A soft cable with a copper core, a polyvinyl chloride insulation sheath and a shielding sheath

Abstract

The utility model relates to cable technical field especially relates to a kind of insulation sheath copper core polyvinyl chloride insulation shield sheath flexible cable, including three groups of copper conductor, each group of copper conductor is stranded by multiple copper wires, inner insulation layer is coated in the outer surface of copper conductor, shielding layer is coated in the outer surface of inner insulation layer, sheath layer is coated in the outer surface of shielding layer, shielding layer is composed of inner layer aluminium foil and outer layer copper wire braided mesh, further including conductive adhesive layer, aluminium foil and copper wire braided mesh between being provided with conductive adhesive layer, a kind of insulation sheath copper core polyvinyl chloride insulation shield sheath flexible cable of the utility model in use process, double-layer sheath structure is complementary by material characteristics, while keeping the soft and flexible characteristics of cable, make anti-scratching performance improve two times, adapt to complex industrial environment use demand, overall design is through material innovation and structure optimization, on the basis of keeping soft characteristics, electromagnetic compatibility, mechanical durability and environmental adaptability are comprehensively improved.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and in particular to a flexible cable with copper core, polyvinyl chloride insulation and shielding. Background Technology

[0002] In complex electromagnetic environments such as industrial automation, rail transportation, and new energy equipment, cables must simultaneously meet the requirements of electromagnetic compatibility, mechanical durability, and environmental adaptability. Traditional cables typically employ a single-layer shielding structure, which has limited electromagnetic interference reflection capabilities in the high-frequency band (>100MHz), while the shielding effectiveness in the low-frequency band (<30MHz) depends on the porosity of the braided mesh, resulting in poor broadband interference suppression. The sheath layer is mostly made of single-layer polyvinyl chloride or similar materials, which, although possessing basic insulation properties, are easily damaged by scratches, compression, or repeated bending in complex industrial scenarios. In addition, the conductor stranding process generally adopts conventional bundling methods, resulting in a large bending radius (usually ≥8 times the cable outer diameter). Long-term bending can easily cause the conductor to loosen, increase contact resistance, and thus lead to a decrease in conductivity.

[0003] When cables are in use, the aforementioned traditional cables have the following technical problems: First, the single-layer shielding structure cannot simultaneously cover high-frequency and low-frequency electromagnetic interference, leading to signal interference between devices, data transmission errors, or control command failures. Especially in scenarios where high-frequency pulse interference (such as frequency converters and wireless communication equipment) and low-frequency power frequency interference coexist, electromagnetic compatibility is difficult to guarantee. Second, the single-layer sheath has weak resistance to mechanical stress. When frequently in contact with metal parts in industrial environments, subjected to scratches from sharp objects, or exposed to vibration environments for a long time, problems such as sheath cracking and insulation failure are likely to occur, shortening the cable's service life. Third, the large bending radius caused by the conventional conductor stranding process limits the cable's installation flexibility in confined spaces, and the conductor structure becomes loose after repeated bending, further aggravating the attenuation of conductivity and increasing equipment maintenance costs.

[0004] Therefore, to address the issue of the difficulty in comprehensively improving the electromagnetic compatibility, mechanical durability, and environmental adaptability of cables in scenarios where high-frequency pulse interference and low-frequency power frequency interference coexist, a copper-core PVC insulated shielded flexible cable with an insulating sheath can be designed. When using this cable, firstly, the composite shielding layer combines the high-frequency reflection characteristics of aluminum foil with the low-frequency shielding capability of copper wire braiding, along with the continuous conductivity of the conductive adhesive layer, to effectively suppress wide-band electromagnetic interference. The shielding effectiveness is more than 30% higher than that of the traditional single-layer structure. Secondly, the double-layer sheath structure, through complementary material properties, maintains the cable's flexibility and bendability while doubling its scratch resistance, adapting to the needs of complex industrial environments. Finally, the optimized conductor stranding process reduces the bending radius to six times the cable's outer diameter while maintaining the conductor's structural integrity and reducing conductivity degradation caused by repeated bending. The overall design, through material innovation and structural optimization, achieves a comprehensive improvement in electromagnetic compatibility, mechanical durability, and environmental adaptability while maintaining flexibility. Utility Model Content

[0005] To overcome the problem that the single-layer shielding structure of traditional cables cannot simultaneously cover high-frequency and low-frequency electromagnetic interference, leading to signal interference between devices, data transmission errors, or control command failures, it is inconvenient to comprehensively improve the electromagnetic compatibility, mechanical durability, and environmental adaptability of cables when used in scenarios where high-frequency pulse interference and low-frequency power frequency interference coexist.

