A tensile-resistant enhanced category 8 cable cross-harness structure

Abstract

The utility model relates to a kind of tensile resistance enhanced type eight category cable cross skeleton structure, belong to network cable structure design and manufacturing technology field, including central strengthening core, PE layer, side pillar and cross skeleton arm body;PE layer is wrapped central strengthening core and forms "hard support+soft buffer" composite structure, cross skeleton arm body is outwardly extended and presents "X" shape from PE layer, side pillar is parallelly arranged in arm body terminal and with central strengthening core same material, when being subjected to pressure, cross skeleton arm body deformation can form point contact with outer sheath inner wall, side pillar can further conduct external force to the overall structure of cross skeleton, avoid arm body terminal deformation due to stress concentration, convert local extrusion into uniform force that entire cross skeleton can bear, lay foundation for subsequent core support.This scheme significantly improves compression resistance, torsion resistance, reduces line pair crosstalk and abrasion, adapts eight category cable high-speed transmission demand, cost controllable and easy mass production.

Description

Technical Field

[0001] This utility model belongs to the field of network cable structure design and manufacturing technology, specifically relating to a tensile-strength reinforced Category 8 cable cross skeleton structure. Background Technology

[0002] In network cables (especially twisted-pair cables), the cross-shaped frame is the core structure that physically separates the four pairs of twisted wires inside. Its main function is to reduce crosstalk by isolating the wire pairs and ensure the stability of signal transmission. Currently, the cross-shaped frame in existing technology is generally made of a single polyethylene (PE) material through injection molding.

[0003] Existing conventional cross-shaped cable frames have significant technical defects: they are prone to deformation or even breakage when subjected to external pressure (such as compression or trampling during cabling) or tension (such as pulling on cabling). For example, in dense cabling scenarios in data centers, the pressure generated by stacking multiple network cables can easily cause the arms of a conventional cross-shaped cable frame to bend, bringing previously separated wire pairs closer together. In industrial environments, mechanical vibrations can increase friction between the cross-shaped cable frame and the wire pairs, further disrupting the separation of the wire pairs. These problems directly lead to increased crosstalk between wire pairs, decreased signal transmission quality, and an inability to meet the structural stability requirements of high-speed data transmission. Currently, publicly available patents on related network cable structures do not address the dual-material composite reinforcement and distributed load-bearing structure design for cross-shaped cables, resulting in insufficient strength. Therefore, those skilled in the art have provided a tensile-strength reinforced Category 8 cable cross-shaped cable frame structure to solve the above problems. Utility Model Content

[0004] The purpose of this utility model is to provide a simple and reasonably designed tensile-strength reinforced Category 8 cable cross skeleton structure in order to solve the above problems.

[0005] This utility model achieves the above objectives through the following technical solutions:

[0006] A tensile-strength reinforced Category 8 cable cross-shaped frame structure includes a central reinforcing core, a PE layer, four side supports, and cross-shaped frame arms. The PE layer is wrapped around the central reinforcing core. The four side supports are respectively located at the four ends of the four arms of the cross-shaped frame arms. The four side supports are made of the same material as the central reinforcing core. The angle between the four side supports and the plane where the central reinforcing core is located is 90° and they are evenly distributed at the edge of the cross-shaped frame arms.

[0007] As a further optimization of this utility model, the cross-section of the four side pillars is "teardrop-shaped", and the axis of the cross-section of the four side pillars is collinear with the center line of the cross-section of the cross-frame arm.

[0008] As a further optimization of this utility model, the central reinforcing core is made of engineering plastic, the PE layer is made of conventional PE material, and the central reinforcing core and the PE layer are fused at the molecular level through a composite injection molding process.

[0009] As a further optimization of this utility model, the cross-shaped frame arm makes point contact with the inner wall of the cable outer sheath when subjected to external pressure.

[0010] As a further optimization of this utility model, both the cross-shaped frame arm and the central reinforcing core are cross-shaped structures, and the included angle of the cross-shaped frame arm adopts a rounded transition design.

[0011] As a further optimization of this utility model, the four included angles of the cross-shaped frame arm form isolation grooves for separating the twisted pairs inside the cable.

[0012] As a further optimization of this utility model, the thickness of the cross-shaped skeleton arms gradually decreases from the end near the central reinforcing core to the ends of the four arms.

[0013] As a further optimization of this utility model, the central reinforced core, PE layer, side pillars and cross skeleton arm are integrally formed by two-color injection molding.

