EP1091363B1 - Data transmission cable and process to manufacture of a data transmission cable - 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 a Data transmission cable with several transmission elements and a plastic profile, as well as one through this Processed 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 optical fibers) fix it in the cable and separate it if necessary. 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 is the data transmission cable to equip with a chamber profile, in the chambers 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 transmission elements contains. From EP 0 763 831 A1 is a Cable with four twisted pairs known in the chambers 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 82461 it is known extrude a chamber profile around individual conductors. This is to serve to make the conductors electrical isolate from each other and thereby for a relative large distance between the individual conductors. From DE 41 28 935 A1 a cable with chamber profile is known, which at a first group of embodiments removable covers has, while in a second group the chambers glued after inserting transmission elements become.

From US-A-5 565 653 is a manufacturing process a flat cable-like data transmission cable with the following Known steps: in one piece Chamber profile, which in cross section a web and has a circumference surrounding the web and thus Forms chambers, the chambers are opened; in the open Each chamber becomes a transmission element brought in; and the chambers are closed.

A data transmission cable is known from US-A-5 132 488 a helical chamber profile known when extruding of the cable jacket is formed.

The invention is based on the technical problem Method of manufacturing a data transmission cable with favorable transmission properties, which is relative requires little effort, as well as using this method to provide manufactured data processing cable.

• bei einem einstückig hergestellten Kammerprofil, welches im Querschnitt einen oder mehrere Stege und einen den bzw. die Stege umgebenden Umfang aufweist und somit Kammern bildet, werden die Kammern geöffnet;
• in die geöffneten Kammern wird jeweils wenigstens ein Übertragungselement eingebracht;
• die Kammern werden geschlossen;
• das Kammerprofil wird als Ganzes verdreht.

According to the invention, this problem is solved by a method for producing a data transmission cable, with the following steps:

• in the case of a one-piece chamber profile which has one or more webs in cross-section and a circumference surrounding the one or more webs and thus forms chambers, the chambers are opened;
• at least one transmission element is introduced into each of the opened chambers;
• the chambers are closed;
• the chamber profile is twisted as a whole.

The chamber profile is therefore together with those in it Transmission elements twisted. The invention also provides a data transmission cable manufactured by this method ready.

The chamber profile, in which the transmission elements the production are inserted, not only points e.g. cross-shaped or comb-shaped webs, but also one Peripheral skirt. It therefore forms closed chambers for the transmission elements. Preferably the chamber profile in one step e.g. made by extrusion. However, multi-step production is also possible, by first manufacturing the inner web part on which the jacket is then extruded. In which Chamber cables according to EP 0 763 831 A1 mentioned above however, the chambers formed by the chamber profile are open; only after the transfer elements have been introduced are different insulating or conductive layers applied to the profile with the transmission elements. So there is no connection in the sense of a continuous Fabric structure between the radially outer edges the webs and the casing touching them, while this in the invention at least in one step Chamber profile is the case.

It should be noted that the method according to the invention also advantageous for the production of data transmission cables in which not at least one of the transmission elements one or more wires with wire insulation is built, i.e. where e.g. exclusively isolated or uninsulated individual wires are introduced into the chambers become.

By fixing the transmission elements in this way during the manufacturing process can be done with little Effort data transmission cable with excellent Establish damping and crosstalk properties. The the cable according to the invention is insensitive to transverse pressures and can be installed with small bending radii, whereby it is its keeps favorable properties. After all, it's easy Can be assembled, as the profile jacket (possibly including a outer casing) simply cut through and then the corresponding section of the profile is slightly subtracted can be.

Advantageous configurations are given below.

On the circumference of the chamber profile is preferably a Wrapping arranged. This can be an extruded one or shrink 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 a shield is applied. This can, for example be realized in that for the tape winding used tape or the film consists of conductive material or has a metallic coating. It is but also possible to have a conductive layer on the outside To produce the envelope or the circumference of the chamber profile, such as by metal spraying, dipping, extruding galvanic or chemical deposition, plasma coating, Vapor deposition. As a shield, it can additionally or alternatively braiding may also be provided.

In a preferred embodiment, the chamber profile acts not shielding itself, unlike with the above-mentioned EP 763 831 A1. This has the advantage that the capacitive cable covering - and thus the attenuation of the cable - are relatively small.

For certain applications where shielding However, configurations are desired between the chambers advantageous in which the webs of the chamber profile shielding.

The transmission elements are preferably symmetrical (Copper) lines in the form of pairs or fours, or Optical fiber or bundle of optical fibers. In general are only similar transmission elements in a cable used. For certain applications but also hybrid cables possible, for example two optical fibers and two pairs in one Cables are grouped together. Preferably runs in everyone Chamber only one transmission element; are also possible several (same or different) per chamber. Out the above Because of a low capacity and thus low 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.

