Special braided cable structure with improved interference immunity

Abstract

The utility model relates to a kind of cable structures, especially a kind of special braided cable structure of improving anti-interference capability.The cable structure includes conductor stranded unit, inner insulation coating, conductive fiber layer, braided shielding layer, flexible cushion layer and outer sheath protective layer, and conductive fiber layer and braided shielding layer are coated in the periphery of conductor stranded unit with layered structure, and are spaced apart by flexible cushion layer and inner insulation coating.The shielding layer is electrically connected with ground wire through conducting sheet, effectively improves the anti-electromagnetic interference capability, has high flexibility, corrosion resistance and flame retardant performance, and is suitable for signal and power transmission in complex industrial electrical environment.

Description

Technical Field

[0001] This utility model relates to the field of cable structure, and in particular to a special braided cable structure that enhances anti-interference capability and is suitable for signal or power transmission in complex electromagnetic environments. Background Technology

[0002] In high-interference industrial applications, traditional cables are prone to signal attenuation, crosstalk, and system failures due to insufficient structural shielding, unstable grounding, or improper conductor arrangement. The design of the cable's anti-interference performance is particularly crucial in environments with strong electromagnetic fields, high-frequency interference sources, and dense concentrations of complex electrical equipment.

[0003] Currently used anti-interference cables typically employ single-layer metal braiding or metal foil shielding, which cannot simultaneously guarantee flexibility and shielding performance. Furthermore, their conductor stranding methods mostly employ an equal-pitch structure, failing to create an interference-neutralizing mechanism. Additionally, the shielding layer often lacks effective conductivity with the ground wire, leading to the accumulation of static electricity or electromagnetic wave energy, affecting cable stability and lifespan.

[0004] Therefore, there is an urgent need to provide a special cable with innovative structure, featuring multi-layer shielding, excellent flexibility, and a highly reliable conduction and grounding mechanism to significantly improve anti-interference performance. Utility Model Content

[0005] The purpose of this utility model is to provide a special braided cable structure that improves anti-interference capability, and solves the problems of poor anti-interference capability, complex structure and unreliable shielding in the prior art.

[0006] To achieve the above objectives, the present invention adopts the following technical solution: a braided cable with a multi-layer composite shielding structure is provided, comprising, in sequence, a conductor stranding unit, an inner insulation covering layer, a conductive fiber layer, a braided shielding layer, a flexible buffer pad layer, and an outer sheath protective layer; the conductive fiber layer and the braided shielding layer are grounded through a shielding conductive sheet, thereby improving the electromagnetic interference resistance.

[0007] Compared to existing technologies, this cable has the following substantial advantages:

[0008] A reverse asymmetric twisting method is used to reduce interference between wire cores;

[0009] The combination of double-layer shielding structure improves shielding depth and frequency band coverage;

[0010] The shielding layer is designed with grounding continuity to prevent energy accumulation;

[0011] The outer sheath provides multi-functional protection and enhances durability. Attached Figure Description

[0012] Figure 1This is a perspective view of the cable structure of this utility model;

[0013] Figure 2 This is a cross-sectional view of the layered structure of the cable of this utility model;

[0014] Figure 3 This is a schematic diagram of the connection structure between the braided shielding layer and the conductive fiber layer.

[0015] Figure 4 This is an enlarged schematic diagram of the conductor stranded structure;

[0016] Figure 5 This is a diagram of the grounding and conductive structure of the shielding layer.

[0017] Figure 6 A cross-sectional view of the anti-interference transition zone structure, illustrating its multi-layered composite structure and arrangement;

[0018] Figure 7 An enlarged view of the structure at the connection point between the shielding conductive plate and the ground wire, showing the installation structure and contact method;

[0019] Figure 8 This is a schematic diagram of the pitch and stranding angle of an asymmetric stranded conductor structure, showing the characteristics of different pitches and reverse distributions.

