WO2012092724A1 - 一种同轴电缆及其制造方法 - Google Patents

一种同轴电缆及其制造方法 Download PDF

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Publication number
WO2012092724A1
WO2012092724A1 PCT/CN2011/071649 CN2011071649W WO2012092724A1 WO 2012092724 A1 WO2012092724 A1 WO 2012092724A1 CN 2011071649 W CN2011071649 W CN 2011071649W WO 2012092724 A1 WO2012092724 A1 WO 2012092724A1
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WIPO (PCT)
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coaxial cable
outer conductor
diameter
insulating layer
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PCT/CN2011/071649
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English (en)
French (fr)
Inventor
寿伟春
陈宁
邹智
韦小兰
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珠海汉胜科技股份有限公司
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Publication of WO2012092724A1 publication Critical patent/WO2012092724A1/zh

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Classifications

    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/18—Coaxial cables; Analogous cables having more than one inner conductor within a common outer conductor
    • H01B11/1808—Construction of the conductors
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B11/00—Communication cables or conductors
    • H01B11/18—Coaxial cables; Analogous cables having more than one inner conductor within a common outer conductor
    • H01B11/1878—Special measures in order to improve the flexibility

Definitions

  • the present invention relates to the field of mobile communications technologies, and in particular, to a coaxial cable and a method of fabricating the same.
  • a coaxial cable is generally used in a mobile communication system, for example, a mobile communication device and an antenna, an open line feeder for ground antenna communication and wireless communication, a feeder line for an equipment room, an antenna connection line, and a military data information transmission line.
  • the main line for wireless communication usually uses a cable with a large cross section.
  • the traditionally designed aluminum tube outer conductor coaxial cable adopts a smooth wall aluminum tube outer conductor structure or an aluminum strip longitudinally overlaps the outer conductor structure.
  • the cable bending performance of this structural design is poor, at a small When the bending radius is reached, the sheath or outer conductor of the cable is wrinkled or slightly cracked, which cannot meet the actual laying requirements.
  • the present invention provides a coaxial cable and a method of fabricating the same.
  • a coaxial cable including an inner conductor, an insulating layer, a corrugated outer conductor, and a sheath layer from the inside to the outside is provided, wherein the corrugated outer conductor is a corrugated aluminum tube.
  • the coaxial cable has a ratio of a wall thickness of the corrugated outer conductor to an outer diameter of the insulator of 1.15% or more.
  • the ratio of the wall thickness of the corrugated outer conductor to the wrinkle pitch is 6.5% or more and 11% or less;
  • the ratio of the wall thickness of the corrugated outer conductor to the wrinkle pitch is 4% or more and 6% or less.
  • the ratio of the wall thickness of the corrugated outer conductor to the wrinkle pitch is 8% or more and less than or equal to
  • the ratio of the wall thickness of the corrugated outer conductor to the wrinkle pitch is 4.5% or more and 5.5% or less.
  • the coaxial cable has a diameter of the insulating layer equal to or less than
  • the outer conductor is a spiral tubular shape; when the diameter of the insulating layer is greater than 20 mm, the outer conductor is an annular tubular shape.
  • the wrinkle outer conductor in the coaxial cable, when the corrugated outer conductor is a spiral tubular shape, has a wrinkle pitch of 2 mm 5 mm, a wrinkle peak of 6 inm to 14 mm, and a trough of 4 mm. 10mm
  • the corrugated outer conductor when the corrugated outer conductor is an annular tubular shape, the inner conductor has a spiral wrinkle structure, and the inner conductor has a spiral groove pitch of 6 mm to l lmm. Spiral wrinkle peaks from 9mm to 19mm, and troughs from 6mm to 16mm, and The outer conductor has an annular wrinkle pitch of 6 mm to U mm, an annular wrinkle peak of 24 mm to 48 mm, and a trough of 20 mm to 43 mm.
  • said insulating layer is smaller than a diameter equal to the wall thickness of 20mm 5 corrugated outer conductor is not less than 0,20mm; the diameter of the insulating layer is greater than 20mm, the The wall thickness of the outer conductor of the wrinkle is not less than 0.25 mm»
  • the insulating layer in the coaxial cable, wherein the insulating layer has a diameter of 20 mm or less, the insulating layer includes an inner thin layer, an insulating dielectric layer, and an outer thin layer which are sequentially arranged from the inside to the outside, and
  • the insulating layer When the diameter of the insulating layer is greater than 20 mm, the insulating layer includes an insulating dielectric layer and an outer thin layer which are sequentially arranged from the inside to the outside, wherein
  • the inner thin layer and the outer thin layer are highly adhesive polymers, and the insulating layer has a degree of foaming of not less than 70%.