[0006] The technical solution of this utility model is as follows: an insulated sheath copper core polyvinyl chloride insulated shielded flexible cable, comprising three sets of copper conductors, each set of copper conductors being formed by multiple copper wires twisted together, an inner insulation layer covering the outer surface of the copper conductors, a shielding layer covering the outer surface of the inner insulation layer, and a sheath layer covering the outer surface of the shielding layer. The shielding layer is composed of an inner aluminum foil and an outer copper wire braided mesh, and also includes a conductive adhesive layer, with the conductive adhesive layer disposed between the aluminum foil and the copper wire braided mesh.

[0007] Preferably, when using this cable, firstly, the composite shielding layer combines the high-frequency reflection characteristics of aluminum foil with the low-frequency shielding capability of copper wire braid, along with the continuous conductivity of the conductive adhesive layer, to effectively suppress wide-band electromagnetic interference. The shielding efficiency is more than 30% higher than that of the traditional single-layer structure. Secondly, the double-layer sheath structure, through complementary material properties, maintains the cable's flexibility and bendability while doubling its scratch resistance, adapting to the needs of complex industrial environments. Finally, the optimized conductor stranding process reduces the bending radius to six times the cable's outer diameter while maintaining the integrity of the conductor structure and reducing conductivity degradation caused by repeated bending. The overall design, through material innovation and structural optimization, achieves a comprehensive improvement in electromagnetic compatibility, mechanical durability, and environmental adaptability while maintaining flexibility.

[0008] As a preferred embodiment, the sheath layer consists of two layers: an inner sheath and an outer sheath. The inner sheath is directly wrapped around the outer surface of the shielding layer, while the outer sheath is tightly wrapped around the outer surface of the inner sheath.

[0009] Preferably, the inner sheath is made of highly elastic polyvinyl chloride material, the outer sheath is made of wear-resistant polyurethane material, and the inner insulation layer is made of high-temperature resistant polyvinyl chloride material.

[0010] Preferably, a water-blocking layer is wrapped between the inner insulation layer and the shielding layer, and the water-blocking layer is a polyester tape wrapping structure.

[0011] Preferably, the outer surface of the shielding layer is covered with a transition layer, which has a porous structure and is arranged in a honeycomb pattern.

[0012] Preferably, the outermost layer of the cable is provided with a marking layer, which is wrapped around the outer surface of the sheath layer and is formed by laser printing.

[0013] The beneficial effects of this utility model are:

[0014] 1. When using this cable, firstly, the composite shielding layer combines the high-frequency reflection characteristics of aluminum foil with the low-frequency shielding capability of copper wire braid, along with the continuous conductivity of the conductive adhesive layer, to effectively suppress wide-band electromagnetic interference. The shielding efficiency is more than 30% higher than that of the traditional single-layer structure. Secondly, the double-layer sheath structure, through complementary material properties, maintains the cable's flexibility and bendability while doubling its scratch resistance, adapting to the needs of complex industrial environments. Finally, the optimized conductor stranding process reduces the bending radius to six times the cable's outer diameter while maintaining the integrity of the conductor structure and reducing conductivity degradation caused by repeated bending. The overall design, through material innovation and structural optimization, achieves a comprehensive improvement in electromagnetic compatibility, mechanical durability, and environmental adaptability while maintaining flexibility.

[0015] 2. The synergistic effect of the polyester tape water-blocking layer and the honeycomb transition layer not only blocks the water penetration path, but also reduces the risk of interlayer peeling by 50% through the stress buffering effect of the porous structure, significantly improving the long-term reliability of the cable. The laser marking process ensures that the product information is permanently identifiable and meets the traceability requirements in industrial environments. Attached Figure Description

[0016] Figure 1 The diagram shown is a first three-dimensional structural schematic of a copper core polyvinyl chloride insulated shielded flexible cable according to this utility model.

[0017] Figure 2 The diagram shown is a second three-dimensional structural schematic of a copper core polyvinyl chloride insulated shielded flexible cable according to this utility model.

[0018] Figure 3The diagram shown is a partial three-dimensional structural schematic of a copper core polyvinyl chloride insulated shielded flexible cable according to the present invention.

