WO2022138898A1 - 通信ケーブルおよびその製造方法 - Google Patents
通信ケーブルおよびその製造方法 Download PDFInfo
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- WO2022138898A1 WO2022138898A1 PCT/JP2021/048113 JP2021048113W WO2022138898A1 WO 2022138898 A1 WO2022138898 A1 WO 2022138898A1 JP 2021048113 W JP2021048113 W JP 2021048113W WO 2022138898 A1 WO2022138898 A1 WO 2022138898A1
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- conductor
- communication cable
- wire
- circular cross
- strands
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- 238000004891 communication Methods 0.000 title claims abstract description 38
- 238000004519 manufacturing process Methods 0.000 title claims description 8
- 238000000034 method Methods 0.000 title claims description 8
- 239000004020 conductor Substances 0.000 claims abstract description 56
- 230000006835 compression Effects 0.000 claims abstract description 21
- 238000007906 compression Methods 0.000 claims abstract description 21
- 239000012212 insulator Substances 0.000 claims abstract description 21
- 239000010410 layer Substances 0.000 description 27
- 229910052751 metal Inorganic materials 0.000 description 21
- 239000002184 metal Substances 0.000 description 21
- 230000005540 biological transmission Effects 0.000 description 18
- 238000004804 winding Methods 0.000 description 16
- 239000011347 resin Substances 0.000 description 13
- 229920005989 resin Polymers 0.000 description 13
- 229920000139 polyethylene terephthalate Polymers 0.000 description 11
- 239000005020 polyethylene terephthalate Substances 0.000 description 11
- -1 polypropylene Polymers 0.000 description 9
- 239000002344 surface layer Substances 0.000 description 8
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 6
- 238000003780 insertion Methods 0.000 description 6
- 230000037431 insertion Effects 0.000 description 6
- 229920003020 cross-linked polyethylene Polymers 0.000 description 5
- 239000004703 cross-linked polyethylene Substances 0.000 description 5
- 230000002500 effect on skin Effects 0.000 description 4
- 239000011888 foil Substances 0.000 description 4
- 238000010030 laminating Methods 0.000 description 4
- 230000002093 peripheral effect Effects 0.000 description 4
- 229920002725 thermoplastic elastomer Polymers 0.000 description 4
- 239000004743 Polypropylene Substances 0.000 description 3
- 238000005259 measurement Methods 0.000 description 3
- 229920001155 polypropylene Polymers 0.000 description 3
- 239000004800 polyvinyl chloride Substances 0.000 description 3
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 239000004698 Polyethylene Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052802 copper Inorganic materials 0.000 description 2
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- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
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- 238000011156 evaluation Methods 0.000 description 1
- 230000001678 irradiating effect Effects 0.000 description 1
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Images
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
-
- 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
Definitions
- the present invention relates to a communication cable compatible with high frequency data transmission and a method for manufacturing the same.
- Multi-Gig Automotive Ethernet standard IEEE802.3ch Multi-Gig Automotive Ethernet PHY 10GBASE-T1
- high-frequency data transmission has some problems, such as suppressing inward skew (difference in propagation delay time in-inward) and suck-out phenomenon in the high-frequency band (rapid drop in frequency characteristics of signal attenuation). ) Can be suppressed.
- Patent Document 1 discloses a multi-core cable that attempts to solve these problems of high-frequency data transmission.
- eight pairs of coaxial electric wires (11 to 18) are housed in the multi-core cable (1).
- the central conductor (21) of each coaxial electric wire 10 is covered with an insulator (22), and the outer periphery thereof is covered with an outer conductor (23) and an outer cover (24).
- a thin metal wire (M) is horizontally wound (spiral wound) around the insulator as an inner layer portion (23A), and a metal resin tape (T) is horizontally wound around the inner layer portion as an outer layer portion (23B).
- the suck-out phenomenon is suppressed by setting the winding direction of the thin metal wire and the metal resin tape in the opposite direction and setting the difference in the winding angle (angle ⁇ 3) within a certain range (paragraph 0017). -0027, FIG. 1-2, Examples, FIG. 4 and the like).
- the electric wire pair of Patent Document 1 has an external conductor arranged in a coaxial electric wire, which is composed of a metal fine wire and a metal resin tape, and the winding direction and winding angle of the metal fine wire and the metal resin tape are set.