  • a coaxial cable when the coaxial cable is a 7/8'' feeder, a coaxial cable according to another aspect of the present invention, a wrinkle pitch of the corrugated outer conductor It is 6,90mm, the outer diameter of the trough is 22.30mm to 23.80mm, the outer diameter of the wave crest is 25, 50mm to 26,80mm, and the outer diameter of the insulating layer is 22,50mm to 23,00mrr.
  • a coaxial cable is a spiral tubular metal, a linear metal or a smooth tubular metal, wherein the metal is copper, aluminum or copper clad aluminum.
  • an aluminum strip of a soft material is prepared into an aluminum tube, wherein the aluminum strip is prepared into an aluminum tube, and wrinkles are formed on the outer surface of the aluminum tube as the Wrinkle outer conductor.
  • an aluminum strip having a thickness of not less than 0.10 mm is prepared as the aluminum tube, and the aluminum tube is The outer surface of the tube forms a spiral wrinkle;
  • an aluminum strip having a thickness of not less than 0,25 mm is prepared as the aluminum tube, and annular wrinkles are formed on the outer surface of the aluminum tube.
  • the aluminum strip has a tensile strength The degree of not less than 50 MPa, the elongation is not less than 25%; or the aluminum strip of the hard material is prepared into an aluminum tube, wherein the aluminum strip has a tensile strength of not less than 70 MPa and an elongation of not less than 15%.
  • the coaxial cable provided by the invention adopts a super-flexible structure design and the outer conductor adopts the aluminum strip outer conductor wrinkle light structure design, has special soft performance, small bending radius, excellent performance, light weight, convenient transportation and installation, and at the same time It saves a lot of copper resources and provides wireless mobile communication users with a cost-effective light shield super soft transmission product.
  • FIG. 1 is a schematic structural view of a coaxial cable according to a first embodiment of the present invention
  • FIG. 2 is a schematic structural view of a coaxial cable according to a second embodiment of the present invention.
  • FIG. 3 is a flow chart showing the manufacture of a coaxial cable according to a first embodiment of the present invention
  • FIG. 4 is a flow chart showing the manufacture of a coaxial cable in accordance with a second embodiment of the present invention. Specific way
  • the first coaxial cable structure provided by the present invention is as shown in FIG. 1 , and includes a sheath layer 16 , an aluminum tube spiral corrugated outer conductor 1 1 , an outer thin layer 15 , an insulating dielectric layer 12 , an inner thin layer 14 , and a metal inner conductor . 13.
  • the inner thin layer 14 wraps the inner metal conductor 13 , and the insulating dielectric layer 12 is located between the inner thin layer 14 and the outer thin layer 15 .
  • the aluminum tube spiral corrugated outer conductor 1 1 is surrounded by the outer thin layer 15 , and the sheath layer 16 is located on the coaxial cable The outermost side is used to protect the coaxial cable from damage.
  • the structure of the coaxial cable provided by the embodiment is used for manufacturing an aluminum tube outer conductor wrinkle coaxial cable having an insulation layer diameter of 20 mm (mm means millimeter, hereinafter the same) or less (ie, the insulation layer diameter is less than or equal to 20 mm).
  • the outer conductor adopts a spiral tubular aluminum-wrinkled outer conductor, and the inner metal conductor adopts a metal wire or a metal tubular structure; preferably, the thickness of the aluminum metal strip for the outer conductor is not less than 0,20 mm.
  • the outer conductor is trimmed, formed by a strip, and then welded into a tubular shape by argon, and sizing to form a spiral corrugated tube of a desired diameter.
  • the spiral wrinkle pitch of the aluminum tube spiral corrugated outer conductor 1 1 is 25 mm, the spiral slope peak is 5-14 mm, and the trough is 3 Dmm.
  • the insulation is a three-layer structure: consisting of an inner thin layer 14, an insulating dielectric layer 12 and an outer thin layer 15, and the inner thin layer 14 is composed of an ethylene acrylic acid copolymer (EAA) or other highly adhesive polymer.
  • the insulating interlayer 12 is made of high-density polyethylene low-density polyethylene and a nucleating agent
  • the outer layer 15 is made of polyethylene oxide and EAA or other highly adhesive polymer; preferably The degree of foaming of the insulating layer is not less than 70%; the outer layer 15 ensures sufficient adhesion between the insulation and the outer conductor to ensure that the cable is not affected by any moisture and humidity and has high strength.
  • the aluminum metal strip may be a soft material or a hard material; preferably, the soft aluminum metal strip has a tensile strength of not less than 50 MPa and an elongation of not less than 25%; preferably, the hard aluminum The tensile strength of the metal strip is not less than 70 MPa, and the elongation is not less than 15%.
  • the jacket layer 16 is a tubular structure that surrounds the outer layer of the outer conductor to protect the cable.
  • the material of the sheath layer 16 may be polyethylene, a flame-retardant polysulfonated hydrocarbon polymer, or a thermoplastic sheath-level coating material such as rubber or polyurethane.