[0019] Figure 4 What is shown is Figure 3 Schematic diagram of the three-dimensional structure at the circled mark;

[0020] Explanation of reference numerals in the attached diagram: 1. Copper conductor; 2. Inner insulation layer; 3. Inner aluminum foil layer; 4. Conductive adhesive layer; 5. Outer copper wire braided mesh layer; 6. Inner sheath; 7. Outer sheath; 8. Water-blocking layer; 9. Transition layer; 10. Identification layer. Detailed Implementation

[0021] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0022] Please see Figure 1 and Figure 4 This utility model provides an embodiment: an insulated sheathed copper core polyvinyl chloride insulated shielded flexible cable, including three sets of copper conductors 1, each set of copper conductors 1 is made of multiple copper wires twisted together, an inner insulation layer 2 covers the outer surface of the copper conductors 1, a shielding layer covers the outer surface of the inner insulation layer 2, a sheath layer covers the outer surface of the shielding layer, the shielding layer is composed of an inner aluminum foil 3 and an outer copper wire braided mesh 5, and also includes a conductive adhesive layer 4, with the conductive adhesive layer 4 disposed between the aluminum foil and the copper wire braided mesh.

[0023] Please see Figure 3 and Figure 4 The sheath layer consists of two layers: an inner sheath 6 and an outer sheath 7. The inner sheath 6 is directly wrapped around the outer surface of the shielding layer, while the outer sheath 7 is tightly wrapped around the outer surface of the inner sheath 6. The sheath layer adopts a double-layer structure design. The inner sheath 6 is made of high-elasticity polyvinyl chloride material, while the outer sheath 7 is made of wear-resistant polyurethane material. The inner insulation layer 2 is made of high-temperature resistant polyvinyl chloride material. The inner sheath 6 uses high-elasticity polyvinyl chloride material to maintain the cable's flexibility, while the outer sheath 7 uses wear-resistant polyurethane material to form a rigid protective layer. The two layers achieve a balance between flexibility and mechanical strength through complementary material properties.

[0024] Please see Figure 2 and Figure 4A water-blocking layer 8 is wrapped between the inner insulation layer 2 and the shielding layer. The water-blocking layer 8 is a polyester tape wrapping structure. The water-blocking layer 8 forms a physical barrier through tight wrapping, effectively blocking the penetration path of water along the longitudinal or transverse direction. A transition layer 9 is wrapped on the outer surface of the shielding layer. The transition layer 9 has a porous structure and is arranged in a honeycomb pattern. When the cable is subjected to thermal expansion or mechanical stress, the honeycomb porous transition layer 9 absorbs the difference in thermal stress and mechanical impact through the elastic deformation of the pores, realizing the stress gradient buffer from the inside to the outside. The outermost layer of the cable is provided with a marking layer 10, which is wrapped on the outer surface of the sheath layer. The marking layer 10 is formed by laser printing process. The outermost laser-printed marking layer 10 undergoes surface modification treatment to ensure that the marking information remains clearly visible during long-term use.

[0025] When using this cable, the cable adopts a multi-layer composite structure design to optimize performance. The conductor part is made of three sets of multi-strand copper wires twisted together. The flexible twisting process improves the conductivity stability under bending conditions. The inner insulation layer 2 is made of high-temperature resistant polyvinyl chloride material to cover the conductor and form a basic insulation barrier.

[0026] A polyester tape-wrapped water-blocking layer 8 and a composite shielding layer are sequentially arranged outside the insulation layer. The water-blocking layer 8 forms a physical barrier by tightly wrapping, effectively blocking the penetration path of water along the longitudinal or transverse direction. The composite shielding layer adopts a double-layer structure of aluminum foil and copper wire mesh. The aluminum foil layer provides a high-frequency electromagnetic wave reflection interface, and the copper wire mesh enhances the shielding effectiveness of low-frequency magnetic fields. The conductive adhesive layer 4 set between the two not only ensures the electrical conduction between the metal layers, but also eliminates micro gaps through the filling effect of the adhesive, forming a continuous conductive layer. The shielding layer is wrapped with a honeycomb porous transition layer 9.

[0027] When the cable is subjected to thermal expansion or mechanical stress, this structure absorbs the difference in thermal stress and mechanical impact through the elastic deformation of the pores, achieving stress gradient buffering from the inside to the outside. The sheath layer adopts a double-layer structure design. The inner sheath 6 uses highly elastic polyvinyl chloride material to maintain the cable's flexibility, while the outer sheath 7 uses wear-resistant polyurethane material to form a rigid protective layer. The two achieve a balance between flexibility and mechanical strength through complementary material properties. The outermost laser-printed marking layer 10 undergoes surface modification treatment to ensure that the marking information remains clearly visible during long-term use.

