A flexible cable

Abstract

The utility model relates to cable technical field discloses a kind of flexible cables, comprising: cable assembly, comprising several first wire groups, several first wire groups are spaced and arranged side by side, the first wire group includes two groups of unit wire, and the unit wire includes the wrapping layer, shielding layer and a pair of wire core sequentially arranged from outside to inside;And sheath layer, for covering the outside of cable assembly and connecting each first wire group.The utility model's flexible cable splits cable into multiple first wire groups, so that each first wire group contains a pair of wire core, and is covered by sheath layer, so that the toughness of overall cable can be improved.

Description

Technical Field

[0001] This utility model belongs to the field of cable technology, and specifically relates to a flexible cable. Background Technology

[0002] The precision equipment on the market is now developing towards miniaturization and refinement, making the installation environment smaller and narrower. This places extremely high demands on the spatial adaptability of cables. Furthermore, the power supply and communication needs of different equipment and under different working conditions are diverse, requiring cables to be flexible and adaptable to stretching and bending working environments.

[0003] Currently, existing cable structures combine various types of cables. Some cables are glued together, which makes them prone to detachment during use and unsuitable for cable chains. Furthermore, the materials used for the cable sheathing require high precision during splicing. Additionally, most composite cables on the market have large bending radii, making them susceptible to fatigue cracking in cable chain environments. Utility Model Content

[0004] To address the shortcomings of the existing technology, this utility model provides a flexible cable. The cable assembly is implemented by dividing the cable into groups, and then covered by an outer sheath to form a flat push-chain cable, which can adapt to the various power supply and communication needs of various electrical equipment.

[0005] The technical effects to be achieved by this utility model are realized through the following aspects: This utility model provides a flexible cable, comprising: A cable assembly includes several first wire groups arranged side-by-side with intervals between them. Each first wire group includes two sets of unit wires, and each unit wire includes a wrapping layer, a shielding layer, and a pair of wire cores arranged sequentially from the outside to the inside. An outer sheath is used to cover the outside of the cable assembly and connect each of the first cable groups.

[0006] In some implementations, the outer coating layer is an FEP membrane and / or a PTFE membrane.

[0007] In some implementations, the outer coating layer includes an outer layer and an inner layer, wherein the outer layer is a PTFE membrane and the inner layer is an FEP membrane.

[0008] In some implementations, the outer coating layer includes an outer layer and an inner layer, wherein the outer layer is an FEP membrane and the inner layer is a PTFE membrane.

[0009] In some implementations, the outer coating layer includes an outer layer and an inner layer, wherein the outer layer is a PTFE membrane and the inner layer is a PU membrane or a PFA membrane.

[0010] In some implementations, the wrapping layer includes a wrapping tape with a width of 1cm to 2cm, and the wrapping tape is made of PTFE material.

[0011] In some implementations, the shielding layer is a copper-tin alloy braided layer.

[0012] In some implementations, the spacing between two adjacent first line groups is 0.5 mm to 2 mm.

[0013] In some implementations, the thickness of the outer coating layer ranges from 0.2 mm to 0.8 mm.

[0014] In some implementations, the cable assembly further includes at least one second wire group, the second wire group comprising twisted pairs.

[0015] In summary, this utility model has at least the following advantages: This utility model provides a flexible cable comprising two parts: a cable assembly and an outer sheath. The outer sheath covers the cable assembly, which includes several separately arranged first wire groups. The outer sheath covers and separates and connects adjacent first wire groups, thus forming a flat flexible cable. This reduces the cable's space occupation during installation and makes it suitable for smaller installation environments. The unit wires within each first wire group employ a layered structure with a pair of cores, an outer shield, and a wrapping layer. Combined with the overall design of the flat outer sheath, this reduces the risk of structural damage to the cable due to friction or bending. Dividing the cable into multiple parallel, spaced wire groups, each wrapped by the outer sheath, enhances the overall toughness of the cable. The flattened cable better releases the internal stress caused by the bending motion of the cable chain, preventing fatigue cracking of the outer sheath and maintaining good flexibility and bending performance. Attached Figure Description

[0016] Figure 1 This is a schematic diagram of the structure of the flexible cable in Embodiment 1 of this utility model.