  • the second coaxial cable structure provided by the present invention is as shown in FIG. 2, and includes a sheath layer 16, an aluminum tube annular corrugated outer conductor 17, an outer thin layer 15, an insulating dielectric layer 12, and a spiral wrinkle inner conductor.
  • the insulating dielectric layer 12 encloses the spiral wrinkle inner conductor 18, and the aluminum tube bad wrinkle outer conductor 17 wraps the outer thin layer 15, and the sheath layer 16 is located at the outermost side of the coaxial cable for protecting the coaxial cable from damage.
  • the structure of the coaxial cable provided by the embodiment is used for manufacturing an aluminum tube outer conductor corrugated coaxial cable having an insulating layer diameter of more than 20 mm, and the outer conductor is an aluminum strip wrinkle outer conductor adopting an annular tube; the inner conductor adopts a spiral
  • the metal structure (which may be a copper strip or an aluminum strip or a copper clad aluminum strip) tubular structure; alternatively, the thickness of the aluminum metal strip for the outer conductor is not less than 0. 25 mm.
  • the outer conductor is trimmed, formed by a strip, and then argon welded into a tubular shape to form an annular corrugated tube of a desired diameter.
  • the inner spiral of the spiral corrugated metal tube has a spiral wrinkle pitch of 6 l lmni, a spiral wrinkle peak of 9 to 19 mm, and a trough of 6 16 mm.
  • the annular wrinkle structure of the outer conductor has a pitch of 6 mm to 1 imm, a bad wrinkle peak of 24 mm to 48 mm, and a trough of 20 mm to 43 mm.
  • the insulation is a two-layer structure: consisting of an insulating barrier layer 12 and an outer thin layer 15, and the insulating dielectric layer 12 is made of a mixture of high density polyethylene, low density polyethylene, ADD or other nucleating agent. 15 made of polyethylene and EAA. or other highly adhesive polymer; preferably, the insulating layer has a degree of foaming of not less than 70%; the outer layer 15 ensures sufficient adhesion between the insulating and outer conductors, To ensure that the cable is not affected by any moisture and humidity and has a high strength.
  • the aluminum metal strip may be a soft material shield or a hard material; preferably, the soft aluminum metal strip has a tensile strength of not less than 50 MPa and an elongation of not less than 25%; preferably, a hard material
  • the tensile strength of the aluminum metal strip is not less than 70 MPa, and the elongation is not less than 15%.
  • the jacket layer 16 is a tubular structure that surrounds the outer layer of the outer conductor to protect the cable.
  • the material of the sheath layer 16 may be polyethylene, a flame-retardant polyolefin polymer, or a thermoplastic sheath-level coating material such as rubber or polyurethane.
  • the inner conductor, the insulating layer, the corrugated outer conductor and the sheath layer are included from the inside to the outside, wherein the corrugated outer conductor is a corrugated aluminum tube.
  • the wrinkle outer conductor is a corrugated aluminum tube.
  • the ratio of the wall thickness of the corrugated outer conductor to the wrinkle pitch is 6.5% or more and 11% or less, preferably 8% or more and 11% or less; the diameter of the insulating layer is larger than 20 mm.
  • the ratio of the wall thickness of the wrinkle outer conductor to the wrinkle pitch is 4% or more and 6% or less, preferably 4 or more.
  • the ratio of the wall thickness of the wrinkle outer conductor to the outer diameter of the insulation is greater than or equal to 1, 15%.
  • the present invention improves the influence of wrinkle outer diameter, embossing depth, embossing pitch on attenuation index and bending index, appropriately adjusts embossing depth and embossing pitch, and creatively proposes superior outer
  • the conductor wrinkle structure ensures uniform, tidy and minimal dimensional fluctuations in the shape of the spiral wrinkles of the thick aluminum strip, thereby greatly improving the overall surname of the product, especially the high frequency characteristics.
  • Take the 7 ⁇ 8" super-flexible aluminum feeder as an example:
  • both the feeder 1 and the feeder 2 are designed with a low loss structure, so that the aluminum feeder reaches the attenuation index requirement of the feeder of the same specification.
  • the wall thickness of the corrugated outer conductor may be any thickness between 0, 30 mm and 0, 40 mm.
  • the wrinkles of the wrinkled outer conductor The pitch can be 6,90 mm
  • the outer diameter of the trough can be any value between 22.30 mm and 23.80 mm
  • the outer diameter of the wave crest can be any value between 25, 50 mni and 26,80 mm
  • the outer diameter of the insulating layer can be 22.50 mm. Any value between 23.00mm.
  • the aluminum strip is prepared into an aluminum tube, and wrinkles are formed on the outer surface of the aluminum tube. Wrinkle outer conductor.
  • the aluminum strip having a thickness of not less than 0.20 mm is prepared into an aluminum tube, and spiral wrinkles are formed on the outer surface of the aluminum tube; when the diameter of the insulating layer is greater than 20 mm, the thickness is not less than 0.25.