[0014] The beneficial effects of this utility model are as follows:

[0015] 1. This utility model, through the collaborative design of "central reinforced core + side support", uses high-strength engineering plastic to provide core anti-torsional and anti-compression support, and the side support forms a distributed load-bearing structure to disperse external forces, which solves the pain point of weak anti-deformation ability of traditional skeletons and significantly extends the service life of cables.

[0016] 2. This utility model, with its structural stability brought by "central reinforcement + side support", forms an isolation groove between two adjacent cross skeleton arms to accommodate twisted pairs, ensuring that the four pairs of twisted pairs in the cable are independently separated and the relative positions between the pairs are stable. Under the same external force, the near-end crosstalk value between the pairs is improved compared with the existing technology, the bit error rate is reduced, and the signal attenuation is reduced, which can continuously ensure the reliability of high-speed data transmission. It is especially suitable for scenarios with stringent transmission quality requirements, such as data centers and industrial control.

[0017] 3. In this utility model, the cross-section of the four side pillars is "teardrop-shaped". The small ends of the four side pillars are conducive to dispersing the external force. When subjected to pressure, the deformation of the cross frame arm will form point contact with the inner wall of the outer sheath. The side pillars can further transmit the external force to the overall structure of the cross frame, avoid the deformation of the arm end due to stress concentration, and transform local compression into a uniform force that the entire cross frame can withstand, laying the foundation for subsequent core support. Compared with traditional surface contact, it reduces the friction area and reduces the risk of wear. At the same time, the flexibility of the PE layer avoids brittle fracture caused by excessive rigidity of the structure, and can adapt to bending, compression and environmental forces during wiring construction and long-term use. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of the axonal structure of this utility model;

[0019] Figure 2 This is the utility model Figure 1 A schematic diagram of the structure viewed from behind;

[0020] Figure 3 This is the utility model Figure 1 Side view structural diagram;

[0021] Figure 4 This is the utility model Figure 1 Front view of the structural diagram.

[0022] In the diagram: 1. Central reinforced core; 2. PE layer; 3. Side support pillars; 4. Cross-shaped frame arm. Detailed Implementation

[0023] The present application will now be described in further detail with reference to the accompanying drawings. It should be noted that the following specific embodiments are only used to further illustrate the present application and should not be construed as limiting the scope of protection of the present application. Those skilled in the art can make some non-essential improvements and adjustments to the present application based on the above application content.

[0024] Example 1

[0025] like Figures 1-4As shown, a tensile-reinforced Category 8 cable cross-shaped frame structure includes a central reinforcing core 1, a PE layer 2, side supports 3, and cross-shaped frame arms 4. The central reinforcing core 1, as the core supporting component of the entire cross-shaped frame, is shaped like a cross and made of high-strength nylon 66 (PA66). Formed through injection molding, it has a regular cross-shaped outline and is a key structure for resisting axial pressure and torque. The PE layer 2 covers the outside of the central reinforcing core 1 in a wrapping manner and is integrally molded with the cross-shaped frame arms 4. Made of conventional low-density polyethylene (LDPE), it combines flexibility and insulation, achieving a mechanical balance of "central rigid support + peripheral flexible transition" while preventing direct friction between the central reinforcing core 1 and the twisted pairs inside the cable. The cross-shaped frame arms 4 extend outward from the PE layer 2 outside the central reinforcing core 1, with a total of four arms. They are symmetrically distributed at 90° around the central reinforcing core 1, forming a cross-shaped overall structure. An isolation groove is formed between two adjacent cross-shaped frame arms 4 to accommodate the twisted pair wires, ensuring that the four pairs of twisted pairs in the cable are independently separated. The side pillars 3 are arranged parallel to the end of each cross-shaped frame arm 4. They are made of the same Nylon 66 (PA66) material as the central reinforcing core 1 and are integrally injection molded with the cross-shaped frame arms 4. The cross-section of the four side pillars 3 is teardrop-shaped. The small ends of the four side pillars 3 are conducive to dispersing the pressure. The four side pillars 3 are located at the four quadrant edges of the cross-shaped frame arms 4, forming a distributed load-bearing structure.

