WO2017140129A1 - 特高频数字通信电缆及其制备方法 - Google Patents

特高频数字通信电缆及其制备方法 Download PDF

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WO2017140129A1
WO2017140129A1 PCT/CN2016/104804 CN2016104804W WO2017140129A1 WO 2017140129 A1 WO2017140129 A1 WO 2017140129A1 CN 2016104804 W CN2016104804 W CN 2016104804W WO 2017140129 A1 WO2017140129 A1 WO 2017140129A1
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layer
twisted
sub
pairs
shielding
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PCT/CN2016/104804
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English (en)
French (fr)
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王子纯
唐秀芹
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江苏东强股份有限公司
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Publication of WO2017140129A1 publication Critical patent/WO2017140129A1/zh

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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • 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
    • H01B11/02—Cables with twisted pairs or quads
    • H01B11/06—Cables with twisted pairs or quads with means for reducing effects of electromagnetic or electrostatic disturbances, e.g. screens
    • 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
    • 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
    • H01B11/005—Quad constructions
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0208—Cables with several layers of insulating material
    • H01B7/0225—Three or more layers
    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
    • H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
    • H01B7/00—Insulated conductors or cables characterised by their form
    • H01B7/02—Disposition of insulation
    • H01B7/0275—Disposition of insulation comprising one or more extruded layers of insulation

Definitions

  • the present invention relates to a digital communication cable, and more particularly to a communication cable for transmitting UHF digital signals of seven types and eight types for the Internet.
  • the multi-service transmission platform technology is gradually matured and promoted in the metropolitan area network; the construction of China's "three networks in one" communication network Just like a fire.
  • the rapid development of structured cabling systems has made Gigabit Ethernet unable to meet user broadband requirements, and 10 Gigabit Ethernet will become the mainstream technology.
  • the corresponding digital communication cable needs to be developed from communication cable products of Category 6, Category 7 to Category 8 and higher transmission frequencies.
  • the increase of the working frequency of the digital communication cable means that the electromagnetic radiation and electromagnetic coupling are more likely to occur, and a new electromagnetic interference source is constantly generated in the environment.
  • the frequency broadband digital communication cable must not only effectively prevent the intrusion of external electromagnetic interference signals, but also prevent electromagnetic radiation from the inside of the cable from leaking out, so that it has very good electromagnetic compatibility characteristics and confidentiality.
  • the existing seven- or eight-class digital communication cable effectively prevents the intrusion of external electromagnetic interference signals and the leakage of electromagnetic radiation from the inside of the cable through the twisting balance of the twisted pair and the shielding effect of the metal shielding layer.
  • the four pairs of twisted pair units of the shielded cable are individually metal shielded, which better separates the surrounding electromagnetic field and reduces the crosstalk between the individual shielded pairs due to the skin effect and reflection and absorption of the metal shield.
  • the insulated single wire constituting the twisted pair adopts a three-layer co-extruded insulating layer covering the copper conductor on the copper conductor. This structure greatly reduces the working capacitance between the lines, reduces the transmission attenuation constant, and has a good transmission high frequency number. The technical performance of the signal.
  • the existing twisted pair unit shields of the seven and eight types of digital communication cables mostly use a shielding foil strip longitudinally wrapped on the twisted pair to form a foil layer shield.
  • the two overlapping sides of the wrapping foil strip are in a freely overlapping state, wrinkles and opening are easily formed, and the contact can not be reliably and tightly contacted, and a foil strip is formed in the manufacturing process of the twisted pair unit.
  • the lap joint gap of the edge will inevitably increase the lap joint when the digital cable is laid, and the electromagnetic wave has a strong penetration and radiation force at high frequencies.
  • the technical problem to be solved by the present invention is to provide a UHF digital communication cable, which can ensure that the longitudinally wrapped shielding foil strips are firmly and reliably adhered to each other, thereby effectively preventing electromagnetic wave intrusion and leakage. .
  • Another technical problem to be solved by the present invention is to provide a method of manufacturing the UHF digital communication cable.
  • the ultra-high frequency digital communication cable of the present invention comprises a cable core and a total shielding layer coated on the cable core, and the outer shielding layer is coated on the total shielding layer, and the cable core is composed of four pairs.
  • the twisted pair is stranded, and each pair of strands is twisted by two insulated single wires.
  • the insulated single wire includes a copper conductor and a solid inner layer, an intermediate foam layer and a solid outer layer which are sequentially coated from the inside to the outside.
  • each of the pair of twisted wire sets is covered with a partial shielding layer, and the overlapping side of the partial shielding layer is clamped between two adjacent insulated single wires to form a partial shielding laminated wire, and the partial shielding laminated layer
  • the twisting direction and the twisting pitch of the cable are the same; the sub-shielding stacking lines corresponding to the adjacent two pairs of twisted pairs are offset from each other; the overlapping protruding sides of the splitting layer are separated from the splitting shield
  • the length of the inward extension is L1, which is 10% to 15% of the width of the sub-shield coated foil strip, and the inwardly extending side of the sub-shield layer extends inward from the sub-shielding overlay line to a length L2.
  • the L2 is 20% to 25% of the width of the sub-shield coated foil tape.