  • the aluminum strip of mm is prepared into an aluminum tube, and an annular wrinkle is formed on the outer surface of the aluminum tube.
  • the aluminum strip of the soft material is prepared into an aluminum tube, wherein the tensile strength of the aluminum strip is not less than
  • the elongation is not less than 25%; or the aluminum material of the hard material is prepared into an aluminum tube, wherein the aluminum strip has a tensile strength of not less than 70 MPa and an elongation of not less than 15%.
  • the inner conductor may be a spiral tubular metal, a linear metal or a smooth tubular metal.
  • the metal may be copper, aluminum or copper clad aluminum.
  • the process for manufacturing the coaxial cable described in the first embodiment is as shown in FIG. 3, and includes: Step 101, metal wire or metal pipe discharge;
  • Step 102 traction
  • Step 103 the inner conductor is laid and sized
  • Step 104 the inner conductor is clean
  • Step 105 extruding the inner layer
  • Steps 106-107 physical foaming extrusion of polyethylene, outer thin layer extrusion
  • Step 108 cleaning the aluminum strip
  • Step 109 the aluminum outer conductor is argon arc welded into a smooth tube
  • Step 110 smooth aluminum tube spiral wrinkles
  • Step 1 U the jacket layer is extruded.
  • the process for manufacturing the coaxial cable described in the second embodiment is as shown in FIG. 4, and includes: Step 201, metal tape discharge;
  • Step 202 pulling;
  • Step 203 cutting the metal strip
  • Step 204 the metal is argon I welded into a smooth tube
  • Step 205 smooth metal tube spiral wrinkles
  • Steps 206-207 physical foaming extrusion of polyethylene, outer thin layer extrusion
  • Step 208 the aluminum strip is cleaned
  • step 209 the aluminum outer conductor is argon-melted into a smooth tube
  • step 210 smooth aluminum tube annular wrinkles
  • step 211 the sheath layer is extruded.

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Description

Figure imgf000003_0001
本发明涉及移动通信技术领域， 尤其涉及一种同轴电缆及其制造方法。