[0028] In summary, firstly, the composite shielding layer combines the high-frequency reflection characteristics of aluminum foil with the low-frequency shielding capability of copper wire braid, and works in conjunction with the continuous conductivity of conductive adhesive layer 4 to effectively suppress wide-band electromagnetic interference. The shielding efficiency is more than 30% higher than that of the traditional single-layer structure. Secondly, the double-layer sheath structure complements the material properties, maintaining the cable's flexibility and bendability while the wear-resistant polyurethane material of the outer sheath 7 doubles the scratch resistance, meeting the needs of complex industrial environments.

[0029] Third, the synergistic effect of the polyester tape water-blocking layer 8 and the honeycomb transition layer 9 not only blocks the water penetration path, but also reduces the risk of interlayer delamination by 50% through the stress buffering effect of the porous structure, significantly improving the long-term reliability of the cable. Fourth, the optimized conductor stranding process reduces the bending radius to six times the cable outer diameter while maintaining the integrity of the conductor structure and reducing the attenuation of conductivity caused by repeated bending. Finally, the laser marking process ensures that product information is permanently identifiable and meets the traceability requirements in industrial environments. The overall design, through material innovation and structural optimization, achieves a comprehensive improvement in electromagnetic compatibility, mechanical durability, and environmental adaptability while maintaining flexibility.

[0030] Through the above steps, when using this cable, firstly, the composite shielding layer combines the high-frequency reflection characteristics of aluminum foil with the low-frequency shielding capability of copper wire braid, and works in conjunction with the continuous conductivity of conductive adhesive layer 4 to effectively suppress wide-band electromagnetic interference. The shielding efficiency is more than 30% higher than that of the traditional single-layer structure. Secondly, the double-layer sheath structure, through complementary material properties, maintains the cable's flexibility and bendability while doubling its scratch resistance, adapting to the needs of complex industrial environments. Finally, the optimized conductor stranding process reduces the bending radius to six times the cable's outer diameter while maintaining the integrity of the conductor structure and reducing conductivity degradation caused by repeated bending. The overall design, through material innovation and structural optimization, achieves a comprehensive improvement in electromagnetic compatibility, mechanical durability, and environmental adaptability while maintaining flexibility.

[0031] The embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the present invention is not limited to the above embodiments. Within the scope of knowledge possessed by those skilled in the art, various changes can be made without departing from the spirit of the present invention.

Claims

1. A copper core polyvinyl chloride insulated shielded flexible cable with an insulating sheath, comprising three sets of copper conductors (1), each set of copper conductors (1) being formed by multiple copper wires twisted together, an inner insulation layer (2) covering the outer surface of the copper conductors (1), a shielding layer covering the outer surface of the inner insulation layer (2), and a sheath layer covering the outer surface of the shielding layer, the shielding layer being composed of an inner aluminum foil (3) and an outer copper wire braided mesh (5), characterized in that: It also includes a conductive adhesive layer (4), and a conductive adhesive layer (4) is provided between the aluminum foil and the copper wire mesh.

2. The copper core polyvinyl chloride insulated shielded flexible cable according to claim 1, characterized in that: The sheath layer consists of two layers: an inner sheath (6) and an outer sheath (7). The inner sheath (6) is directly wrapped around the outer surface of the shielding layer, while the outer sheath (7) is tightly wrapped around the outer surface of the inner sheath (6).

3. The copper core polyvinyl chloride insulated shielded flexible cable according to claim 2, characterized in that: The inner sheath (6) is made of high-elasticity polyvinyl chloride material, the outer sheath (7) is made of wear-resistant polyurethane material, and the inner insulation layer (2) is made of high-temperature resistant polyvinyl chloride material.

4. The copper core polyvinyl chloride insulated shielded flexible cable according to claim 1, characterized in that: A water-blocking layer (8) is wrapped between the inner insulation layer (2) and the shielding layer. The water-blocking layer (8) is a polyester tape wrapping structure.

5. The copper core polyvinyl chloride insulated shielded flexible cable according to claim 1, characterized in that: The outer surface of the shielding layer is covered with a transition layer (9), which has a porous structure and is arranged in a honeycomb pattern.

6. The copper core polyvinyl chloride insulated shielded flexible cable according to claim 1, characterized in that: The outermost layer of the cable is provided with a marking layer (10), which is wrapped around the outer surface of the sheath layer and is formed by laser printing process.

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