High performance power conversion link

Abstract

The utility model discloses a kind of high-performance power conversion connecting wires, including a cable, cable two ends are connected male connector and female connector respectively. Male, female connector are 6pin connector of pin spacing 1.25mm. Cable inside includes six insulated wire cores, and wire core is made of tinned copper wire stranded with 8-10mm lay and is clamped with tensile fiber. The pin definition of six wire cores corresponding connection is defined as two pairs of differential signal (TX+ / -, RX+ / ), a ground a power supply (+12V). Cable adopts aluminum foil milar layer and high-density braided layer to form double shielding structure. The utility model has low direct current resistance (≤500mΩ), high current carrying capacity (≥3A), excellent shielding effectiveness, high mechanical strength (terminal retention force ≥9N, high and low temperature swing resistance), flame retardant (UL94-V0) and wide operating temperature (-30℃ to +70℃) and the like, suitable for the internal connection of electronic equipment with high quality requirement for power supply and signal transmission.

Description

Technical Field

[0001] This utility model relates to the field of electronic connection line technology, specifically to a high-performance power conversion connection line for transmitting power and signals. Background Technology

[0002] In modern electronic devices, such as servers, communication equipment, and industrial controllers, internal modules typically require power and data transmission via connecting cables. As device performance improves, the requirements for these connecting cables also increase, demanding not only stable power transmission but also the integrity of high-speed data signals.

[0003] Traditional power cables may have the following problems: excessive DC resistance leading to voltage drop and overheating; poor shielding resulting in signal interference; insufficient cable flexibility and durability, making them prone to damage in frequent plugging and unplugging or equipment vibration environments; and loose connector terminals, easily leading to poor contact. Furthermore, in harsh environments such as high or low temperatures, the physical properties of the cables may degrade, affecting the reliable operation of the equipment.

[0004] Therefore, there is an urgent need for a high-performance power conversion cable with low resistance, high shielding effectiveness, excellent mechanical properties, and a wide operating temperature range. Utility Model Content

[0005] The purpose of this utility model is to overcome the shortcomings of the prior art and provide a high-performance power conversion cable with advantages such as stable transmission, good shielding effect, high mechanical strength, good durability and safety.

[0006] To achieve the above objectives, this utility model provides the following technical solution: a high-performance power conversion cable, comprising a cable with a male connector and a female connector connected to each end. Both the male and female connectors are 6-pin connectors with a pin pitch of 1.25mm. The cable internally contains six parallel insulated cores, each core being composed of multiple strands of tinned copper wire twisted together, with a twist pitch of 8-10mm.

[0007] Furthermore, the pins of the six wires at the connector end are defined as follows: pin 1 corresponds to the TX+ signal terminal, pin 2 corresponds to the TX- signal terminal, pin 3 corresponds to the RX+ signal terminal, pin 4 corresponds to the RX- signal terminal, pin 5 corresponds to the GND ground terminal, and pin 6 corresponds to the +12V power supply terminal.

[0008] Furthermore, the tin-plated copper wire has a specification of 0.05mm30 or 0.05mm60, and the insulated wire core is intercalated with tensile fibers to enhance the overall tensile strength of the wire core.

[0009] Furthermore, the total DC resistance of the cable is no more than 500 mΩ to ensure low line loss.

[0010] Furthermore, the terminal holding force of the male and female connectors is not less than 9N to ensure the mechanical stability of the connection.

[0011] Furthermore, the cable can withstand a conduction current of not less than 3A, meeting the requirements for high current transmission.

[0012] Furthermore, the cable can pass at least 16,000 swing tests at room temperature and at least 5,000 swing tests at -30°C, indicating that it has excellent resistance to bending fatigue and low temperature performance.

[0013] Furthermore, the cable sheath is made of a material with a flame retardant rating of UL94-V0, improving safety during use.

[0014] Furthermore, the cable, from the inside out, comprises: the insulated core, an aluminum foil Mylar shielding layer wrapped around the core, and a braided shielding layer woven outside the aluminum foil Mylar shielding layer, which together form a double shielding structure to effectively suppress electromagnetic interference.

[0015] Furthermore, the braided shielding layer has a braiding density of not less than 85% to ensure excellent shielding performance.

[0016] Compared with the prior art, the present invention has the following significant advantages: 1. High mechanical strength and durability: By adopting an 8-10mm strand pitch structure and adding tensile fibers to the insulated core, the cable's flexibility, tensile strength, and bending resistance are greatly improved, enabling it to pass rigorous swing tests and significantly extending its lifespan. The connector terminal retention force is not less than 9N, ensuring a stable connection.

[0017] 2. Excellent electrical performance and safety: The cable has low total DC resistance (≤500 mΩ), high current carrying capacity (≥3A), and high transmission efficiency. The double shielding structure (aluminum foil Mylar layer + high-density braided layer) provides excellent electromagnetic shielding, ensuring the integrity of signal transmission. The sheath is made of UL94-V0 grade flame-retardant material, which is flame-retardant, fireproof, safe, and reliable.

[0018] 3. Excellent environmental adaptability: It has a wide operating temperature range, and can maintain its performance, especially in low-temperature environments of -30℃. It has also passed the low-temperature swing test and is suitable for various harsh working environments.

[0019] 4. Compact structure: The 1.25mm pin pitch makes the connector small in size, suitable for high-density integration applications. Attached Figure Description

[0020] The accompanying drawings are provided to further illustrate the present invention and form part of the specification. They are used together with the embodiments of the present invention to explain the present invention, but do not constitute a limitation thereof. In the drawings: Figure 1 This is a schematic diagram of the overall structure of this utility model.