  • the sub-shielding laminate lines corresponding to the adjacent pairs of twisted pairs are offset from each other by an angle of 80° to 100° in the cross section of the cable.
  • the twisting directions of the four pairs of twisted pairs of the core are the same, and the twist pitch of the four pairs of twisted pairs is not equal.
  • the total shielding layer is a mesh braided shielding layer.
  • a filling cord is filled in the middle of the four pairs of twisted pairs.
  • the method for preparing the UHF digital communication cable of the present invention comprising the following steps:
  • drawing a copper conductor the solid soft copper wire is drawn into a circular copper conductor having a diameter of 0.580 mm ⁇ 0.001 mm, the elongation of the copper conductor is 24.5% ⁇ 1.5%;
  • the three-layer insulation layer is co-extruded on the circular copper conductor to form an insulated single wire.
  • the insulation layer is solid inner layer, intermediate foam layer and solid outer skin layer from inside to outside, and is insulated.
  • the total thickness of the layer is 0.41 mm ⁇ 0.03 mm, wherein the thickness of the intermediate foam layer is 0.31 mm ⁇ 0.03 mm; the concentricity of the insulated single wire is greater than 99%, and the ellipticity of the insulated single wire is less than 0.005 mm;
  • Covering and shielding layer the copper foil strip or the aluminum foil strip is coated on the twisted pair by a covering mold to form a sub-shield layer.
  • the two sides of the sub-shield foil strip overlap each other;
  • twisted composite cable four pairs of twisted wire bundles coated with sub-shielded layers are twisted into a composite cable core, the stranding pitch of the cable core is 80mm ⁇ 5mm; each pair of twisted wire groups after cable core twisting
  • the overlapping side of the sub-shield layer is sandwiched between two adjacent insulated single wires to form a sub-shielded laminated wire which is the same as the twisting direction and the twisting pitch of the cable core; adjacent The sub-shielding superimposed lines corresponding to the two pairs of twisted pairs are mutually staggered;
  • the overlapping outer side of the sub-shield layer protrudes outward from the sub-shielding superimposed line by a length L1
  • the L1 control is a sub-shield layer package 10% to 15% of the width of the foil strip, the inwardly extending side of the sub-shield layer extends inward from the sub-shielding line L2, and the L2 is controlled to be 20% of the width of the
  • woven total shielding layer the total shielding layer is woven by wire around the core
  • the foaming degree of the intermediate foam layer is 44% to 50%
  • the elongation of the insulating layer is 400%
  • the tensile strength of the insulating layer is 12 MPa
  • the solid endothelial layer and the copper conductor are The adhesion is from 6 N/mm 2 to 12 N/mm 2 .
  • the sub-shielding laminate lines corresponding to the adjacent two pairs of twisted pairs are offset from each other by 90° on the cable cross section.
  • the total shielding layer is woven from tinned copper wire.
  • the outer sheath is a low-smoke halogen-free sheathing material extrusion layer, and the thickness of the extrusion layer is 0.55 mm ⁇ 0.1 mm.
  • the sub-shielding laminated wire happens to be in the direction of twisting of the cable core.
  • the twisting pitch such that the foil strip and the core are synchronously twisted so that the overlapping side of the sub-shield foil strip is always clamped between the adjacent two insulated single wires
  • the two overlapping strips of the foil strip The longitudinal side edges are always reliably and closely overlapped with each other, thereby avoiding the existence of the wrinkled opening and the contact gap of the foil strip overlapping side, which not only effectively prevents the electromagnetic interference signal from intruding into the twisted pair unit from the overlapping gap, but also avoids
  • the external electromagnetic signal radiated from the twisted wire unit has a more rigorous and reliable shielding effect; on the other hand, the insulated single wire is crimped on the overlapping side edges of the overlapping foil strips, thereby greatly reducing the contact stress between the insulated single wires.
  • the extrusion deformation at the insulated single-wire contact line is reduced, and the core structure and the cable impedance are better ensured to be even and stable.
  • the structure makes the adjacent two insulated single wires only tightly clamp the overlapping portions of the one-sided shielding foil strip, and the clamping force Reliable and stable, ensuring that the lap joints of the foil strips do not form lap seams.
  • This structure also facilitates the design of the foil strip wrapping process and the design of the mold to avoid wrinkles on the sides of the foil strip to ensure shielding effect and transmission performance.
  • the L1 is a sub-shield layer package. 10% to 15% of the width of the foil strip, and the inwardly extending side of the sub-shield layer extends inward from the sub-shielding line L2, which is 20% to 25 of the width of the sub-shield foil strip. %; this not only ensures that the foil strip is tightly wrapped, avoids leakage, and sufficient foil strip overlap width can always ensure that two adjacent insulated single wires are clamped on the overlapping side of the foil strip, so that the overlapping side is always firmly attached. Hehe.
  • the insulating layer outside the copper conductor adopts a solid inner layer, a three-layer insulating structure of the intermediate foam layer and the solid outer skin layer, so that the working capacitance between the insulated single wires is greatly reduced, thereby reducing the transmission attenuation constant, and on this basis,
  • the double shielding structure of the partial shielding and the total shielding is adopted, so that the cable has better comprehensive shielding effect against internal and external electromagnetic interference.