The transmission elements are preferably essentially located without play in the chambers. This helps the Transmission elements as precisely as possible at their target positions to fix and is therefore beneficial in terms of the electrical transmission properties of the data transmission cable - especially when installed (so-called Laying stability) - off.

Preferably, the transmission elements - as far as it is are symmetrical cables - twisted in themselves, in order to minimize interference from interference signals to keep. To crosstalk between the lines if possible to avoid, the individual is stranded Lines preferably with different swirl lengths and / or opposite swirl directions. The twist in itself in addition to the common twist of all Transmission elements due to the twisting of the chamber profile is beneficial. If the twist in itself If there is a common twist direction, the twist direction becomes the total twist i. a. chosen opposite. The chamber profile can be rotated by Choosing a sufficiently flexible plastic material (e.g. based on polyethylene) and a sufficiently low one Wall thickness of the circumference of the chamber profile.

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

The material thickness on the circumference of the chamber profile is advantageous less than 0.25 mm, preferably less than 0.15 mm. In electrical terms, it is a small thickness the scope in many cases sufficient to achieve the desired one Spacing the shield with respect to one to achieve 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 easy rotatability it is advantageous in terms of a simple one Laying and assembling the cable. Have the webs i. a. a greater material thickness, e.g. smaller 0.75 mm, preferably less than 0.55 mm. As a material plastics are preferably used for the chamber profile with low loss factor, such as plastics on polyethylene and / or polypropylene base selected.

To achieve good damping and crosstalk properties it is advantageous to make one with small tolerances To use chamber profile, with tolerances less than or equal to ± 0.1 mm, preferably less than or equal to ± 0.05 mm. These tolerances are to be understood that none of the geometric sizes of the profile (e.g. wall thicknesses, location of a possible crossing point between bars etc.) over the specified area may deviate from the nominal value. This ensures in particular that that these geometric sizes are not in Longitudinal direction of the cable can vary, which affects the electrical Transfer properties detrimental would.

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, e.g. e.g. with a longitudinal cut in the area each chamber to be opened.

The chamber profile is advantageously designed so that the Chambers - also in the cut state - due to the The elasticity of the profile material is closed. To open them, the ones in front of the chambers are opened Circumferential sections against the inherent elasticity of the profile material spread. The transmission elements are then introduced into the chambers thus opened.

The spread circumferential sections become closed of the chambers returned to their original position. With sufficient elastic restoring force of the chamber material this can only be done by the spreading tool is removed from the cable. The corresponding Circumferential sections of the profile then close off self.

The advantageous twisting of the transmission elements is preferred before they are introduced into the chambers performed. The chamber profile is after insertion the transmission elements and closing the chambers twisted as a whole. The two twists can be in two-stage stranding or also in one-stage stranding (so-called group winning). Advantageous the manufacturing process is in a bundle stranding machine integrated. Since a group winner after Stranding point constructed analogous to a bundle stranding machine is, the manufacturing process can also in one Group winners can be integrated. In general it is Reverse torque of the twisted chamber profile is relatively small, so that of the inserted transmission elements and / or the wrapping is prevented from turning back.

The covering is preferably on the closed chamber profile angry, e.g. glued.

With the application of the covering, a shield can also be used be applied, for example by a metal foil or a plastic film with a metallic coating is used, e.g. an Al-PET tape. In addition, outside a braid can be arranged.

Alternatively, it is possible to start with a non-conductive one Apply wrapping, and then a shield. This can be a continuous conductive Act layer and / or interlacing.

A continuous conductive layer can be on the wrapper e.g. by metal spraying, dipping, extruding, galvanic or chemical deposition, plasma coating, vapor deposition getting produced.

According to the invention, for example, a data transmission cable with four not shielded from each other Pair lines can be realized, which is a thin Structure has (diameter approx. Between 5 mm and 7 mm), extreme small bending radii allowed (2 x outer diameter), and which due to the stabilized by the chamber profile Stranding in pairs and bonding with shielding film even when installed, its impedance and its good damping and cross-talk properties practical keeps unchanged. The cable holds all electrical Parameters that are included in the proposed standard for category 6, d. H. for data cables up to 250 MHz (standards EN 50173, EN 61156 and pr EN 50288). Here is the cable easy to process and therefore has the advantage less Assembly times and costs.

In the following, the invention is based on exemplary embodiments and the attached drawing explained.

