DE19947825C1 - Data transmission cable manufacturing method has data transmission elements inserted in separate chambers provided by one-piece reception chamber profile before wrapping band around outside of latter - Google Patents

Abstract

The data transmission cable manufacturing method uses a one-piece reception chamber profile having a number of radial struts for dividing it into separate chambers (4), the peripheral wall sections of the profile opened to allow the data transmission elements (9) for the cable to be inserted in the chambers, before wrapping a wound band (11), incorporating a cable screening, around the outside of the profile.

Description

The invention relates to a method for producing egg data transmission cable.

Various measures are known in the prior art, in the case of data transmission cables, the transmission elements (e.g. symmetrical copper lines or fiber optic cables ter) in the cable and, if necessary, separate from each other rieren. This can be done, for example, by embedding the Transmission elements happen in an intermediate jacket as it is from DE 42 40 209 A1 for a cable with a Star quad and from DE 196 36 287 A1 for a cable is known with four pairs.

Another way to fix and separate the Transmission elements lies in the data transmission equip cables with a chamber profile, in the cam the transmission elements run. From DE 40 04 Such a chamber cable is known from 429 A1, which Optical fibers and / or electrical conductors as over contains support elements. From EP 0 763 831 A1 is a Cable with four twisted pairs known to be in the chimney of a cross-shaped profile. This works as an electrical shield between the pairs by it consists entirely or partially of conductive material. Out A corresponding cable is known from DE 298 19 410 U1, where the chamber profile is not conductive, however has no shielding function. From DE-PS 82 461 is knows to ex a chamber profile around individual conductors trudge. This is to serve to make the conductors electrical  isolate from each other and thereby for a relative to ensure a large distance between the individual conductors. From DE 41 28 935 A1 is a cable with a chamber profile knows that in a first group of embodiments has removable lid while a second Group the chambers after inserting transfer elements elements are glued.

The invention is based on the technical problem another method for producing a data transfer power cable, which on the one hand places high demands on the electrical and mechanical properties are sufficient and appropriate on the other hand, can be produced with relatively little effort and is easy to lay and connect.

According to the invention, this problem is solved by a Ver drive to manufacture a data transmission cable several transmission elements and one piece provided chamber profile, with the following steps: at the Chamber profile, which in cross-section one or more Webs and a circumference surrounding the one or more webs points and thus forms chambers, chambers become Spreading of peripheral sections of the chamber profile ge opens; at least in each case in the open chambers introduced a transmission element; the chambers will closed (claim 1).

The chamber profile in which the transmission elements the production are inserted, not only z. B. cross-shaped or comb-shaped webs, but also an um mantle. So it forms closed chambers for the Transmission elements. Preferably the chamber profile in one step z. B. produced by extrusion. Poss Lich is also a multi-step production by first the inner web part is made, on the then the jacket is extruded. With the chamber cable  According to EP 0 763 831 A1 mentioned above, these are by the chamber profile formed chambers open; first after the introduction of the transmission elements are ver different insulating or conductive layers on the Profile applied with the transmission elements. Consequently there is no connection in the sense of going through the fabric structure between the radially outer edges of the Webs and the wrapping touching them while this manufactured in the invention at least in one step tem chamber profile is the case.

To open them, the one in front of the chambers Circumferential sections against the inherent elasticity of the profile materials spread. The transmission elements are then introduced into the chambers thus opened.

By fixing the transmission elements in this way can be used during the manufacturing process according to effort data transmission cable with excellent Establish damping and crosstalk properties. The Cable manufactured according to the invention is insensitive ge against transverse pressures and with small bending radii where while maintaining its favorable properties. Finally it is easy to assemble because of the profile jacket (if necessary, including an outer casing) simply cut through ten and then the corresponding section of the profile can be easily removed.

Advantageous refinements are in the subclaims specified.

According to claim 2 is on the circumference of the chamber profile an envelope arranged. This can be a act on extruded or shrunk tubing. Wrapping with a tape or is also advantageous a film that is provided with adhesives.  