  • FIG. 1 is a schematic cross-sectional structural view of a specific embodiment of an ultra high frequency digital communication cable of the present invention
  • FIG. 2 is a schematic enlarged view of a twisted pair in the structure shown in FIG. 1.
  • 1 copper conductor
  • 2 single wire insulation layer
  • 3 twisted wire group
  • 4-layer shielding layer 5-filled rope
  • 6 total shield layer
  • 7 outer sheath
  • 8-minute shielded overlay Line 21 - solid endothelial layer
  • 22 - middle foam layer 22 - middle foam layer
  • the core of the cable is covered with a total shielding layer 6 , and the total shielding layer 6 is formed by cross-weaving 96 tinned copper wires with a diameter of 0.1 mm.
  • the weave coverage is 60% and the weaving pitch is 28mm.
  • An outer sheath 7 composed of a low-smoke halogen-free cable sheathing material is extruded on the total shielding layer 6.
  • the wall thickness of the outer sheath 7 is controlled to 0.55 ⁇ 0.1 mm, and the outer diameter of the cable after covering the outer sheath is not More than 8.20mm.
  • the cable core of the cable is formed by twisting four pairs of twisted pairs 3, and each pair of twisted pairs 3 is twisted by two insulated single wires, and each pair of twisted pairs 3 is wrapped with
  • the sub-shield layer 4 is formed by wrapping an aluminum foil strip composed of a polyester film fused aluminum layer, and the sub-shield layer 4 can also be made of a copper-aluminum foil strip.
  • the filling line 5 is filled in the middle of the four pairs of twisted pair 3, and the filling rope 5 is a filling cord of a non-metallic material such as a usual acrylic rope or hemp rope.
  • the laminated wire 8 and the sub-shielded laminated wire 8 formed by stranding have the same stranding direction and twisting pitch as the core.
  • the clamping force is insufficient, and the overlapping portions are easily formed, and the adjacent pairs are
  • the sub-shielding stacking wires 8 corresponding to the twisted wire group 3 are arranged offset from each other, and the angle of the staggered angle on the cable cross section is 90°, and the stagger angle is preferably 80°. Between 100°; the offset angle is the angle between the radii of the sub-shielding lines 8 passing through the sections of the circle in which the shields of the adjacent twisted pair components are located.
  • the length of L1 should be controlled to be 10%-15% of the unfolding width of the sub-shield layer 4, and the inwardly extending side of the sub-shield layer 4 extends inward from the sub-shielding line 8 by a length L2.
  • the length of the L2 is 20%-25% of the unfolding width of the sub-shield layer 4 wrapping foil, and the outer elongation L1 and the inner elongation L2 ensure that the aluminum foil tape has a suitable coating overlap ratio.
  • the insulated single wire includes a copper conductor 1 and a solid inner layer 21, an intermediate foam layer 22 and a solid outer skin layer 23 which are sequentially coated from the inside to the outside, and the copper conductor 1 is drawn by a solid soft copper wire.
  • the twisting directions of the four pairs of twisted pair 3 constituting the core are the same.
  • the twisting direction of the twisted pair is S direction, and the twisting pitch is different, but the difference is controlled at a certain value.
  • the pitch of each pair of twisted pairs is 18.5 mm, 21 mm, 22.8 mm, and 24 mm.
  • the stranding pitch of the core is 80 ⁇ 5mm, and the stranding direction is also S-direction.
  • the method for preparing a UHF digital communication cable of the present invention comprises the following steps:
  • the extruder heats and melts the three layers of insulating material and forms a solid inside from the inside to the outside of the conductor.
  • the three layers of the skin layer, the intermediate foam layer and the solid outer skin layer have a total thickness of 0.41 mm ⁇ 0.03 mm, wherein the thickness of the intermediate foam layer is 0.31 mm ⁇ 0.03 mm.
  • the solid inner layer is made of low-density polyethylene insulation to enhance the adhesion between the conductor and the insulation layer.
  • the intermediate foam layer is made of a combination of low-density polyethylene, high-density polyethylene and a nucleating agent.
  • the high-pressure nitrogen gas is sent into the middle of the screw through the small gas injection needle to interact with the foamed insulating material for physical foaming, and the in-line foaming degree of the intermediate foam layer is controlled between 44% and 50% to ensure fine and uniform cells.
  • the solid outer skin layer is made of high-density polyethylene material to increase the strength of the insulated single wire, so that the tensile strength of the insulating layer reaches 12 MPa or more. Insulating layer at an elongation of 300% or more, adhesion between the insulating layer and the copper conductor control 6-12N / mm 2, insulated single concentricity is controlled to 99% or more, of the insulated single ellipse is less than 0.005mm;
  • the eight insulated single wires are twisted and twisted into four pairs of twisted pairs, and the twisted directions of the four pairs of twisted pairs are all in the S direction, using reasonable sections. It is twisted and has a small pitch difference, which can reduce cable deformation and ensure stable cable crosstalk and echo performance.
  • the twisting pitches of the four pairs of twisted pairs are 18.5 mm, 21 mm, 22.8 mm, and 24 mm, respectively.
  • the twisting and twisting can improve the impedance fluctuation caused by the single line eccentricity or uneven line diameter. Make transmission performance more stable.
  • the decoupling rate is controlled between 30% and 35%.