[0017] Figure 2 This is a partial structural diagram of the flexible cable in embodiments 1, 2, and 3 of this utility model.

[0018] Figure 3 This is a schematic diagram of the structure of the flexible cable in Embodiment 3 of this utility model.

[0019] Figure 4 This is a partial structural diagram of the flexible cable of Embodiment 3 of this utility model.

[0020] Marked in the image: 1. Cable assembly; 11. First wire group; 12. Unit wire; 13. Wire core; 131. Inner sheath layer; 14. Wrapping layer; 15. Shielding layer; 16. Second wire group; 17. Twisted pair shielded wire; 18. Twisted pair wire; 2. Outer sheath layer; 21. Outer layer; 22. Inner layer; 3. Spacing area. Detailed Implementation

[0021] 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. The described embodiments are some, but not all, of the embodiments of this utility model.

[0022] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.

[0023] Example 1: Please see Figure 1 and Figure 2 The present invention discloses a flexible cable structure comprising: a cable assembly 1, comprising a plurality of first wire groups 11, the plurality of first wire groups 11 being spaced apart and arranged side by side, each first wire group 11 comprising two sets of unit wires 12, each unit wire 12 comprising a wrapping layer 14, a shielding layer 15 and a pair of wire cores 13 arranged sequentially from the outside to the inside; and an outer sheath 2, used to cover the outside of the cable assembly 1 and connect each first wire group 11.

[0024] Specifically, the flexible cable has a flat structure, with the outermost layer consisting of an outer sheath 2 that covers the cable assembly 1. Multiple independent channels are formed within the outer sheath 2 to accommodate the first wire groups 11, allowing the first wire groups 11 to be spaced apart and arranged side-by-side. Adjacent first wire groups 11 are connected and separated by the outer sheath 2, providing stable support and protection for the first wire groups 11. Each first wire group 11 includes two sets of unit wires 12, each set containing a pair of cores 13. These cores 13 are covered by a shielding layer 15, which is then covered by a wrapping layer 14, thus forming a set of unit wires 12. In one embodiment, the arrangement direction of the unit wires 12 within the same set is consistent with the arrangement direction of the first wire groups 11, both arranged side-by-side to reduce internal stress during bending. Of course, the arrangement direction of the unit wires 12 within the same set can also be different from that of the first wire groups 11.

[0025] Understandably, the cable assembly 1 consists of multiple first wire groups 11 and unit wires 12. The number and specifications of the first wire groups 11 and unit wires 12 can be flexibly adjusted according to the power supply and communication needs of different devices to improve the versatility and adaptability of the cable. The unit wires 12 can be configured according to actual usage requirements and can be any linear object, including but not limited to air pipes, copper core wires, and optical fibers. This application does not limit them in this regard.

[0026] It is worth noting that each group of unit wires 12 is individually covered with a shielding layer 15 and a wrapping layer 14, which makes it less likely for the core 13 to become loose or the shielding layer 15 to be damaged during long-term use. This ensures the cable's service life and performance stability, and makes it better suited for dragging and bending scenarios.

[0027] Furthermore, the outer sheath 2 does not completely wrap each of the first wire groups 11 into a flat cable. Instead, it forms a gap region 3 between adjacent first wire groups 11. The gap region 3 consists of two outer sheath layers 2, with the thickness of the outer sheath layers 2 remaining constant. The connection structure is formed solely by the outer sheath layers 2, allowing the cable to bend radially in addition to axial bending. Because the flat cable is flat both top and bottom, the stretching and compression during horizontal movement of the cable chain are less than that of a round cable, resulting in less internal stress and making the outer sheath less prone to fatigue cracking.