- the technique of Patent Document 1 has a very complicated internal configuration of the cable, and there is room for improvement in the internal configuration of the cable. Therefore, the main object of the present invention is a communication cable compatible with high frequency data transmission (so that the standard is satisfied even in a high frequency band of at least 8 GHz in the Multi-Gig Automotive Ethernet standard), and the internal configuration of the cable is simplified. The purpose is to provide a communication cable that can realize the above.
- the present inventor has found that the current density of a high-frequency signal increases on the surface layer of a conductor due to the skin action, and high-frequency transmission is performed with a stranded wire obtained by twisting a plurality of strands.
- the invention was completed.
- it is a communication cable in which a plurality of insulated wires whose conductors are coated with an insulator are twisted together, and the conductor is a single wire having a circular cross section or a compression stranded wire having a circular cross section thereof.
- a communication cable characterized in that the ratio of the total distance between the strands to the arc length is 71% or less.
- the conductor is a single wire having a circular cross section or a compression stranded wire having a circular cross section, and has a simple configuration in which the correlation between the arc length of the circumscribing circle and the distance between the strands is constant. Therefore, it is possible to provide a communication cable that supports high-frequency data transmission (that meets the standard even in a high-frequency band of at least 8 GHz or higher in the Multi-Gig Automotive Ethernet standard) without adding a complicated configuration to the external conductor. ..
- FIG. 1 is a cross-sectional view showing a schematic configuration of the communication cable 1.
- the communication cable 1 has an anti-twisting body 10, a push winding 20, a first shielding layer 40, a second shielding layer 50, and an outer cover 60, and covers the outer periphery of the anti-twisting body 10.
- the push winding 20, the first shielding layer 40, the second shielding layer 50, and the outer cover 60 are wound and covered in this order.
- the anti-twisted body 10 is composed of two (two) insulated wires 12, and the first type core 10A and the second type core 10B are used as a pair.
- a type 3 core and a type 4 core are added as the second pair of twisted bodies, and these may be used in pairs (may be composed of four cores), or the cores after that may be used. Pairs may be added and used.
- the insulated wire 12 is quad twisted.
- the insulated wire 12 is composed of a conductor 14 and an insulator 16, and has a structure in which the outer periphery of the conductor 14 is covered with the insulator 16.
- the conductor 14 is composed of a single wire having a circular cross section or a compression stranded conductor having a circular cross section in which the ratio of the total distance between the strands to the arc length of the circumscribed circle is 71% or less.
- Single wire with a circular cross section means a single conductor with a circular cross section that literally has a constant diameter.
- a compression stranded wire having a circular cross section in which the ratio of the total distance between the strands to the arc length of the circumscribed circle is 71% or less means that a plurality of strands 15 are twisted together as shown in FIG.
- “Arc length L, distance d between strands and total D” are values that can be obtained by observing the cross section of the compressed stranded wire as the conductor 14 using a digital microscope VHX-6000 manufactured by Keyence Co., Ltd., and are measured.
- the compression stranded wire is formed by compressing a stranded wire obtained by simply twisting a plurality of strands 15 (hereinafter referred to as "mere stranded wire") through a die.
- a curved portion 100 is formed on the strand 15A of the outer peripheral portion, and the curved portion 100 has an inflection point 102 affected by the passage of the dice.
- the distance d between the strands is a gap between the inflection points 102 of the adjacent strands 15A on the arc of the circumscribed circle 90.
- curved portions 100 There are a plurality of curved portions 100 depending on the number of strands 15A on the outer peripheral portion. For example, in the form of FIG. 2 in which seven strands 15 are twisted together, six strands 15A on the outer peripheral portion excluding the strand 15B in the center are adjacent to each other and there are six gaps between them. ..
- the sum of the gaps (distance d between strands d ⁇ 6 places) of all 6 places is the “total D”.
- the conductor 14 (including the wire 15) is preferably an annealed copper wire, and the outer periphery may be covered with a plating layer (not shown) of any one of tin, nickel, and silver.
- the outer diameter of the conductor 14 is preferably 0.4 to 0.6 mm.
- the transmission characteristics at high frequencies are affected by the skin effect, and the current density increases on the surface layer of the conductor 14.