Fig. 1

eine Querschnittsdarstellung eines Kammerprofils mit vier Kammern im Anfangszustand vor der Herstellung des Kabels;

Fig. 2

eine Darstellung gemäß Fig. 1, jedoch mit aufgeschnittenem und teilweise aufgespreiztem Kammerprofil;

Fig. 3

eine Veranschaulichung des Herstellungsverfahrens eines Kabels mit dem Kammerprofil gemäß Fig. 1;

Fig. 4-6

Kabel mit vier, zwei und drei Kammern und einer entsprechenden Anzahl von Paarleitungen im Querschnitt;

Fig. 7-9

Kabel entsprechend den Fig. 4-6, jedoch mit Sternvierern anstelle von Paarleitungen;

Fig. 10

eine Querschnittsdarstellung einer weiteren Ausführungsform eines Kammerprofils.

The drawing shows:

Fig. 1

a cross-sectional view of a chamber profile with four chambers in the initial state before the manufacture of the cable;

Fig. 2

a representation of Figure 1, but with a cut and partially spread chamber profile.

Fig. 3

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

Fig. 4-6

Cable with four, two and three compartments and a corresponding number of pairs in cross-section;

Fig. 7-9

Cable corresponding to Figures 4-6, but with star quads instead of pair lines;

Fig. 10

a cross-sectional view of a further embodiment of a chamber profile.

The figures have elements that are functionally identical or similar 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, are also for transmission higher (and lower) frequencies. The plastic insulation of the wires as well as those described in more detail below Chamber profiles generally consist of polyethylene, Polypropylene, mixtures thereof, or other suitable Plastics. The plastic can be foamed. The examples described below have symmetrical ones Lines as transmission elements, which have an impedance of 100 ohms. In other embodiments other impedance values are realized, e.g. in the Range between 75 ohms and 150 ohms. The wire diameter are less than 1 mm to connect with Allow RJ-45 connectors.

Fig. 1 shows a chamber profile 1, which for receiving four transmission elements (pairs, quads and / or Fiber optic bundles) is suitable. It has two Bridges 2, which are at the center of the profile 1 at right angles cross, as well as a surrounding the webs 2 Circumferential jacket 3, which has a circular cross section and is arranged concentrically to the center. hereby four are formed in the longitudinal direction of the cable Chambers 4, each having the cross-sectional shape of a 90 ° - have circular sector. Along the center axis of profile 1 runs a reinforcing insert 5, which is e.g. is a thread or a wire.

By choosing the material thicknesses of the webs 2 and the peripheral jacket 3, the distances from the transmission element to transmission element or from transmission element for external shielding - and thus the impedance, the attenuation and crosstalk behavior of the cable - in constructively set wide limits. The one at the present Cable construction relatively large spacing between the transmission elements from the outer shield in return, it allows the wire spacing of the To choose transmission elements relatively narrow, i.e. the core insulation training relatively thin. This allows the Use of miniature plugs, which have small wire diameters require. For graphic reasons is in the Figures of the peripheral jacket 3 shown with a large thickness. In general, however, its thickness is only approximate half to 1/5 of the thickness of the webs 2.

Profile 1 is in a separate, the actual Cable production preceding step by extrusion manufactured. The entire is preferably produced Profiles in a single extrusion step. It is also possible, initially only the web part of the profile manufacture, and only in a second step the Circumferential jacket 3 on the already prefabricated web part to extrude. In any case, the production takes place of the entire profile including the circumferential jacket 3 before inserting the transmission elements.

In the embodiment shown, the profile 1 exclusively from non-conductive materials. With others Embodiments (not shown) have the webs 2 a shielding function by working on their surfaces or equipped with a conductive layer inside are, or by being made of conductive plastic are.

Fig. 2 illustrates the further processing of the prefabricated Chamber profile 1 in the context of cable production. Namely, in each chamber 4 in the longitudinal direction running cut 6 attached to the peripheral jacket 3 severed. In the embodiment shown the cuts 6 are each centered over the chambers 4; in other (not shown) embodiments you can also, for example, near a the webs 2 delimiting the chambers 4 are arranged his. By making the cuts 6, flaps are formed Circumferential sections 7. These are for insertion of the transmission elements bent, as shown in FIG. 2 is shown at the upper right chamber 4. The bend up can e.g. using a spreading tool.

In other (not shown) embodiments, this is Chamber profile 1 already with opening lines - accordingly the cuts 6 - made so that the step of Slicing can be omitted.

