shielding layer 6 boasts a high braiding coverage of up to 85%, significantly enhancing the cable's resistance to bending fatigue and its electromagnetic shielding effectiveness. Its multi-strand fine copper wire interwoven mesh structure not only disperses deformation stress during repeated bending, preventing shielding damage caused by single-wire breakage, but also effectively blocks electromagnetic interference thanks to the excellent conductivity of pure copper. Furthermore, the tight fit between this pure copper braided layer and the inner polyester tape and outer sheath helps enhance the overall structural stability of the cable, reduces interlayer friction loss, and further improves the operational reliability and service life of the ABS sensor cable under complex dynamic conditions.

[0022] The aluminum foil shielding layer 7 uses single-sided aluminum foil Mylar tape, made of high-ductility pure aluminum foil and high-strength Mylar substrate composite. This ensures excellent electromagnetic shielding performance while significantly improving the cable's bending resistance and interlayer bonding stability. The aluminum foil layer effectively reflects and blocks electromagnetic interference, ensuring accurate signal transmission during braking. The Mylar substrate has tear resistance and bending fatigue resistance, providing stable support for the aluminum foil layer during repeated bending, preventing aluminum foil breakage or delamination between the aluminum foil and Mylar layers due to deformation. The oil resistance of the Mylar substrate resists corrosion from engine compartment oil, further ensuring the operational reliability and service life of the ABS sensor cable under complex dynamic conditions.

[0023] The elastomeric sheath 8, serving as the outermost protective armor of the cable, is made of the same elastomeric material as the insulation, with a thickness of 0.6-0.8mm, providing crucial physical protection for the internal precision structure. Its highly elastic molecular chain structure not only actively disperses deformation stress during repeated bending of the cable, preventing damage to the inner insulation and shielding layers due to excessive local stretching or compression, but also maintains sheath integrity even in demanding applications such as automotive chassis suspensions and steering knuckles, which experience tens of thousands of bending cycles daily. This effectively blocks the intrusion of external dust and moisture, further ensuring the cable's structural stability and guaranteeing accurate and reliable signal transmission.

[0024] The ABS sensor cable of this embodiment, through the combination structure of the central memory fiber filling layer 3 and the ring-shaped core wire, combined with the double-layer shielding (copper wire braided layer and aluminum foil layer) and the elastomer sheath 8 design, significantly improves the cable's bending resistance, shape recovery ability, electromagnetic shielding effectiveness and mechanical durability, and is especially suitable for harsh environments such as vehicle ABS systems with high vibration, high frequency bending and strong electromagnetic interference.

[0025] This utility model is not limited to the above embodiments. Based on the technical solutions disclosed in this utility model, those skilled in the art can make some substitutions and modifications to some of the technical features without creative labor, and these substitutions and modifications are all within the protection scope of this utility model.

Claims

1. A bend-resistant ABS sensor cable comprising a core set, the core set comprising a number of looped core wires, characterized in that: The core wire includes a bare copper conductor and an elastomeric insulation layer covering the bare copper conductor. The core wire assembly has a memory fiber filling layer at its center. The core wire assembly is provided with a polyester tape wrapping layer, a copper wire braided shielding layer, an aluminum foil shielding layer and an elastomeric sheath in sequence from the inside to the outside. A tinned copper lead wire is provided between the polyester tape wrapping layer and the copper wire braided shielding layer.

2. The bend-insensitive ABS sensor cable of claim 1, wherein: The bare copper conductor is a multi-strand stranded structure that has undergone annealing.

3. The bend-insensitive ABS sensor cable of claim 1, wherein: Both the elastomeric insulation layer and the elastomeric sheath are tubular structures made of thermoplastic polyester elastomer material. The thickness of the elastomeric insulation layer is 0.3-0.5 mm, and the thickness of the elastomeric sheath is 0.6-0.8 mm.

4. The bend-insensitive ABS sensor cable of claim 1, wherein: The memory fiber filling layer is a columnar structure composed of multiple layers of highly elastic fibers and shape memory polymers that mimic the structure of muscle fibers in an alternating composite.

5. The bend-insensitive ABS sensor cable of claim 1, wherein: The polyester tape wrapping layer is a continuous tubular structure formed by wrapping a biaxially oriented polyester film tape with a wrapping rate of 20% to 25%.

6. The bend-resistant ABS sensor cable according to claim 1, characterized in that: The braided coverage of the copper wire braided shielding layer is not less than 85%.

7. The bend-insensitive ABS sensor cable of claim 1, wherein: The aluminum foil shielding layer is a single-sided aluminum foil Mylar wrapping shielding layer formed by a composite process of pure aluminum foil and Mylar substrate.

8. The bend-insensitive ABS sensor cable of any of claims 1-7, wherein: The core wire group includes 4 core wires, and the outer surfaces of the elastomeric insulation layers of adjacent core wires are in contact with each other.

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