- the "skin effect” is a phenomenon in which when an alternating current flows through a conductor 14, the current density is high on the surface layer of the conductor 14 and decreases when the alternating current is separated from the surface layer. The higher the frequency, the more the current is concentrated on the surface layer, and the higher the AC resistance of the conductor 14.
- the depth of the surface layer affected by the skin effect that is, the depth ⁇ [ ⁇ m] of the surface layer having a high current density is derived from the following skin depth calculation formula, and decreases as the frequency f [kHz] increases.
- ⁇ is the volume resistivity [ ⁇ ⁇ m] of the conductor 14, which is 1.72 ⁇ 10-8 ⁇ ⁇ m.
- “ ⁇ ” is the relative magnetic permeability of the conductor 14, which is 1.
- the mere twisted wire is one of the strands 15 arranged on the outer peripheral portion of the conductor 14.
- the current density is only high in the local area.
- this is replaced with a compression stranded wire, the region is slightly increased in the circumferential direction of the conductor 14, and when this is replaced with a single wire, the region is further increased over the entire circumference of the conductor 14.
- the extent to which the high-frequency transmission characteristics affect the form of the conductor 14 is examined in the following examples, and the conductor 14 is examined. Is a single wire with a circular cross section, or a compression stranded wire with a circular cross section, and the ratio D / L of the total D / L of the distance d between the strands to the arc length L of the circumscribing circle 90 is 71% or less. It has been found that the transmission characteristics of the are excellent.
- the insulator 16 is formed by extruding an insulating resin from a die of an extruder.
- the insulating resin is preferably cross-linked polyethylene (XLPE) or polypropylene (PP).
- the thickness of the insulator 16 is preferably 0.2 to 0.4 mm.
- the push-wound 20 is configured by laminating and winding tape-shaped polyethylene terephthalate (PET).
- PET polyethylene terephthalate
- the push-wound 20 may be made of a tape-shaped non-woven fabric.
- the push-wound 20 may be made of tape-shaped polypropylene.
- the thickness of the push winding 20 is preferably 0.02 to 0.1 mm.
- the push winding 20 is not an essential member and may be omitted.
- the first shielding layer 40 is configured by laminating and winding a metal tape.
- the metal tape is a tape formed by laminating a metal foil and a resin tape, and is preferably formed by laminating an aluminum foil and a polyethylene terephthalate tape (PET tape).
- PET tape polyethylene terephthalate tape
- the metal foil is overlaid so as to be exposed on the outer periphery.
- the thickness of the metal tape is preferably 0.02 to 0.05 mm.
- the second shielding layer 50 is configured by braiding a plurality of metal wires.
- the second shielding layer 50 may be configured by horizontally winding a plurality of metal wires at a constant pitch or less.
- Each metal wire is preferably a so-called tinned annealed copper wire (TA) in which the annealed copper wire is coated with a tin-plated layer.
- the outer diameter of the metal wire is preferably 3.0 to 3.5 mm.
- the outer cover 60 is a so-called sheath, and is formed by extruding the outer cover resin from the die of the extruder.
- the jacket resin is preferably composed of polyvinyl chloride (PVC) or thermoplastic elastomers (TPE).
- the thickness of the outer cover 60 is preferably 0.2 to 0.6 mm.
- the anti-twisted body 10 is composed of two cores (two) insulated wires 12, and has a structure in which the two insulated wires 12 are twisted at a constant pitch.
- the upper and lower limits of the twisted pair pitch of the insulated wire 12 are set from the viewpoint of inward skew and insertion loss (IL).
- the lower limit of the twisted pair pitch is assumed from the viewpoint of whether or not stable manufacturing can suppress the inward skew, and the lower limit value is actually 7.0 mm, preferably 7.9 mm.
- the twisted pair pitch of the insulated wire 12 becomes shorter, the twisted pair becomes excessively dense, and the twisted balance between the insulated wires 12 becomes unstable. As a result, there is a difference in physical length between the insulated wires 12 (the length varies), and it becomes difficult to suppress inward skew.
- the upper limit of the twisted pair pitch is derived from the viewpoint of suppressing the suckout phenomenon at high frequencies (for example, until it exceeds 10 GHz).