背景技术
现有技术中， 同轴电缆一般用于移动通信系统中 例如连接移动通信设 备与天线， 作为地面天线通讯及无线通讯的开线馈线和机房用馈线及天线连 接线、 军用数据信息传输线等。
当前移动通信已成为发展最迅速的领域， 由于移动用户增长迅速全球移 动通信事业继续保持强劲的增长势头， 移动服务在全球的普及率不断增加。 随着发展中国家移动普及率的上升和用户需求的高涨， 网络运营商们需要以 空前的高速度进行无线网络的建设， 在某些市场上他们会不断地寻求新的技 术、 成本方式， 来为用户提供性价比更优的移动业务和覆盖。 作为移动通信 系统的重要传输部件之一， 同轴电缆具有十分广阔的市场前景。
为满足无线通信用主干线的信号损耗小和大平均功率的要求， 无线通信 用主千线通常采用大截面的电缆。 传统设计的铝管外导体同轴电缆采用平滑 墙铝管外导体结构或铝带纵包搭接外导体结构， 对于大截面电缆而言， 这种 结构设计的电缆弯曲性能较差， 在较小的弯曲半径时， 电缆的护套层或外导 体有起皱或轻微开裂现象， 不能满足实际敷设要求。
因此， 近来提出了一种铜管皱紋外导体超柔馈线。 但是， 虽然铜管皱紋 外导体超乘馈线的电气性能和弯曲性有了提高， 但其成本昂贵。 这种同轴电 缆的铜材的重量占了整个产品重量的 50〜60%。 因此， 在全球的铜材资源需 求十分紧张， 国际铜价大幅度波动的形势下， 寻找理想的替代材料， 研发出 新型的轻质同轴电轴馈线， 提升产品盾量和技术竟争能力， 成为同轴馈线生 产厂商关注.的一个热点。 发明内容
针对现有技术中存在的上述问题， 本发明提供了一种同轴电缆及其制造 方法。
根据本发明的一方面提供了一种同轴电缆， 该同轴电缆由内至外包括内 导体、 绝缘层、 皱紋外导体和护套层， 其中， 所述皱纹外导体为皱纹铝管。
根据本发明的另一方面提供的同轴电缆， 所述皱紋外导体的管壁厚度与 所述绝缘体外径的比大于等于 1.15%。
根据本发明的另一方面提供的同轴电缆， 所述绝缘层的直径小于等于 20mm时， 所述皱紋外导体的管壁厚度与皱纹节距的比大于等于 6.5%且小于 等于 11%;
所述绝缘层的直径大于 20mm时， 所述皱纹外导体的管壁厚度与皱紋节 距的比大于等于 4%且小于等于 6%。
根据本发明的另一方面提供的同轴电缆， 所述绝缘层的直径小于等于 20mm时，所述皱紋外导体的管壁厚度与皱紋节距的比大于等于 8%且小于等 于
所述绝缘层的直径大于 20mm时， 所述皱紋外导体的管壁厚度与皱纹节 距的比大于等于 4.5%且小于等于 5.5%»
根据本发明的另一方面提供的同轴电缆， 所述绝缘层的直径小于等于
20mm时， 所述外导体为螺旋形管状； 所迷绝缘层的直径大于 20mm时， 所 述外导体为环形管状。 根据本发明的另一方面提供的同轴电缆， 在所述皱紋外导体为螺旋形管 状时， 所迷皱纹外导体的皱纹节距为 2mm 5mm、 皱紋波峰为 6inm~14mm以 及.波谷为 4mm- 10mm
根据本发明的另一方面提供的同轴电缆， 在所述皱纹外导体为环形管状 时， 所述内导体采用螺旋皱纹结构时， 所述内导体的螺旋鼓紋节距为 6mm 至 l lmm、 螺旋皱紋波峰为 9mm至 19mm、 以及波谷为 6mm至 16mm, 以 及 所述外导体的环形皱紋节距为 6mm至 Umm、环形皱纹波峰为 24mm至 48mm、 以及波谷为 20mm至 43mm„
根据本发明的另一方面提供的同轴电缆， 所述绝缘层的直径小于等于 20mm时5 所述皱紋外导体的管壁厚度不小于 0,20mm; 所述绝缘层的直径大 于 20mm时， 所述皱紋外导体的管壁厚度不小于 0.25mm»
根椐本发明的另一方面提供的同轴电缆， 所述绝缘层的直径小于等于 20mm时， 所述绝缘层包括由内向外依次排列的内薄层、 绝缘介质层和外薄 层， 以及
所述绝缘层的直径大于 20mm时， 所述绝缘层包括由内向外依次棑列的 绝缘介质层和外薄层， 其中，
所述内薄层和所述外薄层为高粘结性的聚合物， 以及绝缘层的发泡度不 小于 70%。
根据本发明的另一方面提供的同轴电缆，当所述同轴电缆为 7/8' '馈线时， 根据本发明的另一方面提供的同轴电缆， 所述皱纹外导体的皱紋节距为 6,90mm,波谷外径为 22.30mm至 23.80mm、波峰外径为 25,50mm至 26,80mm 以及绝缘层外径为 22,50mm至 23,00mrr
根据本发明的另一方面提供的同轴电缆，所述内导体为螺旋形管状金属、 线状金属或平滑管状金属， 其中， 所述金属是铜质、 铝质或铜包铝质。
根据本发明的另一方面提供的同轴电缆的制造方法， 将软态材质的铝带 制备成铝管， 其中， 将铝带制备成铝管， 并在铝管外表面形成皱紋， 作为所 述皱紋外导体。
根据本发明的另一方面提供的同轴电缆的制造方法， 在所述绝缘层的直 径小于等于 20mm时， 将厚度不小于 0。20mm的铝带制备成所述铝管， 且在 所述铝管外表面形成螺旋形皱紋；