[0020] Figure label:

[0021] 1. Conductor stranded unit; 2. Inner insulation covering layer; 3. Conductive fiber layer; 4. Braided shielding layer; 5. Flexible buffer pad layer; 6. Outer sheath protective layer; 7. Shielding conductive sheet; 8. Ground wire; 9. Anti-interference transition strip; 10. Asymmetric stranded conductor. Detailed Implementation

[0022] like Figures 1 to 5 As shown, this utility model provides a special braided cable structure to enhance anti-interference capabilities, including a conductor stranding unit 1, an inner insulation covering layer 2, a conductive fiber layer 3, a braided shielding layer 4, a flexible buffer pad layer 5, and an outer sheath protective layer 6.

[0023] The conductor stranding unit 1 employs an asymmetrical pitch arrangement, with multiple asymmetrical stranded conductors 10 arranged in reverse stranding. The relative positional changes of each conductor during the stranding process create an interference cancellation effect, significantly reducing signal crosstalk and external interference coupling. Specifically, the pitch range of the asymmetrical stranded conductors 10 is set between 25mm and 45mm, the stranding angle is maintained between 18° and 24°, and the pitch difference between adjacent conductors is not less than 3mm. This creates a complementary interference structure through pitch offset and phase difference. Comparative tests were conducted with a conventional equal-pitch stranding structure in the 10MHz to 100MHz frequency band. The results show that its average interference suppression is improved by more than 40%, effectively reducing the peak values ​​of common-mode interference and differential-mode interference superposition, and improving the stability of cable signal transmission.

[0024] The inner insulating covering layer 2 is made of polyvinyl fluoride material, which has high dielectric strength and heat resistance. It tightly covers the periphery of the conductor stranded unit 1 and plays a role in electrical isolation.

[0025] The conductive fiber layer 3 is made of graphite-modified polyester fiber, which has excellent flexibility, and is covered by the inner insulating covering layer 2 on the outside. Together with the braided shielding layer 4, it forms a double-layer shielding system for shielding high-frequency and low-frequency electromagnetic interference.

[0026] The braided shielding layer 4 is made of tin-plated copper wires crisscrossed and woven with a braiding density of not less than 85%, which ensures that electromagnetic waves are difficult to penetrate and has good flexibility. It is electrically connected to the conductive fiber layer 3 through a shielding conductive piece 7. The other end of the shielding conductive piece 7 is pressed into a grounding wire 8 to achieve reliable grounding.

[0027] The flexible buffer layer 5 is disposed between the braided shielding layer 4 and the outer sheath protective layer 6. It is made of microporous silicone and has vibration resistance and pressure reduction function, enhancing the durability of the cable under conditions such as movement and bending.

[0028] The outer sheath protective layer 6 is made of thermoplastic elastomer, with a graphite coating on the outer surface to form an anti-corrosion layer and anti-slip texture to enhance the friction and environmental adaptability during cable laying and use.

[0029] The anti-interference transition strip 9 is located between the braided shielding layer 4 and the flexible buffer pad layer 5. It is composed of a shielding film and a wave-absorbing material, effectively absorbing external interference waves and preventing them from entering the conductor layer structure, thus improving the overall shielding effectiveness. Its structure comprises a composite of three functional materials: the first layer is an aluminum foil-polyester composite shielding film with a thickness of approximately 0.02 mm, facing the braided shielding layer 4, used to reflect external high-frequency electromagnetic waves; the second layer is a nano-ferrite wave-absorbing material layer with a thickness of 0.1–0.15 mm, possessing good high-frequency energy absorption capabilities, mainly used to dissipate residual interference waves after penetrating the shielding layer; the third layer is a conductive adhesive layer with a thickness of approximately 0.05 mm, used to adhere to the flexible buffer pad layer 5 and provide a path to discharge residual surface charge. The three layers are composited into a strip structure through a hot-pressing process, continuously and annularly wound around the circumference of the cable, with an attached... Figure 2 The cross-section at mark 9, located between the shielding layer and the buffer layer, is multi-layered and ring-shaped.