It is advantageous outside the circumference of the chamber profile applied a shield (claim 3). This can be realized, for example, in that for Tape winding used tape or the film made of conductive Material exists or a metallic coating points (claim 4). For example, a metal foil or a plastic film with a metallic coating layering is used, e.g. B. an Al-PET tape. Additional Lich braiding can be arranged outside.

According to claim 5, the envelope is closed Chamber profile glued on.

According to claim 6, it is alternatively possible to start with one apply non-conductive sheathing, and then a shield. This can be a through going conductive layer and / or a braid han deln.

A continuous conductive layer can be on the wrapper by metal spraying, dipping, extruding, galvanic or chemical deposition, plasma coating, vapor deposition fen are produced (claim 7). Can be used as a shield additionally or alternatively, a braid is also provided hen.

According to claim 8, the chamber profile itself does not act shielding, unlike the above EP 763 831 A1. This has the advantage that the capacitive Lei covering - and thus the attenuation of the cable - relatively are small.  

For certain applications where shielding between the chambers is desired, the webs of the Chamber profile, however, act shielding (claim 9).

The transmission elements are preferably symmetrical (Copper) lines in the form of pairs or fours, or Optical fiber or fiber optic bundle (claim 10). In general, only one type of cable is used ge transmission elements used. For certain users However, hybrid cables are also possible for example 2 optical fibers and 2 pairs in are combined in one cable. Preferably runs in only one transmission element per chamber; possible are also several (same or different) per chamber. From the above Because of a low capacity and thus lower damping is on the pairs or fours preferably no shield is arranged. Possible are but also versions in which shielded pairs or Fours are used.

According to claim 11, the transmission elements are game free in the chambers. This helps the transfer supply elements as precisely as possible at their target positions fix and therefore has a favorable effect in terms of electrical transmission properties of the data transmission supply cable - especially when installed (so-called installation stability) - off.

An in. Can advantageously be in the center of the chamber profile Longitudinal reinforcing agent embedded that is, for example, a wire or can act a thread (claim 12).

According to claim 13, the material thickness on the circumference of the Chamber profile smaller than 0.25 mm, preferably smaller  than 0.15 mm. In electrical terms it is a minor one Thickness of the perimeter sufficient in many cases to accommodate the desired spacing of the shield with regard to to achieve a low capacity. A small Material thickness is i. a. sufficient to fix the Transmission elements, even with small bending radii. Next the already mentioned aspect of slight twisting Availability is advantageous in terms of simple Laying and assembling the cable. The bridges ha ben i. a. a larger material thickness, the z. B. smaller 0.75 mm, preferably less than 0.55 mm. As a mate Rial for the chamber profile are preferably plastics with low loss factor, like plastics on polye ethylene and / or polypropylene base selected.

To achieve good attenuation and crosstalk properties It is advantageous to use a small tolerance used chamber profile, with tolerances less than or equal to ± 0.1 mm, preferably less than or equal to ± 0.05 mm. This tolerance information is so ver stand that none of the geometric sizes of the profile (e.g. wall thicknesses, location of a possible crossing points between bars etc.) over the specified area may deviate from the nominal value. This is especially si made sure that these geometric sizes are not in Longitudinal direction of the cable can vary, depending on the elec trical transmission properties would be detrimental.

An extruded chamber profile is preferably used in which the profile jacket is a closed surface forms, so is initially not open. To open the chamber profile is therefore cut open, with a longitudinal cut in the area provided the chamber to be opened (claim 14).  

According to claim 15, the spread circumference cuts to close the chambers to their starting position brought back. With sufficient elastic recovery by virtue of the chamber material, this alone see that the spreading tool is removed from the cable becomes. The corresponding peripheral sections of the profile then close by themselves.

Preferably, the transmission elements - as far as it is are symmetrical lines - ver rotates in order to minimize interference from interference signals to keep. To crosstalk between the lines possible To avoid as much as possible, the individual is stranded Lines preferably with different swirl lengths and / or opposite swirl directions. According to An Proverb 16 becomes the twist of the transmissions elements before they are introduced into the chambers.