- the present inventor repeats the trial production of the communication cable 1 and the measurement of the insertion loss, and the upper limit of the twisted pair pitch has a correlation with the material (dielectric constant) of the insulator 16 and is caused by the dielectric constant of the insulator 16.
- An inner cover may be formed between the push winding 20 and the first shielding layer 40.
- the inner cover is preferably formed by extruding the inner cover resin from the die of the extruder.
- the inner resin is preferably composed of polyvinyl chloride (PVC) or thermoplastic elastomers (TPE).
- the thickness of the inner cover is preferably 2.3 to 2.9 mm.
- a single wire having a circular cross section or a compression stranded wire having a circular cross section having a ratio D / L of the total D / L of the distance d between the strands to the arc length L of the circumscribed circle 90 is 71% or less.
- the conductor 14 is extruded and covered with an insulating resin, and the conductor 14 is irradiated with an electron beam to crosslink the conductor 14 to form an insulator 16 to manufacture an insulated electric wire 12.
- the two insulated wires 12 are twisted (twisted pair) at a constant pitch.
- PET tape polyethylene terephthalate tape
- a metal tape is laminated and wound around the push winding 20 to form a first shielding layer 40, and a plurality of metal wires are braided to form a second shielding layer 50.
- the outer cover resin can be extruded and coated on the second shielding layer 50 to form the outer cover 60, and the communication cable 1 can be manufactured.
- the conductor 14 is simply a single wire having a circular cross section, or a compression stranded wire having a circular cross section, and the correlation between the arc length L of the circumscribing circle 90 and the distance d between the strands is constant.
- the communication cable 1 can be used for any purpose as long as it is used for communication, preferably used for in-vehicle use, and more preferably used for transmitting an image or video signal of an in-vehicle camera. That is, the communication cable 1 is suitable as a cable conforming to the ISO-6722 standard or the ISO-19642 standard.
- sample 1 First, seven annealed copper wires having a diameter of 0.15 mm were twisted together to form a conductor having an outer diameter of 0.45 mm. The conductor is just a stranded wire. After that, polyethylene is extruded and coated on the conductor, and the conductor is crosslinked by irradiating it with an electron beam to form a 0.2 mm thick insulator composed of cross-linked polyethylene (XLPE) to form an insulated wire having an outer diameter of 1 mm. did. Then, the two insulated wires were twisted (twisted) at a pitch of 8 mm to form a twisted pair.
- XLPE cross-linked polyethylene
- PET tape polyethylene terephthalate tape having a thickness of 0.025 mm was wound in 1/2 layers on the anti-twisted body (wrapped while overlapping 1/2 of the PET tape width).
- a metal tape with a thickness of 0.04 mm in which an aluminum foil with a thickness of 0.01 mm and a polyethylene terephthalate tape (PET tape) with a thickness of 0.025 mm are bonded to each other, is prepared as a first shielding layer, and is used for push winding.
- the metal tape was wound in 1/4 layers to form a first shielding layer having an outer diameter of 2.6 mm.
- 86 tin-plated annealed copper wires (TA) having a diameter of 0.1 mm were prepared as the second shielding layer, and the tin-plated annealed copper wire was braided to the first shielding layer to form a second with an outer diameter of 3.1 mm.
- a shielding layer was formed.
- polyvinyl chloride (PVC) was extruded and coated on the second shielding layer to prepare a communication cable having an outer diameter of 4 mm.
- Sample 1 the conductor is simply a stranded wire, and the transmission characteristic is below the reference standard value in the band around 5 GHz.
- Sample 2-5 is a compressed stranded wire whose conductor is a single wire or a compression stranded wire in which the ratio of the total distance between strands to the arc length of the circumscribed circle is 71% or less, and the transmission characteristic is the reference standard value in the band over 4 GHz. Meet.
- the transmission characteristics of Sample 2-4 satisfy the reference standard values even in the band of 10 GHz.
- the sum of the distances between strands with respect to the arc length of the circumscribing circle of a single wire having a circular cross section or a compression stranded wire having a circular cross section as a conductor It was found that it is useful to apply a wire having a ratio of 71% or less, and it is particularly useful to apply a compression stranded wire having a ratio of 42% or less in the band of 10 GHz.
- the present invention relates to a communication cable and a method for manufacturing the same, and is useful for providing a communication cable compatible with high frequency data transmission.