[0030] This structure utilizes a triple mechanism of aluminum foil reflection, ferrite absorption, and conductive adhesive dissipation to significantly enhance its shielding capability against broadband electromagnetic interference. According to measured data, the anti-interference transition band is 18dB at 30MHz, resulting in an overall shielding improvement of over 20%, demonstrating excellent electromagnetic compatibility and structural adaptability.

[0031] The shielding conductive piece 7 adopts a U-shaped bending structure, is made of nickel-plated phosphor bronze, has an unfolded length of 1216 mm, a bending width of 46 mm, and a thickness of 0.3–0.5 mm. A double-toothed crimping area is provided in the middle section of the conductive piece, which can pierce the mesh structure of the conductive fiber layer 3 and the braided shielding layer 4 to achieve stable contact. One end is inserted between the conductive fiber layer 3 and the braided shielding layer 4, and the other end is crimped to the grounding wire 8 via spot welding or a self-locking insert, ensuring that the contact resistance is not higher than 0.05 Ω and the overall impedance of the conductive path is controlled within 0.1 Ω, thereby effectively improving the reliability and anti-interference capability of grounding conductivity. To ensure the long-term stability of the electrical connection, a pressure-locking contact method is used between the shielding conductive piece and the contact area, providing vibration resistance and anti-loosening capability. The surface of the conductive piece has excellent anti-oxidation properties; after continuous operation for 1000 hours in a high-temperature and high-humidity environment (85℃ / 85%RH), its contact resistance change rate is controlled within 5%, and the contact interface still maintains good conductivity. After 72 hours of salt spray and thermal shock tests, the grounding connection showed no signs of loosening, corrosion, or performance degradation. It can operate stably for a long time in harsh industrial environments, with a temperature range of -40℃ to +125℃.

[0032] This utility model has a reasonable structure, is easy to manufacture, and has reliable performance. It is particularly suitable for data and power transmission scenarios in complex electromagnetic environments such as industrial control systems, rail transit, and power automation, and has broad application prospects.

Claims

1. A special braided cable structure for improving anti-interference capability, characterized in that, include: Conductor stranding unit; An inner insulating sheathing layer covers the outside of the conductor stranded unit; A conductive fiber layer is disposed on the outside of the inner insulating covering layer; A braided shielding layer is used to cover the conductive fiber layer; A flexible buffer layer is placed between the braided shielding layer and the outer protective sheath layer; The outermost protective layer is provided to cover the flexible cushioning pad layer; The conductive fiber layer and the braided shielding layer are electrically connected to the ground wire through a shielding conductive sheet.

2. The cable structure according to claim 1, characterized in that: The conductor stranding units are arranged in a reverse stranding manner with asymmetrical pitch to achieve interference cancellation effect.

3. The cable structure according to claim 1, characterized in that: The conductive fiber layer is made of graphite-modified polyester fiber.

4. The cable structure according to claim 1, characterized in that: The braided shielding layer is composed of tin-plated copper wires crisscrossed together, with a braiding density of not less than 85%.

5. The cable structure according to claim 1, characterized in that: The flexible cushioning layer is made of microporous silicone material and has vibration damping function.

6. The cable structure according to claim 1, characterized in that: The outer protective layer is made of thermoplastic elastomer and has an additional graphite anti-corrosion coating on its surface.

7. The cable structure according to claim 1, characterized in that: The shielding conductive sheet adopts a bent structure, with its end pressed into the ground wire.

8. The cable structure according to claim 1, characterized in that: An anti-interference transition band is provided between the woven shielding layer and the flexible buffer pad layer to reduce the intrusion of external interference waves.

9. The cable structure according to claim 1, characterized in that: The outer protective layer has an anti-slip textured surface, which enhances frictional stability during installation.

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