  • the tension of the single wire and the tension of the wire are strictly controlled.
  • the tension of the wire is controlled between 800CN ⁇ 20CN, and the tension of the wire is controlled to 16N. Between ⁇ 1N, the twist pitch deviation does not exceed ⁇ 0.03mm;
  • the single-sided polyester film aluminum foil tape with the specification of 0.07 ⁇ 15mm is longitudinally wrapped with four pairs of twisted pair by special mold, and the aluminum foil is facing outward when wrapped, and the aluminum foil tape is wrapped.
  • the sub-shield layer is formed on the twisted pair of wires, and the two sides of the sub-shield foil strip are overlapped and overlapped. After stranding, the aluminum foil strip has the same twist pitch and direction on the twisted pair as the core.
  • twisted composite cable four pairs of twisted wire bundles coated with sub-shielded layers are twisted into a composite core, and a filling rope is filled in the middle of four pairs of twisted pairs, and the filling rope is assembled with a diameter of 1.3 mm.
  • Acrylic rope The cable stranding pitch of the cable core is 80mm ⁇ 5mm, the cable stranding direction is also the S direction, and the take-up tension is controlled to be 90N ⁇ 5N.
  • the overlapping side of the sub-shield of each pair of twisted pairs is clamped between two adjacent insulated single wires to form a sub-shielded laminated wire, and the insulated single wire is clamped to the sub-shield layer.
  • the overlapping side On the overlapping side, not only the wrinkles and open gaps of the overlapping side are avoided, but also the mutual pressing force between the adjacent insulated single wires is reduced, and the capacitance and resistance imbalance caused by the single-line extrusion deformation of the insulation are avoided.
  • the sub-shielding overlapping lines corresponding to the two adjacent pairs of twisted pairs are offset from each other.
  • the outer side and the inner side of the sub-shield foil strip are respectively arranged, and the length of the inner side is larger than the length of the outer side, and the overlapping side of the sub-shield layer