[0026] like Figures 1-4As shown, the central reinforcing core 1 and the PE layer 2 achieve molecular-level fusion through a dual-material composite injection molding process, with no obvious gaps at the interface. During the injection molding process, the surface of the central reinforcing core 1, which is formed first, retains a slightly rough texture. The subsequently injected PE material can fill the gaps in the texture, forming a tightly bonded integrated structure after cooling, thus avoiding delamination during long-term use. The four corners of the cross-shaped frame arm 4 adopt a rounded transition design, with the radius of the rounded transition matching the outer diameter of the twisted pair inside the cable. This reduces stress concentration when the arm contacts the twisted pair and prevents scratches on the insulation layer of the twisted pair when the cable is bent. At the same time, the thickness of the arm gradually decreases from the end near the central reinforcing core 1 to the end, reducing the overall weight while ensuring support strength. The axis of the cross-section of each side support 3 coincides with the center line of the cross-section of the cross-shaped frame arm 4. When the network cable is stepped on and radially compressed, the external force is first transmitted to the cross-shaped frame arm 4 through the outer sheath of the network cable. The boom 4 is an outer support structure extending outward from the central reinforced core 1, and is closer to the outer sheath than the central core. It will preferentially bear the compressive force transmitted by the outer sheath. At this time, the primary function of the cross-shaped boom 4 is to initially disperse the external force, avoiding the direct concentration of compressive pressure in a localized area. At the same time, relying on the flexible characteristics of the outer PE layer 2, it buffers part of the impact force, reducing the risk of the cross-shaped boom 4 bending due to excessive instantaneous pressure. Subsequently, the cross-shaped boom 4 transmits the remaining external force that has not been completely dispersed to the side support 3 at its end. Since the side support 3 is parallel to the cross-shaped boom 4, when the cross-shaped boom 4 deforms under pressure, it will form point contact with the inner wall of the outer sheath. The side support 3 can further transmit the external force to the overall structure of the cross-shaped frame, avoiding deformation of the end of the cross-shaped boom 4 due to stress concentration. At the same time, through the "distributed load-bearing" characteristic, it transforms the local compression into a uniform force that the entire cross-shaped frame can withstand, laying the foundation for subsequent core support.

[0027] In this embodiment, the cross-shaped frame is integrally molded using a two-color injection mold. The specific steps are as follows:

[0028] Mold preparation: A custom two-color injection mold is used. The mold has two independent cavities. The first cavity is adapted to the shape of the central reinforced core 1 and the side support 3. The second cavity is adapted to the shape of the PE layer 2 and the cross skeleton arm 4. The two cavities are precisely aligned by positioning pins to ensure that the positional deviation of each component after molding is ≤0.1mm.

[0029] The first stage of injection molding of the central reinforced core 1 and the side support 3: After drying the Nylon 66 granules at 80°C for 4 hours to remove moisture, they are added to the first barrel of the injection molding machine. The melting temperature is set to 255°C and the injection pressure is set to 80MPa. The molten Nylon 66 is injected into the first cavity of the mold. After holding the pressure for 3 seconds, it is initially cooled to form an integrated preform of the central reinforced core 1 and the side support 3.

[0030] The second stage of injection molding of PE layer 2 and cross skeleton arm 4: switch the second barrel of the injection molding machine, add LDPE granules, set the melt temperature to 185℃ and the injection pressure to 60MPa, inject the molten PE into the second cavity of the mold, so that the PE material wraps the outside of the central reinforced core 1 and completely fills the side support 3 root and cross skeleton arm 4 cavity in the preform, and holds the pressure for 5 seconds.

[0031] Cooling and demolding: Control the mold temperature at 60℃, continue cooling for 15 seconds, then open the mold and take out the formed cross frame product. After visual inspection to ensure there are no flashes and that the total length and arm width of the cross frame meet the design requirements, it can be used for the assembly of Category 8 cables.

[0032] It should be noted that this tensile-strength reinforced Category 8 cable cross-shaped frame structure, through the synergistic effect of the central reinforcing core 1, PE layer 2, side support pillars 3, and cross-shaped frame arms 4, balances mechanical stability and signal transmission reliability, and can be specifically divided into three key stages:

[0033] The first stage is the initial force absorption and dispersion phase. When subjected to external pressure, the force is first transmitted through the outer sheath of the cable to the cross-shaped support arm 4. Because the cross-shaped support arm 4 is an outer support structure extending outward from the central reinforced core 1 and is closer to the outer sheath than the central reinforced core 1, it will preferentially absorb the compressive force transmitted by the outer sheath. At this time, the primary function of the cross-shaped support arm 4 is to initially disperse the external force, preventing the compressive pressure from being directly concentrated in a localized area. The cross-shaped support arm 4 then transmits the remaining external force that has not been completely dispersed to the side support 3 at its end. Since the side support 3 is parallel to the cross-shaped support arm 4 and is subjected to pressure, the cross-shaped support arm 4... The deformation will form point contact with the inner wall of the outer sheath. The side support 3 can further transmit the external force to the overall structure of the cross frame, avoiding deformation of the arm end due to stress concentration. At the same time, through the "distributed load-bearing" characteristic, the local compression is transformed into a uniform force that the entire cross frame can withstand, laying the foundation for subsequent core support. Due to the slight elastic deformation of the cross frame arm 4 through the flexible characteristics of the PE layer 2, the impact force is buffered while transmitting the external force to the center in the radial direction of the cross frame arm 4. In addition, the included angle of the cross frame arm 4 is a rounded transition design, which further reduces stress accumulation and lays the foundation for subsequent core support.