According to claim 17, the chamber profile after the insertion conditions of the transmission elements and closing of the chambers twisted as a whole. Such a common twist all transmission elements can be advantageous in addition to the in-itself twist can be provided. If the In twisting takes place in a common direction of swirl, the twist direction of the total rotation i. a. opposite chose. The twist of the chamber profile is possible by choosing a sufficiently flexible art material (e.g. based on polyethylene) and one of sufficiently small wall thickness of the perimeter of the Kammerpro fils. The two rotations can be done in two steps rope or also in one-stage stranding (so-called Group twinning). It will be advantageous Manufacturing process in a bundle stranding machine inte freezes. As a group winner after the stranding point analog  a bundle stranding machine, the Her position procedure also integrated into a group winner become. In general, the turning force is twisted ten chamber profile relatively small, so that the inserted th transmission elements and / or the envelope a back rotation is prevented.

According to the invention can be realized in a simple manner, for example, a data transmission cable with four mutually unshielded pair lines, which has a thin structure (diameter approximately between 5 mm and 7 mm), allows extremely small bending radii (2 × outer diameter), and which due the twisted pair stabilized by the chamber profile and the adhesive bonding with shielding foil keeps its impedance and its good damping and crosstalk properties practically unchanged even when installed. The cable complies with all the electrical parameters required in the proposed standard for category 6 , ie for data cables up to 250 MHz (standards EN 50173, EN 61156 and pr EN 50288). The cable is easy to process and therefore has the advantage of shorter installation times and costs.

In the following the invention based on execution examples and the attached drawing explained.  

Show in the drawing

Figure 1 is a cross-sectional view of a chamber profile with four chambers in the initial state before the position of the cable ago.

FIG. 2 shows a representation according to FIG. 1, but with a cut-open and partially spread-open chamber profile;

Fig. 3 is an illustration of the manufacturing process of a cable with the chamber profile of FIG. 1;

Fig. 4-6 cables with four, two and three chambers and a corresponding number of pair lines in cross section;

Fig. 7-9 cables corresponding to Figures 4-6, but with star quads instead of pair lines;

Fig. 10 is a cross-sectional view of a further embodiment of a chamber profile.

In the figures, functionally identical or similar elements are shown elements marked with the same reference numerals.

The exemplary cables described in more detail below are designed for a frequency range from 1 MHz to 250 MHz but are also for transmission higher (and lower) frequencies. The art insulation of the wires as well as those described in more detail below Benen chamber profiles are generally made of polyethylene len, polypropylene, mixtures thereof or other suitable neten plastics. The plastic can be foamed. The examples described below have symmetri cal lines as transmission elements, which an Im have a tolerance of 100 ohms. In other execution forms  other impedance values have been realized, e.g. B. in Range between 75 ohms and 150 ohms. The vein diameters are less than 1 mm to connect with Allow RJ-45 connectors.

Fig. 1 shows a chamber profile 1 , which is suitable for receiving four transmission elements (pairs, quads and / or fiber optic bundles). It has two webs 2 , which intersect at right angles in the center of the profile 1 , and a circumferential jacket 3 surrounding the webs 2 , which has a circular cross section and is arranged concentrically to the center. Here, four chambers 4 running in the longitudinal direction of the cable are formed, each of which has the cross-sectional shape of a 90 ° circular sector. Along the center axis of the profile 1 is a reinforcing insert 5 , which is, for. B. is a thread or a wire.

By choosing the material thicknesses of the webs 2 and the Um ummantels 3 , the distances from the transmission element to transmission element or from transmission element to the outer shield - and thus the impedance, the attenuation and the crosstalk behavior of the cable - can be set constructively within wide limits. The relatively large spacing between the transmission elements from the outer shielding in front of the cable construction, in turn, allows the wire spacing of the transmission elements to be chosen relatively narrow, that is to say, the Ade risolation be made relatively thin. This allows the use of miniature plugs, which require small wire diameters. For reasons of drawing, the circumferential jacket 3 is shown in the figures with a large thickness. In general, however, its thickness is only approximately half to 1/5 of the thickness of the webs 2 .