所述绝缘层的直径大于 20mm时， 将厚度不小于 0,25mm的铝带制备成 所述铝管， 且在所述铝管外表面形成环形皱紋。
根据本发明的另一方面提供的同轴电缆的制造方法， 所述铝带的抗拉强 度不小于 50MPa， 伸长率不小于 25%; 或者将硬态材 的铝带制备成铝管， 其中， 所述铝带的抗拉强度不小于 70MPa, 伸长率不小于 15%。
本发明提供的同轴电缆采用超柔结构设计和外导体采用铝带外导体皱紋 轻质结构设计， 具有特别柔软性能， 弯曲半径小， 性能优异， 重量轻的犹点， 方便运输和安装， 同时节约了大量铜材资源， 给无线移动通信用户提供了一 种性价比俛的轻盾超柔传输产品。
本发明的其它特征和优点将在随后的说明书中阐述。 本发明的目的和其 他优点可通过在说明书、 权利要求书以及 图中所特别指出的结构来实现和 获得。
虽然在下文中将结合一些示例性实施及使用方法来描述本发明， 但本领 域技术人员应当理解为并不旨在将本发明限制于这些实施倒； 反之， 旨在覆 盖包含在所附的权利要求书所定义的本发明的精神与范围内的所有替 品、 修正及等效物。
附图说明
附图用来提供对本发明的进一步理解， 并且构成说明书的一部分， 与本 发明的实施例一起用于解释本发明 , 但并不构成对本发明的限制。
图 1是才艮据本发明第一实施例的同轴电缆结构示意图；
图 2是根据本发明第二实施例同轴电缆结构示意图；
图 3是根据本发明第一实施例同轴电缆制造流程图；
图 4是根据本发明第二实施例的同轴电缆制造流程图。 具体实旄方式
以下将结合附图及实施例来详细说明本发明的实施方式， 借此对本发明 如何应用技术手段来解决技术问题， 以及达成技术效果的实现过程能充分理 解， 并据以实施。 需要说明的是， 在不冲突的情况下本发明实施例以及实施 例中的各个特征可以相互结合， 这些均落在本发明的保护范围之内。 第一实施例
本发明提供的第一种同轴电缆结构如图 1所示， 包括护套层 16, 铝管螺 旋皱纹外导体 1 1 , 外薄层 15， 绝缘介质层 12, 内薄层 14， 金属内导体 13。 内薄层 14包裹金属内导体 13，绝缘介质层 12位于内薄层 14和外薄层 15之 间， 铝管螺旋皱紋外导体 1 1包褒外薄层 15， 护套层 16位于同轴电缆的最外 側， 用于保护同轴电缆免受损害。
优选地， 本实施例所提供的同轴电缆的结构用于制造绝缘层直径为 20mm ( mm表示毫米， 下文同）以下（即绝缘层直径小于或等于 20mm )的 铝管外导体皱紋同轴电缆， 外导体采用螺旋形管状的铝带皱紋外导体， 金属 内导体采用金属线或者金属管状结构； 优选地， 外导体用铝金属带材厚度不 小于 0,20mm。
优选地， 外导体由带材切边、 成型， 再经氩 f瓜焊接成管状， 定径后形成 所要求直径的螺旋形皱紋管。
优选地， 铝管螺旋皱纹外导体 1 1 的螺旋皱紋节距为 2 5mm, 螺旋坡紋 波峰为 5~14mm, 波谷为 3 Dmm。
优选地， 绝缘为三层结构： 由内薄层 14、 绝缘介质层 12和外薄层 15组 成， 内薄层 14由乙烯丙烯酸共聚物（Ethylene Acrylic Acid, EAA )或其它 高粘结性的聚合 制成， 绝缘介盾层 12由高密度聚乙烯 低密度聚乙烯、成 核剂混合制成，外薄层 15用聚乙浠及 EAA或其它高粘结性的聚合物的制成； 优选地， 绝缘层的发泡度不小于 70%; 外薄层 15保证绝缘和外导体之间有 足够附着力， 以保证电缆不受任何潮气和湿度的影响同时具有较高的强度。
铝金属带材可以是软态材质， 也可以是硬态材质； 优选地， 软质的铝金 属带材的抗拉强度不小于 50MPa， 伸长率不小于 25%; 优选地， 硬质的铝金 属带材的抗拉强度不小于 70MPa， 伸长率不小于 15%。
护套层 16为管状结构， 围绕在外导体的外层，起到保护电缆的作用。 护 套层 16的材料可以是聚乙烯、 阻燃聚浠烃聚合物， 也可以是橡胶、 聚氨脂等 热塑性护层级涂覆材料。 本发明提供的第二种同轴电缆结构如图 2所示， 包括护套层 16， 铝管环 形皱纹外导体 17, 外薄层 15, 绝缘介质层 12， 螺旋形皱紋内导体】.8。 绝缘 介质层 12包裹螺旋形皱纹内导体 18，铝管坏形皱紋外导体 17包裹外薄层 15， 护套层 16位于同轴电缆的最外侧， 用于保护同轴电缆免受损害。
优选地， 本实施例提供的的同轴电缆的结构用于制造绝缘层直径大于 20mm的铝管外导体皱纹同轴电缆， 其外导体为采用环形管状的铝带皱紋外 导体； 内导体采用螺旋形金属（可以是铜带或铝带或铜包铝带）管状结构； 铌选地， 外导体用铝金属带材厚度不小于 0。25mm。
优选地， 外导体由带材切边、 成型， 再经氩 焊接成管状， 定径后形成 所要求直径的环形皱紋管。