  • the length extending from the sub-shielding superimposed line is L1, and the L1 is controlled to be 10% to 15% of the width of the sub-shield coated foil strip, and the overlapping inner side of the sub-shield layer is separated from the sub-shielded overlapping line.
  • the inward extension length is L2, and the L2 is controlled to be 20% to 25% of the width of the sub-shield coated foil strip, and the sub-shielding laminate line is the same as the stranding direction and the twisting pitch of the cable core.
  • the outer sheath is extruded on the outer periphery of the total shield layer by using a low-smoke halogen-free cable sheathing material, the outer sheath has a wall thickness of 0.55 mm ⁇ 0.1 mm, and the outer diameter of the cable after the outer sheath is 8.2 mm.

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  • Electromagnetism (AREA)
  • Engineering & Computer Science (AREA)
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Abstract

一种特高频数字通信电缆，包括缆芯、总屏蔽层（6）、外护层（7）和对绞线组（3）上的分屏蔽层（4），分屏蔽层（4）搭接侧边被夹持于相邻两根绝缘单线之间而形成分屏蔽叠合线（8），相邻两对对绞线组（3）所对应的分屏蔽叠合线（8）相互错开设置；分屏蔽层（4）的搭接外伸侧边从分屏蔽叠合线（8）向外伸出长度为L1，L1为分屏蔽层（4）包覆箔带宽度的10％～15％。制备方法包括如下步骤：(1)、拉制铜导体（1）；(2)、挤包绝缘层；(3)、绞合对绞线组（3）；(4)、包覆分屏蔽层（4）；(5)、绞合成缆；(6)、编织总屏蔽层（6）；(7)、挤包外护层（7）成电缆成品。该通信电缆不仅屏蔽效果好，能有效阻止电磁波的侵入和外泄，而且电缆结构牢固，传输性能稳定，特别适用于特高频率段数字信号传输。

Description

特高频数字通信电缆及其制备方法 技术领域
本发明涉及数字通信电缆，尤其涉及一种用于互联网的七类、八类等传输特高频数字信号的通信电缆。
背景技术
随着数字通信网络不断地向大容量、高频率、高速率纵深方向发展，多业务传输平台技术也逐步成熟，并在城域网中得到推广；我国的“三网合一”通信网络的建设正如火如荼。结构化综合布线系统的快速发展，使千兆以太网已不能满足用户宽带要求，万兆以太网将成为主流技术。相应的数字通信电缆需从六类、七类向八类以及更高传输频率的通信电缆产品发展。
数字通信电缆工作频率的提高，意味着越容易产生电磁辐射和电磁耦合，同时环境中还会不断地有新的电磁干扰源产生，网络工作频率越高产生电磁辐射也就越严重，因此具有高频率宽频带的数字通信电缆不仅要能有效防止外界电磁干扰信号的侵入，而且又要不让来自电缆内部的电磁辐射外泄，使之具有非常好的电磁兼容特性和保密性。
现有的七类或八类数字通信电缆通过双绞线的绞合平衡和金属屏蔽层的屏蔽作用，有效地防止外界电磁干扰信号的侵入和来自电缆内部的电磁辐射的外泄。其屏蔽电缆的四对对绞线单元都单独使用金属屏蔽，由于金属屏蔽层的集肤效应及反射和吸收作用，较好地分隔周围的电磁场和减少单独屏蔽对线之间的串音。组成对绞线的绝缘单线又采用了在铜导体上包覆皮泡皮三层共挤绝缘层，这种结构使线间工作电容大幅下降，传输衰减常数降低，具有较好的传输高频数字信号的技术性能。
由于箔层屏蔽具有良好的柔软性、机械强度和绝缘性能，现有七类和八类数字通信电缆的对绞线单元屏蔽大都采用屏蔽箔带纵包于对绞线上以形成箔层屏蔽。但由于包缠箔带两搭接侧边处于自由搭接状态，很容易形成皱折和张口，并不能可靠且严密的贴合接触，在对绞线单元的制造过程中还会形成箔带搭接边的搭接缝隙，当数字电缆在敷设使用中更会不可避免地加大搭接缝隙，而在高频情况下，电磁波又具有极强的穿透作用和辐射力。这种搭接缝隙的存在不仅会使得电磁干扰信号从缝隙侵入对绞线单元中，而且对绞线单元内部的电磁信号也会辐射外泄。这对具有高工作频率、宽频带的数字信号电缆的电性能和信号传输安全往往是致命的。因此如何解决对绞线单元高频屏蔽条件下的电磁波侵入和辐射外泄，成为本领域技术人员的努力方向。
发明内容