[0028] In this embodiment, the flexible cable breaks down the circular structure into multiple small, independent wire groups, facilitating standardized assembly during production and reducing mutual compression and interference between wire groups, thus ensuring the stability of signal transmission. Furthermore, the cable assembly 1 is divided by an outer sheath 2 to form several first wire groups 11, making the cable flat and reducing its thickness. The flat cable fits the equipment better, making it more suitable for mobile applications and adaptable to narrow gaps or bends, eliminating the need for excessive installation space and improving the overall compactness of the equipment layout.

[0029] Example 2: This embodiment represents a further structural optimization of the flexible cable of this invention. Please refer to [link / reference]. Figure 2 .

[0030] In some embodiments, the outer sheath 2 is made of FEP film and / or PTFE film.

[0031] Specifically, the outer sheath 2 is made of FEP film or PTFE film to cover the cable assembly 1. Both FEP film and PTFE film have the characteristics of high temperature resistance and corrosion resistance, which enables the cable to adapt to the complex temperature environment of precision equipment, avoid the aging, cracking or performance degradation of the outer sheath 2 due to temperature changes, and also prevent the outer sheath 2 from being corroded and damaged, resulting in the exposure or performance damage of the wire core 13. Thus, the use of FEP film or PTFE film for the outer sheath 2 can adapt to complex working conditions.

[0032] In addition, the outer sheath 2 can also be a composite membrane of FEP film and PTFE film, which can make the cable lighter while meeting the voltage resistance performance. FEP film and PTFE film themselves have extremely high flexibility and flexural strength. When used as the outer sheath 2, they can significantly reduce the bending radius of the cable.

[0033] It is worth noting that the composite form of the outer sheath 2 can be selected, but is not limited to, using a sintering method to attach the PTFE film onto the EFP film to form a composite outer sheath. An inner sheath 131 is also provided outside the core 13. The core 13 can be selected, but is not limited to, a stranded copper core. Oxygen-free copper wires are twisted together to form the core 13, which is then covered by the inner sheath 131. In some embodiments, the outer layer 2 includes an outer layer 21 and an inner layer 22, wherein the outer layer 21 is made of a PTFE membrane and the inner layer 22 is made of an FEP membrane.

[0034] Specifically, the outer sheath 2 is implemented using a composite membrane, which is composed of two membrane materials. The outer layer 21 is the outer layer, and the inner layer 22 is the inner layer. The outer layer 21 is made of PTFE membrane, and the inner layer 22 is made of FEP membrane. PTFE membrane has excellent high and low temperature resistance and can be used for a long time from -200℃ to 260℃. In addition, PTFE membrane also has good chemical corrosion resistance and is almost unreactive to strong acids, strong alkalis, organic solvents, etc. It can directly resist the erosion of the external environment and also gives the cable good cleaning ability. In addition, the surface friction coefficient of PTFE membrane is extremely low, which makes it have better wear resistance.

[0035] The inner layer 22 uses an FEP film, which has superior flexibility and heat-sealing properties compared to the PTFE film of the outer layer 21. As the inner layer 22, the FEP film can closely fit the outer contour of the cable assembly 1, preventing loosening or gaps between the outer sheath 2 and the inner unit line 12, thus enhancing the stability of the overall cable structure.

[0036] In another embodiment, the outer layer 2 includes an outer layer 21 and an inner layer 22, wherein the outer layer 21 is made of an FEP film and the inner layer 22 is made of a PTFE film.

[0037] Specifically, the FEP membrane, as the outer layer 21, has superior flexibility and fatigue resistance compared to the PTFE membrane. As the outer layer 21, it can withstand high-frequency reciprocating bending of the cable chain. The PTFE membrane, as the inner layer 22, wraps the cable assembly 1, providing more reliable high-temperature protection for its internal unit wires 12. The inner layer 22 and the outer layer 21 form a composite membrane, achieving a balance between rigid support and flexible buffering, thus improving the reliability of the cable during dynamic movement.