优选地， 螺旋皱紋金属管内导体的螺旋皱纹节距为 6 l lmni， 螺旋皱紋 波峰为 9~19mm，波谷为 6 16mm。所述外导体的环形皱紋结构的节距为 6mm 至 l imm、 坏形皱紋波峰为 24mm至 48mm 以及波谷为 20mm至 43mm。
优选地， 绝缘为二层结构： 由绝缘介盾层 12和外薄层 15组成， 绝缘介 质层 12由高密度聚乙烯、 低密度聚乙烯、 ADD或其它成核剂混合制成， 外 薄屋 15用聚乙烯及 EAA.或其它高粘结性的聚合物的制成； 优选地， 绝缘层 的发泡度不小于 70%; 外薄层 15保证绝缘和外导体之间有足够附着力， 以 保证电缆不受任何潮气和湿度的影响同时具有较高的强度。
铝金属带材可以是软态材盾， 也可以是硬态材质； 优选地， 软质的铝金 属带材的抗拉强度不小于 50MPa， 伸长率不小于 25%; 优选地， 硬质的铝金 属带材的抗拉强度不小于 70MPa， 伸长率不小于 15%。
护套层 16为管状结构， 围绕在外导体的外层，起到保护电缆的作用。 护 套层 16的材料可以是聚乙烯、 阻燃聚烯烃聚合物， 也可以是橡胶、 聚氨脂等 热塑性护层级涂覆材料。
Figure imgf000009_0001
综合上述第一实施例和第二实施例可知， 由内至外包括内导体、绝缘层、 皱紋外导体和护套层， 其中， 所述皱紋外导体为皱紋铝管。
此外， 皱纹外导体为皱纹铝管。 绝缘层的直径小于等于 20mm时， 皱纹 外导体的管壁厚度与皱纹节距的比大于等于 6.5%且小于等于 11%，优选为大 于等于 8%且小于等于 11%; 绝缘层的直径大于 20mm时， 皱纹外导体的管 壁厚度与皱纹节距的比大于等于 4%且小于等于 6%, 优选为大于等于 4,5
%且小于等于 5.5ε '0。
此外， 皱纹外导体的管壁厚度与绝缘^外径的比大于等于 1,15%。 综上可知， 本发明改进了皱紋的波峰外径、 轧纹深度、 轧纹节距对衰减 指标及弯曲指标的影响， 适当调整了轧紋深度和轧紋节距， 创造性地提出了 优越的外导体皱紋结构， 同时确保了厚铝带螺旋皱纹形状的均匀、 整齐和极 小的尺寸波动， 从而大大改善了产品的综合姓能， 尤其是高频特性。 以 7Ζ8"超柔铝馈线为例:
Figure imgf000010_0001
在上述中， 馈线 1和馈线 2均采用了低损耗结构尺寸设计， 使铝馈线达 到同类规格锢馈线的衰减指标要求。 此外， 当根据上述实施例的同轴电缆为 7/8"馈线时， 皱纹外导体的管壁 厚度可为 0,30mm至 0,40mm间的任意厚度。 与此相应地， 皱紋外导体的皱 紋节距可为 6,90mm、 波谷外径可为 22.30mm至 23.80mm间的任意值、 波峰 外径可为 25,50mni至 26,80mm间的任意值， 以及绝缘层外径可为 22。50mm 至 23.00mm间的任意值。
为了制造上述第一实施例和第二实施例中的同轴电缆， 本发明下面将详 细描述制造该同轴电缆的流程。
根据本发明的制作上述由内至外包括内导体、 绝缘层、 皱纹外导体和^ 套层的同轴电缆的方法中， 将铝带制备成铝管， 并在铝管外表面形成皱紋， 作为皱紋外导体。
其中， 在绝缘层的直径小于等于 20mm时， 将厚度不小于 0.20mm的铝 带制备成铝管， 且在铝管外表面形成螺旋形皱紋； 绝缘层的直径大于 20mm 时， 将厚度不小于 0.25mm的铝带制备成铝管， 且在铝管外表面形成环形皱 紋。 其中， 将软态材质的铝带制备成铝管， 其中， 铝带的抗拉强度不小于
50MPa， 伸长率不小于 25%; 或者将硬态材质的铝带制备成铝管， 其中， 铝 带的抗拉强度不小于 70MPa， 伸长率不小于 15%。
此外， 内导体可以为螺旋形管状金属， 线状金属或平滑管状金属。 其中， 金属可以是铜质、 铝质或铜包铝质。
第三实施例
制造第一实施例中所描述的同轴电缆的流程如图 3所示， 包括： 步骤 101， 金属线或金属管放线；
步骤 102， 牵引；
步骤 103， 内导体放线、 定径；
步骤 104， 内导体清洁；
步骤 105， 内薄层挤出；
步骤 106- 107, 聚乙烯物理发泡挤塑， 外薄层挤出；
步骤 108, 铝带清洁；
步骤 109, 铝外导体氩弧焊接成光滑管；
步骤 110， 光滑铝管螺旋形皱紋；
步骤 1 U , 护套层挤塑。
第四实施例
制造第二实施例中所描述的同轴电缆的流程如图 4所示， 包括： 步骤 201 , 金属带放线；
步骤 202, 牽引；
步骤 203 , 金属带切边；
步骤 204, 金属带氩 I 焊接成光滑管；
步驟 205, 光滑金属管螺旋形皱紋；
步骤 206-207, 聚乙烯物理发泡挤塑， 外薄层挤出； 步骤 208， 铝带清洁； 步骤 209， 铝外导体氩瓜焊接成光滑管; 步骤 210， 光滑铝管环形皱纹； 步骤 211 , 护套层挤塑。

