A new type of ultra-flexible base station cable

Abstract

This application belongs to the field of communication equipment, specifically a novel ultra-flexible base station cable, comprising a conductor, a support member, an insulation layer, and an outer sheath. The conductor is a multi-strand annealed soft copper wire layered stranded structure. The support member is combined with the multi-strand annealed soft copper wire. The insulation layer covers the outside of the conductor. The outer sheath covers the outside of the insulation layer. The inner wall of the insulation layer has an integrally formed mating groove that matches the outer contour of the insulation layer. The conductor of this application uses annealed soft copper wire with a diameter ≤0.10mm, stranded in three layers with an outer layer pitch ratio of 18-20. The smaller diameter copper wire has lower rigidity, and the large pitch ratio stranding reduces the stranding tension between the copper wires. When bending, the individual wires can smoothly displace along the stranding trajectory, avoiding rigid friction. This allows for multi-directional small-radius bending in confined spaces such as inside base station cabinets and between equipment, improving construction efficiency by more than 40% and reducing the risk of construction failures.

Description

Technical Field

[0001] This application relates to the field of communication equipment, specifically a novel ultra-flexible base station cable. Background Technology

[0002] With the large-scale application of 5G communication technology, base stations, as the core hub of the communication network, are experiencing increasingly higher levels of internal equipment integration. The cabinet space is becoming increasingly limited, and the cable laying environment is also showing complex characteristics of "multi-directional bending, frequent adjustments, and long-term pressure." Flexible cabling is required in narrow areas such as the gaps between equipment inside the cabinet (often less than 200mm) and the connection points between antennas and main equipment. At the same time, the cabling must withstand long-term environmental influences such as equipment operating vibration (10~500Hz), temperature and humidity fluctuations (from -10℃ in winter to 80℃ in summer), and corrosion from dust and cleaning agents.

[0003] Existing base station cables mostly use ordinary copper wires with a diameter of ≥0.15mm for the conductor, and the outer layer twisting ratio is only 12-15 times. The tight twisting structure results in strong overall conductor rigidity, and the minimum bending radius needs to be ≥10 times the cable outer diameter. When laid in narrow areas such as inside base station cabinets and between equipment, if it is forcibly bent to adapt to the space, the copper wires of the conductor are prone to breakage due to rigid friction, resulting in a reduction in conductor cross-section and an increase in resistance, which reduces construction efficiency. Therefore, it is necessary to design a new type of ultra-flexible base station cable to solve the above problems. Utility Model Content

[0004] The purpose of this application is to address the shortcomings of existing technologies by designing a new type of ultra-flexible base station cable using a method of layered stranding of fine-diameter annealed soft copper wire and synergistic support of double-layer aramid wire, and adding an adaptable insulating sheath. This solves the problems of existing base station cables having high conductor rigidity, large minimum bending radius, and easy wire breakage when laid in narrow areas, resulting in low construction efficiency.

[0005] To achieve the above objectives, the following technical solution is adopted: A novel ultra-flexible base station cable includes a conductor, a support member, an insulation layer, and an outer sheath. The conductor is a multi-strand annealed soft copper wire stranded in layers. The support member is combined with the multi-strand annealed soft copper wire. The insulation layer covers the outside of the conductor. The outer sheath covers the outside of the insulation layer. The inner wall of the insulation layer is integrally formed with a mating groove, which is adapted to the outer contour of the insulation layer.

[0006] Preferably, the support includes aramid wires, which are divided into two groups. One group of aramid wires is embedded and fixed in the center layer of the conductor along the axial direction, and the other group of aramid wires is embedded and fixed between the outer annealed soft copper wires of the conductor according to the principle of equal number of wires.

[0007] Preferably, the conductor is stranded in three layers, with the outer layer of annealed soft copper wire having a pitch ratio of 18-20 times.

[0008] Preferably, the insulating layer is made of cross-linked polyethylene.

[0009] Preferably, the outer sheath is made of thermoplastic elastomer.

[0010] Preferably, the mating grooves on the inner wall of the insulating layer are distributed in a ring array.

[0011] Preferably, the diameter of the annealed soft copper wire in the conductor is ≤0.10mm.

[0012] Compared with the prior art, the beneficial effects of this application are: 1. In this application, the conductor uses annealed soft copper wire with a diameter ≤0.10mm, which is stranded in three layers with the outer layer having a pitch ratio of 18-20. The thinner copper wire has lower rigidity, and the large pitch ratio stranding can reduce the stranding tension between the copper wires. When bending, the single wire can smoothly move along the stranding trajectory, avoiding rigid friction. This allows for multi-directional small-radius bending in narrow spaces such as inside base station cabinets and between equipment, improving construction efficiency by more than 40% and reducing the risk of construction failure.