Profile 1 is preferably produced in a separate step preceding the actual cable production by extrusion. The entire profile is preferably produced in a single extrusion step. However, it is also possible to initially only produce the web part of the profile, and only in a second step to extrude the peripheral jacket 3 onto the web part which has already been produced. In any case, it follows the production of the entire profile, including the circumferential casing 3, before the transfer elements are introduced.

In the embodiment shown, the profile 1 consists exclusively of non-conductive materials. In other (not shown) embodiments, the webs 2 have a shielding function by being equipped on their surfaces or in their interior with a conductive layer, or by being made of conductive plastic.

Fig. 2 illustrates the further processing of the pre-manufactured chamber profile 1 in the context of cable manufacturing. Namely, a cut 6 extending in the longitudinal direction is made at each chamber 4 and cuts through the circumferential jacket 3 . In the game Ausführungsbei shown, the cuts 6 are each centered over the chamber 4 ; in other (not shown) exemplary embodiments, however, they can, for example, also be arranged in the vicinity of one of the webs 2 delimiting the chambers 4 . By attaching the cuts 6 lap penartige peripheral portions 7 are formed. These are bent for introducing the transmission elements, as shown in FIG. 2 in the upper right chamber 4 . The Aufbie conditions can z. B. using a spreading tool.

In other (not shown) embodiments, the chamber profile 1 is already produced with opening lines - corresponding to the cuts 6 - so that the cutting step can be omitted.

Fig. 3 illustrates the manufacturing process. In the course of manufacture, the profile 1 shown is shifted from left to right. The profile 1 is guided so that it can not rotate freely, but is freely movable in the longitudinal direction. First, the profile 1 is cut open over the four chambers 4 , for which purpose four cutting knives 8 are used. Then he follows the opening of the chambers 4 with the help of (not shown) spreading tools. The peripheral sections 7 are fixed in their spread position (also not shown). The first stage of the stranding takes place parallel to the cutting of the profile 1 , namely the twisting of four pairs 9 in itself. These are each inserted into an open chamber 4 in so-called stranding point 10 (ie the point at which the second stage of stranding, that is to say the total twisting of the cable) takes place. After inserting the transmission elements, the spread circumferential sections 7 are brought back into their starting position, the chambers 4 are therefore closed. This can be followed solely by the elastic restoring forces of the chamber material; however, it is also possible to use a pressure tool that ensures that it is completely closed. In the stranding point 10 , the second stage of stranding takes place, that is, the total rotation of the profile 1 together with the transmission elements inserted into the chambers 4 . On the bundle prepared in this way, a metal foil 11 treated with an adhesive or a correspondingly treated plastic tape with a metallic layer (e.g. Al-PET tape) is adhered. The application of the film 11 serves to shield and fix the bundle. Alternatively, it is also possible to shrink on a hose (made entirely or partially) of conductive material. As a further possibility, a conductive layer can be produced on the surface of the peripheral sheath 3 or a covering applied to it, for example by metal spraying, dipping, extruding, galvanizing, etc. In addition, a braided shield and an outer protective sheath made of plastic can optionally be applied to the shielding end Layer can be applied.

Figs. 4-9 illustrate various fertigge presented cable in cross section. FIGS. 4 and 7 show ca ble with a four-chamber profile, obtained by using the profile shown in Figs. 1 and 2 who the. FIGS. 5 and 8, however, show cables with 2 chambers that obtained by using a profile with only egg nem, by knife-like extending web 2 who the. FIGS. 6 and 9 show cable with three Kam numbers. 4 They are based on a profile with three webs 2 , which run radially outwards from the center and each form an angle of 120 ° to one another.

In the cables of FIGS. 4-6, the transmission elements are twisted in themselves, unshielded pairs 9. Each pair consists of two similar veins 12 , which touch each other be. Each core 12 is in turn made up of a conductor 13 and a core insulation 14 surrounding it. The pairs 9 lie almost without play in their respective chamber 4 . Due to the inherent twist, the wires 12 of the pairs 9 are not fixed in places by the chamber walls, as is shown, for example, in the left-hand chamber of FIG. 5. In the longitudinal course of the cable, however, there are always twist angles in which the chamber walls enclose the pair 9 without play, so that overall a practically play-free embedding of the pairs 9 in profile 1 is ensured in the longitudinal direction of the cable (see right chamber of FIG. 5).