本发明所要解决的技术问题是提供一种特高频数字通信电缆，该数字通信电缆能够保证其纵包的屏蔽箔带搭接侧边牢固可靠地贴合，从而有效防止电磁波的侵入和外泄。本发明的另一要解决的技术问题是提供一种制造该特高频数字通信电缆的方法。
为了解决上述技术问题，本发明的特高频数字通信电缆，包括缆芯以及包覆于缆芯上的总屏蔽层，在总屏蔽层上包覆有外护层，所述缆芯由四对对绞线组绞合而成，每一对绞线组由两根绝缘单线绞合而成，绝缘单线包括有铜导体以及从里向外依次包覆的实心内皮层、中间泡沫层和实心外皮层；在每一对绞线组外均包覆有分屏蔽层，该分屏蔽层搭接侧边被夹持于相邻两根绝缘单线之间而形成分屏蔽叠合线，该分屏蔽叠合线与缆芯的绞合方向和绞合节距相同；相邻两对对绞线组所对应的分屏蔽叠合线相互错开设置；分屏蔽层的搭接外伸侧边从分屏蔽叠合线向外伸出长度为L1，该L1为分屏蔽层包覆箔带宽度的10％～15％，分屏蔽层的搭接内伸侧边从分屏蔽叠合线向内延伸长度为L2，该L2为分屏蔽层包覆箔带宽度的20％～25％。
作为本发明的一种优选实施方式，所述相邻两对绞线组所对应的分屏蔽叠合线在电缆横截面上相互错开的角度为80°～100°。
作为本发明的又一优选实施方式，所述缆芯的四对对绞线组的绞合方向相同，该四对对绞线组的绞合节距不相等。
作为本发明的另一优选实施方式，所述总屏蔽层为网状编织屏蔽层。在四对对绞线组中间填充有填充绳。
本发明所述特高频数字通信电缆的制备方法，该制备方法包括如下步骤：
(1)、拉制铜导体：将实心软铜线拉制成直径为0.580mm±0.001mm的圆形铜导体，该铜导体的伸长率为24.5％±1.5％；
(2)、挤包绝缘层：在圆形铜导体上同时共挤三层结构的绝缘层而形成绝缘单线，绝缘层从里向外依次为实心内皮层、中间泡沫层和实心外皮层，绝缘层总厚度为0.41mm±0.03mm，其中中间泡沫层厚度为0.31mm±0.03mm；绝缘单线的同心度大于99％，绝缘单线的椭圆度小于0.005mm；
(3)、绞合对绞线组：将绝缘单线两两相互绞合成四对对绞线组，该四对对绞线组的绞合方向相同，四对对绞合线组的绞合节距分别为18.5mm、21mm、22.8mm和24mm；
(4)、包覆分屏蔽层：将铜箔带或铝箔带采用包覆模具包覆于对绞线组上形成分屏蔽层， 分屏蔽层箔带两侧边相互重叠搭接；
(5)、绞合成缆：将四对包覆有分屏蔽层的对绞线组绞合成缆芯，缆芯的绞合节距为80mm±5mm；缆芯绞合后每一对绞线组的分屏蔽层搭接侧边被夹持于相邻两根绝缘单线之间而形成分屏蔽叠合线，该分屏蔽叠合线与缆芯的绞合方向和绞合节距相同；相邻两对对绞线组所对应的分屏蔽叠合线相互错开设置；分屏蔽层的搭接外伸侧边从分屏蔽叠合线向外伸出长度为L1，该L1控制为分屏蔽层包覆箔带宽度的10％～15％，分屏蔽层的搭接内伸侧边从分屏蔽叠合线向内延伸长度为L2，该L2控制为分屏蔽层包覆箔带宽度的20％～25％；在四对对绞线组的中间填充有填充绳；
(6)、编织总屏蔽层：在缆芯外以金属丝编织总屏蔽层；
(7)、在总屏蔽层上挤包外护层形成电缆成品。
本发明制备方法的进一步实施方式，所述中层泡沫层的发泡度为44％～50％，绝缘层的伸长率为400％，绝缘层的抗拉强度为12MPa，实心内皮层与铜导体的粘附力为6N/㎜2～12N/㎜2。
本发明制备方法的又进一步实施方式，所述相邻两对绞线组所对应的分屏蔽叠合线在电缆横截面上相互错开90°。
本发明制备方法的再进一步实施方式，所述总屏蔽层由镀锡铜丝编织而成。所述外护层为低烟无卤护套料挤包层，该挤包层的厚度为0.55mm±0.1mm。
在本发明中，由于分屏蔽层两搭接侧边被夹持于相邻两根绝缘单线之间而形成了分屏蔽叠合线，该分屏蔽叠合线又正巧与缆芯的绞合方向和绞合节距相同，这样箔带与缆芯的同步相对绞合使得分屏蔽箔带的搭接侧边始终夹持于相邻的两根绝缘单线间，一方面使得箔带的两搭接纵向侧边始终可靠且严密地相互重叠贴合，避免了箔带搭接侧边皱折张口和接触缝隙的存在，不仅有效地阻止电磁干扰信号从搭接缝隙侵入到对绞线单元，也避免对绞线单元内部电磁信号辐射外泄，具有更为严密可靠的屏蔽效果；另一方面绝缘单线压接于重叠的箔带搭接侧边上，也大大减轻了绝缘单线之间的接触应力，减少了绝缘单线接触线处的挤压变形，更好地保证缆芯结构和电缆阻抗均匀稳定。又由于相邻两对对绞线组所对应的分屏蔽叠合线相互错开设置，这种结构使相邻两根绝缘单线仅紧紧夹住一分屏蔽箔带的搭接处，夹持力可靠稳定，确保箔带搭接处不会形成搭接缝隙，该结构还便于屏蔽箔带包缠工艺控制和模具的设计，避免箔带侧边出现皱折，以保证屏蔽效果和传输性能。还由于分屏蔽层的搭接外伸侧边从分屏蔽叠合线向外伸出长度为L1，该L1为分屏蔽层包 覆箔带宽度的10％～15％，分屏蔽层的搭接内伸侧边从分屏蔽叠合线向内延伸长度为L2，该L2为分屏蔽层包覆箔带宽度的20％～25％；这不仅保证箔带包缠紧密，避免漏包，而且足够的箔带搭接宽度能始终保证相邻两绝缘单线夹持在箔带搭接侧边上，使搭接侧边始终牢固贴合。在本发明中铜导体外的绝缘层采用实心内皮层，中间泡沫层和实心外皮层的三层绝缘结构，使绝缘单线间的工作电容大幅下降，从而使传输衰减常数降低，在此基础上又采用了分屏蔽和总屏蔽的双重屏蔽结构，使电缆具有较好的抗内、外部电磁干扰的综合屏蔽效果。
附图说明
下面结合附图和实施例对本发明作进一步说明。