Claims

Figure imgf000013_0001
—种同轴电缆， 由内至外包括内导体、绝缘层、皱紋外导体和护套层， 其特征在于， 所述皱紋外导体为皱纹铝管。
2、 如权利要求 1或 2所述的同轴电缆， 其特征在于， 所述皱紋外导体的 管壁厚度与所述绝缘体外径的比大于等于 1 , 15%。
3、 如权利要求 1或 2所述的同轴电缆， 其特征在于，
所述绝缘层的直径小于等于 20mm时， 所述皱紋外导体的管壁厚度与皱 紋节距的比大于等于 6,5%且小于等于 11%;
所述绝缘层的直径大于 20mm时 , 所述皱紋外导体的管壁厚度与皱紋节 距的比大于等于 4%且小于等于 6%。
4、 如权利要求 1.或 2所述的同轴电缆， 其特征在于 5
所述绝缘层的直径小于等于 20mm时， 所述皱紋外导体的管壁厚度与皱 紋节距的比大于等于 8 %且小于等于 1 1 %;
所述绝缘层的直径大于 20mm时， 所述皱紋外导体的管壁厚度与皱紋节 距的比大于等于 4,5%且小于等于 5.5%。
5、如权利要求 1或 2所述的同轴电缆， 其特征在于， 所述绝缘层的直径 小于等于 20mm时，所述外导体为螺旋形管状；所述绝缘层的直径大于 20mm 时， 所述外导体为环形管状。
6、 如权利要求 5所述的同轴电缆， 其特征在于，
在所述皱紋外导体为螺旋形管状时， 所述皱紋外导体的皱紋节距为 2mm 5mm、 铍紋波峰为 6mm 1:4mm以及波谷为 4mm 10mm。
7、 如权刮要求 5所述的同 电缆， 其特征在于，
在所述皱纹外导体为环形管状时，所述内导体采用螺旋皱紋结构，所述内 导体的虫累旋铍紋节 ]1巨为 6mm至 1 1mm, 虫累.旋铍乡丈波峰.为 9mm至 19mm、 以 及波谷为 6mm至 16mm, 以及
所述外导体的环形皱纹节距为 6mm至 l lmm 环形皱紋波峰为 24mm至 48mm, 以及波谷为 20mm至 43mm。
8、如权利要求 i或 2所述的同轴电缆， 其特征在于， 所述绝缘层的直径 小于等于 20mm时， 所述皱紋外导体的管壁厚度不小于（).20mm; 所述绝缘 层的直径大于 20mm时， 所述皱紋外导体的管壁厚度不小于 0,25mm。
9、 如权利要求 1或 2所述的同轴电缆， 其特征在于，
所述绝缘层的直径小于等于 20mm时， 所述绝缘层包括由内向外依次排 列的内薄层、 绝缘介质层和外薄层， 以及
所述绝缘层的直径大于 20mm时， 所述绝缘层包括由内向外依次排列的 绝缘介质层和外薄层， 其中，
所述内薄层和所述外薄层为高粘结性的聚合物， 以及绝缘层的发泡度不 小于 70%。
10、 如权利要求 1或 2所述的同轴电缆， 其特征在于，
当所述同轴电缆为 7/8"馈线时， 所述皱紋外导体的管壁厚度为 0,30mni 至 0.40mm。
11、如权利要求 10所述的同轴电缆， 其特征在于， 所述皱紋外导体的皱 紋节距为 6。90mm、 波谷外径为 22.30mm至 23,80rnm、 波峰外径为 25,50mm 至 26,80mm以及绝缘层外径为 22,50mm至 23,00mm。
12、 如权利要求 1或 2所述的同轴电缆， 其特征在于，
所述内导体为螺旋形管状金属、 线状金属或平滑管状金属， 其中， 所述 金属是铜质、 铝盾或铜包铝质。
13、 一种同轴电缆的制造方法， 所述同轴电缆由内至外包括内导体、 绝 缘层、 皱纹外导体和护套层， 其特征在于， 将铝带制备成铝管， 并在铝管外 表面形成皱纹， 作为所迷皱纹外导体 t,
14、 如权利要求 13所述的制造方法， 其特征在于，
在所述绝缘层的直径小于等于 20mm时， 将厚度不小于 0,20mm的铝带 制备成所述铝管， 且在所述铝管外表面形成螺旋形皱纹；
所述绝缘层的直径大于 20mm时， 将厚度不小于 0.25mm的铝带制备成 所述铝管， 且在所述铝管外表面形成坏形皱紋。
15、 如权利要求 13或 14所述的制造方法， 其特征在于， 将软态材质的铝带制备成铝管， 其中， 所述铝带的抗拉强度不 OMPa, 伸长率不小于 25%; 或者
将硬态材质的铝带制备成铝管， 其中， 所迷铝带的抗拉强度不 OMPa, 伸长率不小于 15%。
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CN101393783A (zh) * 2008-10-17 2009-03-25 珠海汉胜科技股份有限公司 通信同轴电缆及其制作方法
CN101894999A (zh) * 2010-07-15 2010-11-24 中天日立射频电缆有限公司 7/8"铜铝复合管射频同轴电缆及其制备方法

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