[0038] To enhance the applicability of the bilayer composite membrane, in some embodiments, the outer layer 2 includes an outer layer 21 and an inner layer 22. The outer layer 21 is made of PTFE membrane, and the inner layer 22 is made of PU membrane or PFA membrane. It is understood that the composite membrane of the outer layer 2 can be composed of multiple membranes. The membrane selected for the outer layer 21 needs to have wear resistance and self-lubricating properties, while the inner layer 22 needs to contain a highly tough membrane.

[0039] In some embodiments, the thickness of the outer layer 2 ranges from 0.2 mm to 0.8 mm.

[0040] Specifically, the thickness of the outer sheath 2 is set within the range of 0.2mm to 0.8mm. This thickness range ensures the stability of the outer sheath 2's coverage of the internal cable assembly 1, preventing protection failure due to excessive thinness, while also avoiding increased cable rigidity due to excessive thickness. Moreover, when the composite membrane outer sheath 2 uses FEP and PTFE membranes, it achieves lightweight design while still meeting voltage resistance requirements. The composite membrane outer sheath 2 reduces the cable bending radius to meet the high-frequency reciprocating bending requirements of the cable chain system, reducing stress accumulation during bending and thus lowering the probability of cracking of the outer sheath 2 or damage to the internal core 13.

[0041] In this embodiment, the outer sheath 2 uses a fluorine film composite to replace the traditional thick elastic outer sheath, thereby achieving the effect of reducing the weight of the cable. The composite film of the outer sheath 2 can be lightweight and ultra-thin. At the same time, the flat split design into independent wire groups reduces the overall diameter of the cable, allowing it to pass through narrow gaps and passages, and improving the flexibility of the installation layout.

[0042] Example 3: This embodiment represents a further structural optimization of the flexible cable of this invention. Please refer to [link / reference]. Figures 2 to 4 .

[0043] In some embodiments, the wrapping layer 14 includes a wrapping tape with a width of 1cm to 2cm, and the wrapping tape is made of PTFE material.

[0044] Specifically, a wrapping layer 14 is used to reinforce the outside of the shielding layer 15. The wrapping layer 14 is implemented by wrapping tape. During the wrapping process, the PTFE wrapping tape is spirally wrapped at a 45° angle to the axis of the shielding layer 15 to prevent the shielding layer 15 from loosening or shifting during movement. In addition, the width of the wrapping tape is 1cm to 2cm, which allows for greater deformation space for each turn of the wrapping tape and increases the tensile strength of the cable.

[0045] In some embodiments, the shielding layer 15 is a copper-tin alloy braided layer.

[0046] Specifically, a pair of wire cores 13 are twisted together to form a near-circular cross-section. A copper-tin alloy is then braided around the outside to form a shielding layer 15. This shielding layer 15, made of copper-tin alloy braid, retains the excellent conductivity of pure copper while forming a dense mesh structure through the braiding process, effectively reflecting and absorbing external electromagnetic interference signals. The copper-tin alloy braid plays a protective and shielding role in the unit line 12, ensuring the transmission quality and mechanical strength of the unit line 12. It is worth noting that the shielding layer 15 can also be implemented using metal foil wrapping, a pure metal braid, an alloy braid, or non-metallic conductive shielding materials, depending on the specific requirements; this application does not limit the specific implementation method.

[0047] In some embodiments, the spacing between two adjacent first line groups 11 is 0.5 mm to 2 mm.

[0048] Specifically, there is a gap between two adjacent first wire groups 11, with the gap 3 ranging from 0.5mm to 2mm. This gap provides a reasonable physical isolation space between adjacent wire groups, which can reduce the electromagnetic coupling effect between wire groups. In addition, the gap of 0.5mm to 2mm can form a natural air circulation channel, which can help the cable dissipate heat during use.

[0049] In some embodiments, the cable assembly 1 further includes at least one second wire group 16, the second wire group 16 including twisted pair 18.