[0021] Figure 2 for Figure 1 A schematic diagram of the end face where the male connector mates with the female connector.

[0022] In the diagram: 1. Cable; 2. Male connector; 3. Female connector; 4. Insulated wire core. Detailed Implementation

[0023] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. Based on the embodiments of the present utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of the present utility model.

[0024] Please see Figures 1 to 2 This utility model provides a high-performance power conversion cable, mainly composed of a cable 1, a male connector 2, and a female connector 3. The male connector 2 and female connector 3 are crimped or soldered to both ends of the cable 1, respectively. Both are 6-pin connectors with a pin pitch of 1.25mm, resulting in a compact structure. The cable 1 contains six independent insulated cores 4, each composed of multiple extremely fine tinned copper wires twisted together with a pitch of 8-10mm. For example, a 0.05mm*30mm² wire (with a cross-sectional area of ​​approximately 0.059mm²) can be used. 2 ) or 0.05mm*60 (cross-sectional area approximately 0.118mm²) 2 The copper wire is used to balance flexibility and current carrying capacity. When the core is stranded, a tensile fiber made of Kevlar or other materials can be sandwiched in the center (not shown separately in the figure) to significantly improve tensile strength.

[0025] The six insulated wire cores 4 are crimped or soldered to the connectors at both ends according to the clearly defined pins: pin 1 (TX+), pin 2 (TX-), pin 3 (RX+), and pin 4 (RX-) are used for differential signal transmission, pin 5 (GND) is ground, and pin 6 (+12V) is the positive power supply.

[0026] The outer layer of the inline core bundle is first tightly wrapped with an aluminum foil Mylar shielding layer, which primarily provides 100% coverage to combat high-frequency interference. Outside the aluminum foil Mylar shielding layer, a woven shielding layer composed of a metal mesh is formed, with a weave density of no less than 85%. This layer primarily provides good low-frequency shielding and resistance to mechanical abrasion. Together, the aluminum foil layer and the woven layer constitute a highly efficient double-shielded structure, providing all-around protection against electromagnetic interference.

[0027] The outermost layer is the cable sheath, which is made of materials (such as PVC, PE, etc.) that meet the UL94-V0 flame retardant standard, ensuring the safety of the product.

[0028] By carefully selecting materials and optimizing processes, the total DC resistance of the finished cable is controlled within 500mΩ, the terminal holding force reaches more than 9N, it can stably transmit 3A current, and can pass 16,000 swing tests at room temperature and 5,000 swing tests at -30℃. The working temperature range is -30℃ to +70℃, and the total length is precisely controlled within 260mm ± 5.0mm.

[0029] The total length of the adapter cable in this embodiment is designed to be 260mm ± 5.0mm to meet the connection requirements within a specific chassis or between modules.

[0030] Performance metrics: Tested, the total DC resistance of this conversion cable is ≤500 mΩ, ensuring a low voltage drop. The connector's terminal retention force is ≥9N, guaranteeing connection reliability. The cable can stably carry a conducting current of not less than 3A. In cable sway tests, it can withstand more than 16,000 bends at room temperature and more than 5,000 bends at -30℃, demonstrating excellent fatigue resistance. The product's operating temperature range covers -30℃ to +70℃, offering strong adaptability.

[0031] Finally, it should be noted that the above description is merely a preferred embodiment of this utility model and is not intended to limit the utility model. Although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this utility model should be included within the protection scope of this utility model.

Claims

1. A high-performance power conversion cable, characterized in that, The cable (1) includes a male connector (2) and a female connector (3) connected to its two ends respectively; both the male connector (2) and the female connector (3) are 6-pin connectors with a pin pitch of 1.25mm; the cable (1) contains six parallel insulated wire cores, which are made of multiple tinned copper wires twisted together, with a twist pitch of 8-10mm.

2. The high-performance power conversion cable according to claim 1, characterized in that, The six wire cores are defined as follows in the male connector (2) and female connector (3): pin 1 corresponds to the TX+ signal terminal, pin 2 corresponds to the TX- signal terminal, pin 3 corresponds to the RX+ signal terminal, pin 4 corresponds to the RX- signal terminal, pin 5 corresponds to the GND ground terminal, and pin 6 corresponds to the +12V power supply terminal.

3. The high-performance power conversion cable according to claim 1, characterized in that, The tinned copper wire has a specification of 0.05mm*30 or 0.05mm*60, and the insulated wire core is intercalated with tensile fibers.

4. The high-performance power conversion cable according to claim 1, characterized in that, The total DC resistance of the cable (1) is not greater than 500mΩ.

5. The high-performance power conversion cable according to claim 1, characterized in that, The terminal holding force of the male connector (2) and the female connector (3) shall not be less than 9N.

6. The high-performance power conversion cable according to claim 1, characterized in that, The cable (1) can withstand a current of not less than 3A.

7. The high-performance power conversion cable according to claim 1, characterized in that, The cable (1) can pass a swing test of no less than 16,000 times at room temperature and no less than 5,000 times at -30℃.

8. The high-performance power conversion cable according to claim 1, characterized in that, The sheath of the cable (1) is made of a material with a flame retardant rating of UL94-V0.

9. The high-performance power conversion cable according to claim 1, characterized in that, The cable (1) includes, from the inside out: the insulated core, the aluminum foil Mylar shielding layer wrapped around the core, and the braided shielding layer woven outside the aluminum foil Mylar shielding layer. The aluminum foil Mylar shielding layer and the braided shielding layer together form a double shielding structure.

10. The high-performance power conversion cable according to claim 9, characterized in that, The braided shielding layer has a braiding density of not less than 85%.

Images