图1是本发明特高频数字通信电缆一种具体实施方式的横截面结构示意图；
图2是图1所示结构中对绞线组的放大结构示意图。
图中，1—铜导体、2—单线绝缘层、3—对绞线组、4—分屏蔽层、5—填充绳、6—总屏蔽层、7—外护层、8—分屏蔽叠合线、21—实心内皮层、22—中层泡沫层、23—实心外皮层。
具体实施方式
如图1所示的特高频数字通信电缆，该电缆的缆芯外包覆有总屏蔽层6，总屏蔽层6采用96根直径为0.1mm的镀锡铜丝进行交叉编织而成，其编织覆盖率达60％，编织节距为28mm。在总屏蔽层6上挤包有低烟无卤电缆护套料构成的外护层7，该外护层7的壁厚控制在0.55±0.1mm，包覆外护层后的电缆外径不大于8.20mm。电缆的缆芯由四对对绞线组3绞合而成，每一对对绞线组3又由两根绝缘单线绞合而成，在每一对对绞线组3外均包缠有分屏蔽层4，该分屏蔽层4由聚酯薄膜融合铝层而构成的铝箔带包缠而成，该分屏蔽层4也可由铜铝箔带而成。在四对对绞线组3的中间位置填充有填充绳5，填充绳5采用常用的丙烯绳、麻绳等非金属材料的填充绳。
构成分屏蔽层4的铝箔带两侧边相互搭接，搭接部分被夹持于相邻的两根绝缘单线之间，该两根绝缘单线夹持住箔带搭接部分而形成了分屏蔽叠合线8，成缆绞合而形成的分屏蔽叠合线8与缆芯具有相同的绞合方向和绞合节距。
为了避免各对对绞线组3对应的分屏蔽层4搭接部分和分屏蔽叠合线8位置的重合，而造成夹持力的不足，以及易于形成搭接部分皱折，相邻两对对绞线组3所对应的分屏蔽叠合线8相互错开设置，在电缆横截面上其错开的角度为90°，错开角度优选在80°— 100°之间；该错开角度是在两相邻对绞线组分屏蔽层所在圆的截面上通过分屏蔽叠合线8的半径之间的夹角。
如图2所示，分屏蔽层4的包缠铝箔带厚度为0.07mmm，展开宽度B＝15mm，分屏蔽层4搭接部分的外伸侧边从分屏蔽叠合线8向外伸出长度为L1，L1的长度应控制为分屏蔽层4包缠箔带展开宽度的10％—15％，分屏蔽层4的向内延伸侧边从分屏蔽叠合线8向内延伸长度为L2，该L2的长度为分屏蔽层4包缠箔带展开宽度的20％—25％，外伸长度L1和内延长度L2保证了铝箔带具有合适的包覆重叠率。
绝缘单线包括有铜导体1，以及从里向外依次包覆的实心内皮层21、中间泡沫层22和实心外皮层23，铜导体1采用实心软铜线拉制而成。构成缆芯的四对对绞线组3的绞合方向相同，本实施例中对绞线组的绞合方向均为S向，其绞合节距各不相同，但差值均控制在一定范围内，各对绞线组的节距依次为18.5mm、21mm、22.8mm和24mm。缆芯的绞合节距为80±5mm，成缆绞合方向也为S向。
本发明制备特高频数字通信电缆的方法，包括如下步骤：
(1)拉制铜导线，将实心软铜线拉成表面光洁、圆整的直径为0.580mm±0.001mm的圆形导体，该铜导体的伸长率为24.5％±1.5％；
(2)在上述拉制的铜导体送入具有三层同时共挤功能的绝缘层挤出机，该挤出机对三层绝缘料均加热熔融并在导体外形成从里到外的实心内皮层、中间泡沫层和实心外皮层的三层绝缘层，绝缘层的总厚度为0.41mm±0.03mm，其中中间泡沫层厚度为0.31mm±0.03mm。实心内皮层采用低密度聚乙烯绝缘料，以增强导体与绝缘层之间的粘附力，中间泡沫层采用低密度聚乙烯、高密度聚乙烯及成核剂组合而成的发泡料，再通过小型注气针将高压氮气送入螺杆中部与发泡绝缘材料相作用以进行物理发泡，中间泡沫层的在线发泡度控制在44％—50％之间，以保证泡孔细密、均匀。实心外皮层采用高密度聚乙烯材料来提高绝缘单线的强度，使绝缘层抗拉强度达到12MPa以上。绝缘层伸长率在300％以上，绝缘层与铜导体间的粘附力控制在6—12N/mm2,绝缘单线的同心度控制在99％以上，绝缘单线的椭圆度小于0.005mm；
(3)绞合对绞线组，将八根绝缘单线两两相互绞合而绞合成四对对绞线组，该四对对绞线的绞合方向相同均为S向，采用合理的节距对绞，且节距差较小，可减少电缆变形，保证电缆串音及回波性能稳定。本实例中四对对绞线组的绞合节距分别为18.5mm、21mm、22.8mm及24mm。为尽量减少绝缘单线绞合接触点处的挤压变形，除将分屏蔽箔带的搭接 侧边夹持于两根绝缘单线间外，还需保持对绞张力一致，以降低电阻、电容不平衡值；绞对退扭可改善因单线偏心或线径不均匀而造成的阻抗波动等，使传输性能更加稳定。根据绞合节距大小，将退扭率控制在30％—35％之间，严格控制单线的放线张力和收线张力，放线张力控制在800CN±20CN之间，收线张力控制为16N±1N之间，绞合节距偏差不超过±0.03mm；
(4)包覆分屏蔽层，将规格为0.07×15mm的单面聚酯薄膜铝箔带采用专用模具分别对四对对绞线组进行纵向包缠，包覆时铝箔面朝外，铝箔带包缠于对绞线组上形成分屏蔽层，分屏蔽层箔带两侧边重叠搭接。成缆后铝箔带在对绞线组上的绞合节距和方向与缆芯相同。