In Figs. 7-9 the transmission elements are stranded, unshielded star quad 29th They are each formed by four wires 12 , which are arranged at the corners of an (imaginary) square. Two opposite wires 12 each form a symmetrical line. With the same wire diameter, the distance between the conductors forming a line is greater in the star quad than in the pair.

The chambers 4 can have a variety of other shapes, e.g. B. have stripe, honeycomb or triangular shape. An example with chambers 4 in the form of bulbous pentagons is shown in FIG. 10.

Overall, the invention provides a cable in which the transmission elements at a constant distance from each other which are embedded for shielding. This way he the cable has a uniform impedance curve and favorable damping and crosstalk properties. The Easily processable cables keep their cheap mecha niche and electrical properties even when laying with extremely small bending radii.

Claims (17)

1. A method for producing a data transmission cable with several transmission elements ( 9 , 19 ) and a one-piece chamber profile ( 1 ), with the following steps:

• - wherein the chamber profile (1) which in cross section has one or more webs (2) and a the or the webs (2) surrounding the periphery (3) and thus forms chambers (4), chambers (4) by spreading of Peripheral sections ( 7 ) of the chamber profile ( 1 ) opened;
• - In the open chambers ( 4 ) we at least one transmission element ( 9 , 19 ) is introduced;
• - The chambers ( 4 ) are closed.

2. The method according to claim 1, in which on the order of the chamber profile ( 1 ) a sheath ( 11 ), in particular a tape winding, is arranged. 3. The method according to claim 1 or 2, in which a shield is applied from outside the circumference of the chamber profile ( 1 ). 4. The method according to claim 2 and 3, wherein with bringing on the sheath ( 11 ) a shield is brought up, in particular by using a tape winding with a conductive layer. 5. The method according to any one of claims 2 to 4, wherein the covering ( 11 ) is glued on. 6. The method according to claim 2 and 3, wherein after Aufbrin gene of the sheath ( 11 ) a shield, in particular re in the form of a conductive layer and / or braiding, is applied. 7. The method of claim 6, wherein the conductive Layer by metal spraying, dipping, extruding, galvanic or chemical deposition, plasma layers, vapor deposition or banding becomes. 8. The method according to any one of claims 1 to 7, in which chem a non-shielding chamber profile ( 1 ) is used. 9. The method according to any one of claims 1 to 7, in which chem a chamber profile ( 1 ) is used, the webs ( 2 ) act shielding. 10. The method according to any one of claims 1 to 9, in which chem the transmission elements ( 9 , 19 ) are selected from the following group: unshielded pair ( 9 ), shielded pair, unshielded foursome ( 19 ), ge shielded foursome, optical waveguide, Lichtwellenlei terbündel . 11. The method according to any one of claims 1 to 10, wherein the transmission elements ( 9 , 19 ) are inserted into the chambers ( 4 ) without play. 12. The method according to any one of claims 1 to 11, in which a longitudinally extending reinforcing means ( 5 ) is incorporated in the center of the chamber profile ( 1 ). 13. The method according to any one of claims 1 to 12, in which a chamber profile ( 1 ) is used, the material thickness on the circumference is less than 0.25 mm, preferably less than 0.15 mm. 14. The method according to any one of claims 1 to 13, wherein the chamber profile ( 1 ) is cut open before opening the chambers ( 4 ). 15. The method according to any one of claims 1 to 14, wherein to close the chambers ( 4 ), the spread order to start sections ( 7 ) are brought back to their starting position. 16. The method according to any one of claims 1 to 15, wherein the or individual of the transmission elements ( 9 , 19 ) are rotated ver before being introduced into the chambers ( 4 ). 17. The method according to any one of claims 1 to 16, wherein the chamber profile ( 1 ) after the introduction of the transmission elements ( 9 , 19 ) and closing the chambers ( 4 ) is rotated as a whole.