[0034] The next stage is the core resistance and structural balance phase. The external force, dispersed by the side pillars 3 and the cross-shaped frame arms 4, is finally transmitted to the core component of the cross-shaped frame, the central reinforced core 1. The central reinforced core 1 is made of high-strength engineering plastic, which directly resists the final concentrated external force with its high rigidity, ensuring that the overall "cross"-shaped structure does not collapse or deform. At the same time, the PE layer 2 wrapped around the core plays a flexible transition role, buffering the stress difference between the central reinforced core 1 and the cross-shaped frame arms 4 through its own elasticity, avoiding the breakage at the connection due to excessive rigidity contrast, and achieving a mechanical balance of "hard support + soft buffer".

[0035] Finally, in the signal transmission stability assurance stage, throughout the entire stress process, the four isolation grooves formed by the cross-shaped skeleton arm 4 around the central reinforcing core 1 always maintain a stable shape, ensuring that the four pairs of twisted wires inside the cable are always in an independent and separated state, and that the wire pairs will not be attached or misaligned due to skeleton deformation. This stable wire pair spacing effectively suppresses crosstalk and reduces interference and attenuation in signal transmission. Even in complex environments such as long-term bending and vibration, it can still ensure the signal quality of Category 8 cables in high-speed transmission scenarios such as 10Gbps, meeting the needs of scenarios with extremely high transmission reliability requirements such as data centers and industrial control.

[0036] The above-described embodiments are merely illustrative of several implementations of this utility model, and while the descriptions are relatively specific and detailed, they should not be construed as limiting the scope of this utility model patent. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of this utility model, and these modifications and improvements all fall within the protection scope of this utility model.

Claims

1. A tensile-strength reinforced Category 8 cable cross-shaped frame structure, characterized in that: It includes a central reinforced core (1), a PE layer (2), four side pillars (3) and a cross-shaped frame arm (4); the PE layer (2) is wrapped around the outside of the central reinforced core (1), and the four side pillars (3) are respectively set at the four ends of the four arms of the cross-shaped frame arm (4). The four side pillars (3) are made of the same material as the central reinforced core (1), and the angle between the four side pillars (3) and the plane where the central reinforced core (1) is located is 90° and they are evenly distributed at the edge of the cross-shaped frame arm (4).

2. The tensile-strength reinforced Category 8 cable cross-shaped frame structure according to claim 1, characterized in that: The cross-sections of the four side pillars (3) are "teardrop-shaped", and the axes of the cross-sections of the four side pillars (3) are collinear with the center line of the cross-section of the cross-frame arm (4).

3. The tensile-strength reinforced Category 8 cable cross-shaped frame structure according to claim 2, characterized in that: The central reinforcing core (1) is made of engineering plastic, and the PE layer (2) is made of conventional PE material. The central reinforcing core (1) and the PE layer (2) are fused at the molecular level through a composite injection molding process.

4. The tensile-strength reinforced Category 8 cable cross-shaped frame structure according to claim 3, characterized in that: When the cross-shaped frame arm (4) is subjected to external pressure, it comes into point contact with the inner wall of the cable outer sheath.

5. The tensile-strength reinforced Category 8 cable cross-shaped frame structure according to claim 4, characterized in that: Both the cross-shaped frame arm (4) and the central reinforced core (1) are cross-shaped structures, and the included angle of the cross-shaped frame arm (4) adopts a rounded transition design.

6. The tensile-strength reinforced Category 8 cable cross-shaped frame structure according to claim 5, characterized in that: The four included angles of the cross-shaped frame arm (4) form isolation grooves for separating the twisted pairs inside the cable.

7. The tensile-strength reinforced Category 8 cable cross-shaped frame structure according to claim 6, characterized in that: The thickness of the cross-shaped skeleton arm (4) gradually decreases from one end near the central reinforced core (1) to the ends of the four arms.

8. A tensile-strength reinforced Category 8 cable cross-shaped frame structure according to any one of claims 1-7, characterized in that: The central reinforced core (1), PE layer (2), side support pillars (3) and cross skeleton arm (4) are integrally formed by two-color injection molding.

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