[0013] 2. In this application, a single aramid wire is embedded axially in the center of the conductor and multiple aramid wires are embedded between the outer copper wires at equal intervals. When bent, the copper wires can be buffered from the squeezing and wear of the insulation layer, reducing the fatigue damage of the copper wires. At the same time, it enhances the integrity of the outer structure of the conductor, avoids the loosening and displacement of the layered twisted copper wires, and extends the service life of the cable. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of this application; Figure 2 This is a schematic diagram of the front structure of this application; Figure 3 This is an exploded view of this application.

[0015] Among them, 1. conductor; 2. support component; 21. aramid wire; 3. insulation layer; 4. outer sheath; 5. mating groove. Detailed Implementation

[0016] Reference Figures 1-3 A novel ultra-flexible base station cable includes a conductor 1, a support 2, an insulation layer 3, and an outer sheath 4. The conductor 1 is a multi-strand annealed soft copper wire stranded structure. As the core functional component of the cable, the conductor 1 is responsible for transmitting base station communication signals and power supply current. It is made of multi-strand annealed soft copper wire and has a resistivity of ≤0.0172Ω・mm at 20℃. 2 / m, far lower than that of ordinary copper wire (resistivity ≥0.0175Ω・mm). 2 / m), which can minimize signal transmission loss. In the high-frequency signal (100MHz-1GHz) transmission scenario of base station, the signal attenuation is ≤0.5dB within a distance of 100m, ensuring that 5G communication, data command and other signals are distortion-free and delay-free, meeting the transmission requirements of "high bandwidth and low latency" of base station. The support component 2 is combined with multiple strands of annealed soft copper wire, and the insulation layer 3 is tightly wrapped around the outside of the conductor 1 through extrusion process; the outer sheath 4 is tightly wrapped around the outside of the insulation layer 3 through extrusion process, and the inner wall of the insulation layer 3 is integrally formed with a mating groove 5, which is adapted to the outer contour of the insulation layer 3.

[0017] In this embodiment, during use, the required cable length is first measured and cut according to the laying path inside the base station cabinet and between equipment gaps. Because the cable conductor 1 is made of fine-diameter annealed soft copper wire (diameter ≤0.10mm) twisted with a large pitch ratio (outer layer 18-20 times), it has excellent overall flexibility and can be pre-bent and shaped directly on the laying path without the need for forced bending with tools. Small radius bending within 5 times the cable outer diameter can be achieved manually, avoiding the problem of traditional cables needing to reserve large bending space in advance due to their high rigidity. This allows for quick pre-positioning and adapts to the path planning of narrow spaces in base stations.

[0018] During installation, if the cable needs to be dragged (e.g., from the ground to a high-altitude cabinet), the aramid wire 21 in the support 2 will directly bear the tensile stress. The aramid wire 21 has a breaking strength ≥2800MPa, which can withstand the dragging force during installation (maximum tensile force ≤18kN / m in a single instance), preventing the copper wire of conductor 1 from breaking due to stress concentration. When the cable needs to pass through equipment gaps and bend in multiple directions, the aramid wire 21 embedded in the outer layer will buffer the extrusion and wear between the copper wire and the insulation layer 3. At the same time, the thin copper wire of conductor 1 will smoothly move along the stranding trajectory without rigid friction, enabling continuous multiple bends, greatly reducing construction difficulty and improving installation efficiency.

[0019] During long-term operation of the base station, the cross-linked polyethylene material of the insulation layer 3 can adapt to temperature and humidity fluctuations in the equipment room ranging from -40℃ to 90℃. Simultaneously, the annular array of grooves 5 on the inner wall of the insulation layer 3 forms a snap-fit ​​connection with the conductor 1, with a peel strength ≥50N / 100mm. Even under vibrations generated during base station equipment operation (10~500Hz, acceleration 10m / s²), the insulation layer remains stable. 2 In this environment, it can also prevent the insulation layer 3 from shifting relative to the conductor 1.

[0020] As a preferred embodiment, the support member 2 includes aramid wires 21, which are divided into two groups. One group of aramid wires 21 is embedded and fixed in the central layer of the conductor 1 along the axial direction, serving as the rigid support axis of the conductor. The tensile strength of aramid material is ≥2800MPa, which is more than 5 times that of copper wire, and the elastic modulus is ≥70GPa. It can bear the main tensile stress during cable laying, such as the self-weight tension during dragging and hanging, and avoid copper wire breakage due to stress concentration. The other group of aramid wires 21 is embedded and fixed between the outer annealed soft copper wires of the conductor 1 according to the principle of equal number of wires. Since the base station cable needs to be bent and adjusted frequently, the outer aramid wires 21 can buffer the extrusion and wear between the copper wire and the insulation layer 3, reduce the fatigue damage of the copper wire caused by repeated bending, and reduce the risk of wire breakage. At the same time, the aramid wires 21 and the outer copper wire are twisted together, which can enhance the integrity of the outer structure of the conductor 1, prevent the loosening and displacement of the layered twisted copper wire, ensure that the conductor 1 always maintains a compact structure, and extend the service life of the cable.