3 illustrates the manufacturing process. In the course the production takes place a shift of the shown Profile 1 from left to right. Profile 1 is designed so that it cannot twist freely, on the other hand is freely movable in the longitudinal direction. First the profile 1 is cut open over the four chambers 4, for which purpose four cutting blades 8 are used. Then follows the opening of the chambers 4 with the help of (not shown) Spreizwerkzeugen. The peripheral portions 7 are fixed in their spread position (also not shown). Parallel to the slicing profile 1 is the first stage of stranding, namely the twisting of a total of four pairs 9. These are described in the so-called stranding point 10 (i.e. the one Point at which the second stage of stranding, i.e. the Total twist of the cable, effectively takes place) each placed in an open chamber 4. After inserting the transmission elements become the spread ones Brought peripheral portions 7 back to their starting position, the chambers 4 are therefore closed. This can be done by the elastic restoring forces of the chamber material occur; but it is also possible to use a pressure tool, which ensures the complete closure. The second stage takes place at stranding point 10 the stranding, i.e. the total twist of the profile 1 together with the transmission elements inserted into the chambers 4. The bundle prepared in this way is now one with one Adhesive treated metal foil 11 or equivalent plastic tape treated with adhesive with a metallic layer (e.g. Al-PET tape) adhered. The application of the film 11 serves as a shield and the fixation of the bundle. Alternatively it is possible, one (in whole or in part) made of conductive material shrink existing hose. As another Possibility can have a conductive layer on the surface of the circumferential jacket 3 or one applied to it Coating are produced, for example by metal spraying, Dipping, extruding, electroplating, etc. In addition may need a braided screen and an outer protective jacket made of plastic applied to the shielding layer become.

4-9 illustrate various completed ones Cross section of cable. 4 and 7 show cables with a four-chamber profile by use of the profile shown in Figs. 1 and 2 can be obtained. 5 and 8, however, show cables with 2 each Chambers by using a profile with only one, cross-sectional web 2 can be obtained. 6 and 9 show cables with three chambers each 4. They are based on a profile with three webs 2, that run radially outward from the center and each form an angle of 120 ° to each other.

4-6 are the transmission elements twisted, unshielded pairs 9. Each pair consists of two similar wires 12 that touch each other. Each core 12 is in turn made of a conductor 13 and a core insulation 14 enclosing this. The pairs 9 are almost without play in their respective Chamber 4. Due to the twisting in itself, the veins are 12 of the pairs 9 do not pass through the chamber walls in places fixed, such as in the left chamber of the 5 is shown. Come along the length of the cable but always pre-twist angle at which the chamber walls enclose the pair 9 without play, so that a total practically backlash-free embedding in the longitudinal direction of the cable of pairs 9 in profile 1 is ensured (see right chamber of Fig. 5).

7-9, the transmission elements are stranded, unshielded star quads 29. They will each formed by four wires 12, which at the corners of a (imaginary) square are arranged. Two opposite each other Cores 12 form a symmetrical line. With the same wire diameter, the distance is one Conducting conductor larger in the star quad than in the Pair.

The chambers 4 can next to the circular sector shape shown a variety of other forms, e.g. Stripe, honeycomb or Have a triangular shape. An example with chambers 4 in shape bulbous pentagons is shown in Figure 10.

Overall, the invention provides a cable in which the transmission elements at a constant distance from each other and are embedded for shielding. The whole twisted cable provides an even impedance curve and favorable damping and crosstalk properties ready. It is easy to process and keeps its cheap mechanical and electrical properties too when laying with extremely small bending radii.

Claims (8)

1. A manufacturing process for a data transmission cable, having the following steps:

   in the case of a chamber profile (1) produced in one piece, which in cross section has one or more webs (2) and a periphery (3) surrounding the web or webs (2) and thus forms chambers (4), the chambers (4) are opened;

   in each case at least one transmission element (9, 19) is introduced into the opened chambers (4);

   the chambers (4) are closed;

   the chamber profile (1) is twisted as a unit.
2. A process according to Claim 1, whereby the chamber profile (1) is cut open prior to the opening of the chambers (4).
3. A process according to Claim 1 or 2, whereby the opening of the chambers (4) takes place by expanding peripheral sections (7) of the chamber profile (1).
4. A process according to Claim 3, whereby to close the chambers (4) the expanded peripheral sections (7) are brought back into their initial position.
5. A process according to one of Claims 1 to 4, whereby the transmission elements (9, 19) are twisted together before being inserted into the chambers (4).
6. A process according to one of Claims 1 to 5, whereby after the twisting of the chamber profile (1) a sheathing (11) is applied to it.
7. A process according to one of Claims 1 to 6, whereby a shielding is applied outside the periphery of the chamber profile (1).
8. A process according to one of Claims 1 to 7, whereby the transmission elements (9, 19) are selected from the following group: unshielded pair (9), shielded pair, unshielded quad (19), shielded quad, optical waveguide, optical waveguide bundle.

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