[0050] Specifically, the cable assembly 1 also includes a second wire group 16. The cable assembly 1 can be formed by arranging and combining the first wire group 11 and the second wire group 16. In some embodiments, the cable assembly 1 includes multiple first wire groups 11 and at least one second wire group 16, with the second wire group 16 used to extend the cable's functionality. The second wire group 16 may optionally include, but is not limited to, three or four sets of twisted pairs 18 to meet actual usage requirements. In some implementations, the second wire group 16 includes two sets of twisted-pair shielded wires 17, each set of twisted-pair shielded wires 17 containing three pairs of twisted pairs 18, which can specifically carry different types of signals, complementing the function of the first wire group 11. In some implementations, the original cable is a 6*2*0.2 twisted-pair shielded wire 17, which is split into 3*2*0.2 twisted-pair shielded wires 17, with the two sets of wires placed side-by-side and covered by the outer sheath 2.

[0051] In this embodiment, the cable assembly 1 includes a first wire group 11 and a second wire group 16, enabling the flexible cable to improve signal transmission diversity, configuration flexibility, and structural reliability, and better meet the comprehensive electrical needs of precision equipment under complex operating conditions. The wrapping layer 14 within the unit wire 12 uses PTFE material wrapping tape to wrap the shielding layer 15, while the shielding layer 15 uses a copper-tin alloy braided layer to ensure the transmission quality and mechanical strength of the unit wire 12.

[0052] In this utility model, unless otherwise explicitly specified and limited, the terms "installation," "connection," "joining," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0053] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, or the orientation or positional relationship commonly used when the product of this utility model is in use. They are only for the convenience of describing this utility model and 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. In addition, the terms "first," "second," and "third," etc., are only used to distinguish descriptions and should not be construed as indicating or implying relative importance.

[0054] Furthermore, terms such as "horizontal," "vertical," and "sag" do not imply that components must be absolutely horizontal or suspended, but rather that they can be slightly tilted. For example, "horizontal" simply means that its direction is more horizontal relative to "vertical," and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0055] In this invention, unless otherwise expressly specified and limited, "above or below" the first feature may include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on" the first feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the first feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0056] Although the description of this utility model has been given in conjunction with the specific embodiments described above, it is obvious to those skilled in the art that many substitutions, modifications, and variations can be made based on the above description. Therefore, all such substitutions, modifications, and variations are included within the spirit and scope of the appended claims.

Claims

1. A flexible cable, characterized in that, include: A cable assembly includes several first wire groups arranged at intervals and side-by-side. Each first wire group includes two sets of unit wires, and each unit wire includes a wrapping layer, a shielding layer, and a pair of wire cores arranged sequentially from the outside to the inside. An outer sheath is used to cover the outside of the cable assembly and connect each of the first cable groups.

2. The flexible cable according to claim 1, characterized in that, The outer coating is made of FEP film and / or PTFE film.

3. The flexible cable according to claim 2, characterized in that, The outer coating layer includes an outer layer and an inner layer, wherein the outer layer is made of PTFE membrane and the inner layer is made of FEP membrane.

4. The flexible cable according to claim 2, characterized in that, The outer coating layer includes an outer layer and an inner layer, wherein the outer layer is made of FEP film and the inner layer is made of PTFE film.

5. The flexible cable according to claim 1, characterized in that, The outer coating layer includes an outer layer and an inner layer. The outer layer is made of PTFE membrane, and the inner layer is made of PU membrane or PFA membrane.

6. The flexible cable according to any one of claims 1 to 5, characterized in that, The wrapping layer includes a wrapping tape with a width of 1cm to 2cm, and the wrapping tape is made of PTFE material.

7. The flexible cable according to any one of claims 1 to 5, characterized in that, The shielding layer is made of copper-tin alloy braided layer.

8. The flexible cable according to any one of claims 1 to 5, characterized in that, The spacing between two adjacent first line groups is 0.5 mm to 2 mm.

9. The flexible cable according to any one of claims 1 to 5, characterized in that, The thickness of the outer coating layer ranges from 0.2 mm to 0.8 mm.

10. The flexible cable according to claim 1, characterized in that, The cable assembly further includes at least one second wire group, the second wire group comprising twisted pairs.

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