[0021] As a preferred method, conductor 1 is stranded in three layers. The outer layer of annealed soft copper wire has a stranding ratio of 18-20 times. The larger stranding ratio can reduce the stranding tension between the copper wires. When bending, the single wire can smoothly move along the stranding trajectory, avoiding rigid friction between adjacent copper wires. This reduces the minimum bending radius of the cable to less than 5 times the cable outer diameter (traditional cables are ≥10 times the outer diameter). This allows for multi-directional small-radius bending in narrow spaces such as inside base station cabinets and between equipment, without the need for forced dragging, greatly reducing construction difficulty.

[0022] As a preferred embodiment, the insulating layer 3 is made of cross-linked polyethylene. After irradiation cross-linking treatment, cross-linked polyethylene exhibits excellent dielectric properties: a dielectric constant of 2.3-2.5 at 23℃ and 1MHz, a dielectric loss tangent ≤0.0005, and a volume resistivity ≥10⁻⁶. 14 Ω・cm; It can form a high insulation isolation layer between conductor 1 and outer sheath 4, block signal crosstalk between adjacent cables, avoid data confusion, and ensure the safety of base station power supply and signal transmission. The temperature range is -40℃ to 90℃, which is far superior to ordinary polyethylene insulation (-20℃ to 70℃). It does not embrittle or soften in the extreme temperature environment of the base station.

[0023] As a preferred option, the outer sheath 4 is made of thermoplastic elastomer. Thermoplastic elastomer has a Shore hardness of 60-70A and an elongation at break of ≥500%, which is far more flexible than traditional PVC sheaths, with an elongation at break of ≤200%. When bent, it can deform synchronously with conductor 1 and insulation layer 3 without permanent deformation, further enhancing the overall ultra-flexible characteristics of the cable. This ensures that it can return to its original shape after being bent in the confined space of the base station, without affecting subsequent adjustments to the laying position. At the same time, the elastomer material can buffer minor external impacts, such as tool knocks, to prevent the impact force from being transmitted to the internal insulation layer and conductor, reducing structural damage.

[0024] As a preferred method, the mating grooves 5 on the inner wall of the insulation layer 3 are arranged in a ring array. When the insulation layer 3 is extruded, the molten cross-linked polyethylene material fills the outside of the conductor 1 and forms the mating grooves 5 after cooling. Compared with the traditional smooth inner wall, this improves the peel strength and prevents the insulation layer 3 and conductor 1 from shifting relative to each other when the base station equipment is vibrating or the cable is bent, thus preventing the formation of protective gaps.

[0025] As a preferred method, the diameter of the annealed soft copper wire of conductor 1 is ≤0.10mm, and the diameter of a single annealed soft copper wire is ≤0.10mm. Compared with traditional base station cables (copper wire diameter ≥0.15mm), the rigidity of the copper wire is reduced by more than 40%, making it easier to deform when bent and eliminating the risk of "hard creases".

Claims

1. A novel ultra-flexible base station cable, characterized in that: It includes a conductor (1), a support (2), an insulating layer (3), and an outer sheath (4); the conductor (1) is a multi-strand annealed soft copper wire layered stranded structure, the support (2) is combined with the multi-strand annealed soft copper wire, the insulating layer (3) covers the outside of the conductor (1); the outer sheath (4) covers the outside of the insulating layer (3), and the inner wall of the insulating layer (3) is integrally formed with a mating groove (5), the mating groove (5) is adapted to the outer contour of the insulating layer (3); The support member (2) includes aramid wires (21), which are divided into two groups. One group of aramid wires (21) is embedded and fixed in the center layer of the conductor (1) along the axial direction, and the other group of aramid wires (21) is embedded and fixed between the outer annealed soft copper wires of the conductor (1) according to the principle of equal number of wires. The conductor (1) is stranded in three layers, with the outer layer of annealed soft copper wire having a pitch ratio of 18-20 times. The insulating layer (3) is made of cross-linked polyethylene; The outer sheath (4) is made of thermoplastic elastomer; The mating grooves (5) on the inner wall of the insulating layer (3) are arranged in a ring array; The diameter of the annealed soft copper wire of the conductor (1) is ≤0.10mm.

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