(5)绞合成缆，将四对包覆有分屏蔽层的对绞线组绞合成缆芯，在四对对绞线组的中间填充有填充绳，该填充绳采用直径为1.3mm的聚丙烯绳。缆芯的成缆绞合节距为80mm±5mm，成缆绞合方向也为S向，收线张力控制为90N±5N。缆芯绞合后每一对对绞线组的分屏蔽层搭接侧边被夹持于相邻两根绝缘单线之间而形成分屏蔽叠合线，绝缘单线夹持接触于分屏蔽层的搭接侧边上，不仅避免了搭接侧边的皱折和张开缝隙，而且减少了相邻绝缘单线间的相互挤压力，避免绝缘单线挤压变形所带来的电容、电阻不均衡；相邻两对对绞线组所对应的分屏蔽叠合线相互错开设置。在分屏蔽叠合线的两侧分别为分屏蔽搭接箔带的外伸侧边和内伸侧边，内伸侧边的长度大于外侧边的长度，分屏蔽层的搭接外伸侧边从分屏蔽叠合线向外伸出长度为L1，该L1控制为分屏蔽层包覆箔带宽度的10％～15％，分屏蔽层的搭接内伸侧边从分屏蔽叠合线向内延伸长度为L2，该L2控制为分屏蔽层包覆箔带宽度的20％～25％，分屏蔽叠合线与缆芯的绞合方向和绞合节距均相同。
(6)编织总屏蔽层，在屏蔽编织机上采用96根直径0.1mm的镀锡铜丝于缆芯外编织总屏蔽层，其编织屏蔽层覆盖率达到60％，编织节距为28mm；
(7)采用低烟无卤电缆护套料在总屏蔽层外周挤包外护层，外护层的壁厚为0.55mm±0.1mm，包覆外护层后的电缆外径为8.2mm。

Claims (10)

  1. 一种特高频数字通信电缆，包括缆芯以及包覆于缆芯上的总屏蔽层(6)，在总屏蔽层(6)上包覆有外护层(7)，所述缆芯由四对对绞线组(3)绞合而成，每一对绞线组(3)由两根绝缘单线绞合而成，绝缘单线包括有铜导体(1)以及从里向外依次包覆的实心内皮层(21)、中间泡沫层(22)和实心外皮层(23)；在每一对绞线组(3)外均包覆有分屏蔽层(4)，其特征在于：该分屏蔽层(4)搭接侧边被夹持于相邻两根绝缘单线之间而形成分屏蔽叠合线(8)，该分屏蔽叠合线(8)与缆芯的绞合方向和绞合节距相同；相邻两对对绞线组(3)所对应的分屏蔽叠合线(8)相互错开设置；分屏蔽层(4)的搭接外伸侧边从分屏蔽叠合线(8)向外伸出长度为L1，该L1为分屏蔽层(4)包覆箔带宽度的10％～15％，分屏蔽层(4)的搭接内伸侧边从分屏蔽叠合线(8)向内延伸长度为L2，该L2为分屏蔽层(4)包覆箔带宽度的20％～25％。
  2. 根据权利要求1所述的特高频数字通信电缆，其特征在于：所述相邻两对绞线组(3)所对应的分屏蔽叠合线(8)在电缆横截面上相互错开的角度为80°～100°。
  3. 根据权利要求1所述的特高频数字通信电缆，其特征在于：所述总屏蔽层(6)为网状编织屏蔽层。
  4. 根据权利要求1所述的特高频数字通信电缆，其特征在于：所述缆芯的四对对绞线组(3)的绞合方向相同，该四对对绞线组(3)的绞合节距不相等。
  5. 根据权利要求1所述的特高频数字通信电缆，其特征在于：在四对对绞线组(3)中间填充有填充绳(5)。
  6. 一种制备权利要求1所述特高频数字通信电缆的方法，其特征在于：该制备方法包括如下步骤：
    (1)、拉制铜导体：将实心软铜线拉制成直径为0.580mm±0.001mm的圆形铜导体，该铜导体的伸长率为24.5％±1.5％；
    (2)、挤包绝缘层：在圆形铜导体上同时共挤三层结构的绝缘层而形成绝缘单线，绝缘层从里向外依次为实心内皮层、中间泡沫层和实心外皮层，绝缘层总厚度为0.41mm±0.03mm，其中中间泡沫层厚度为0.31mm±0.03mm；绝缘单线的同心度大于99％，绝缘单线的椭圆度小于0.005mm；
    (3)、绞合对绞线组：将绝缘单线两两相互绞合成四对对绞线组，该四对对绞 线组的绞合方向相同，四对对绞线组的绞合节距分别为18.5mm、21mm、22.8mm和24mm；
    (4)、包覆分屏蔽层：将铜箔带或铝箔带采用包覆模具包覆于对绞线组上形成分屏蔽层，分屏蔽层箔带两侧边相互重叠搭接；
    (5)、绞合成缆：将四对包覆有分屏蔽层的对绞线组绞合成缆芯，缆芯的绞合节距为80mm±5mm；缆芯绞合后每一对绞线组的分屏蔽层搭接侧边被夹持于相邻两根绝缘单线之间而形成分屏蔽叠合线，该分屏蔽叠合线与缆芯的绞合方向和绞合节距相同；相邻两对对绞线组所对应的分屏蔽叠合线相互错开设置；分屏蔽层的搭接外伸侧边从分屏蔽叠合线向外伸出长度为L1，该L1控制为分屏蔽层包覆箔带宽度的10％～15％，分屏蔽层的搭接内伸侧边从分屏蔽叠合线向内延伸长度为L2，该L2控制为分屏蔽层包覆箔带宽度的20％～25％；在四对对绞线组的中间填充有填充绳；
    (6)、编织总屏蔽层：在缆芯外以金属丝编织总屏蔽层；
    (7)、在总屏蔽层上挤包外护层形成电缆成品。
  7. 根据权利要求6所述的制备方法，其特征在于：所述中层泡沫层的发泡度为44％～50％，绝缘层的伸长率为400％，绝缘层的抗拉强度为12MPa，实心内皮层与铜导体的粘附力为6N/㎜2～12N/㎜2。
  8. 根据权利要求6所述的制备方法，其特征在于：所述相邻两对绞线组所对应的分屏蔽叠合线在电缆横截面上相互错开90°。
  9. 根据权利要求6所述的制备方法，其特征在于：所述总屏蔽层由镀锡铜丝编织而成。
  10. 根据权利要求6所述的制备方法，其特征在于：所述外护层为低烟无卤护套料挤包层，该挤包层的厚度为0.55mm±0.1mm。
PCT/CN2016/104804 2016-02-18 2016-11-06 特高频数字通信电缆及其制备方法 WO2017140129A1 (zh)

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