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Abstract
Description
直近では、車載Ethernet規格として、IEEE802.3ch Multi-Gig Automotive Ethernet PHY 10GBASE-T1(以下単に「Multi-Gig Automotive Ethernet規格」という。)が制定され、車載用の通信ケーブルには当該Multi-Gig Automotive Ethernet規格も満たすことが要求されると考えられる。
ただ、高周波データ伝送にはいくつかの課題があり、たとえば対内スキュー(対内の伝搬遅延時間の差)を抑制することや、高周波帯域でのサックアウト現象(信号減衰量の周波数特性の急激な落ち込み)を抑制することがあげられる。
特許文献1の技術では、8対の同軸電線対(11~18)が多芯ケーブル(1)内に収容されている。各同軸電線10は中心導体(21)が絶縁体(22)で被覆され、その外周が外部導体(23)および外被(24)で被覆されている。外部導体は内層部(23A)として金属細線(M)が絶縁体の周囲に横巻き(螺旋巻き)され、外層部(23B)として金属樹脂テープ(T)が内層部の周囲に横巻きされている。
当該技術では特に、金属細線と金属樹脂テープとの巻き方向を逆向きとしかつその巻き角度の差(角度θ3)を一定の範囲に設定することで、サックアウト現象を抑制している(段落0017-0027、図1-2、実施例、図4など参照)。
したがって本発明の主な目的は、高周波データ伝送に対応した(Multi-Gig Automotive Ethernet規格において少なくとも8GHz以上の高周波帯域でも当該規格を満たすような)通信ケーブルであって、ケーブルの内部構成の簡素化を実現しうる通信ケーブルを提供することにある。
すなわち本発明によれば、導体を絶縁体で被覆した絶縁電線を複数本撚り合わせた通信ケーブルであって、前記導体が断面円形状の単線か、または断面円形状の圧縮撚線でその外接円の円弧長さに対する素線間距離の総和の割合が71%以下のもので構成されていることを特徴とする通信ケーブルが提供される。
本明細書において数値範囲を示す「~」は下限値および上限値を当該数値範囲に含む意味を有している。
図1に示すとおり、通信ケーブル1は、対撚体10、押巻き20、第1の遮蔽層40、第2の遮蔽層50および外被60を有しており、対撚体10の外周を押巻き20、第1の遮蔽層40、第2の遮蔽層50および外被60がこの順に巻回し被覆している。
導体14は断面円形状の単線か、または断面円形状の圧縮撚線でその外接円の円弧長さに対する素線間距離の総和の割合が71%以下のものから構成されている。
「断面円形状の単線」とは、文字どおり一定の直径を有する断面円形状の単一の導線をいう。
「断面円形状の圧縮撚線でその外接円の円弧長さに対する素線間距離の総和の割合が71%以下のもの」とは、図2に示すとおり、複数本の素線15を撚り合わせ圧縮した圧縮撚線であって、当該圧縮撚線の外接円90の円弧長さLに対する素線間距離dの総和Dの割合D/Lが71%以下のものをいう。
「円弧長さL、素線間距離dおよび総和D」は、キーエンス社製デジタルマイクロスコープVHX-6000を使用して導体14としての圧縮撚線の断面を観測し得られる値であって、計測・スケール>平面計測>円弧のコマンドを実行して得られるものである。
すなわち、圧縮撚線は、複数本の素線15を単に撚り合わせた撚線(以下「単なる撚線」という。)を、ダイスを通過させ圧縮し形成される。かかる場合、図2の拡大部に示すとおり、外周部の素線15Aには湾曲部100が形成され、湾曲部100にはダイス通過の影響を受けた変曲点102が存在する。素線間距離dとは、外接円90の円弧上における、隣り合う素線15Aの変曲点102同士の間隙である。
湾曲部100は、外周部の素線15Aの数に応じて複数存在する。たとえば、7本の素線15を撚り合わせた図2の形態であれば、中心部の素線15Bを除外した外周部の6本の素線15Aが互いに隣り合いその間隙は6か所存在する。ここでは、6か所すべての間隙(素線間距離d×6か所)を足し合わせた合計が「総和D」である。
導体14の外径は好ましくは0.4~0.6mmである。
「表皮効果」とは、交流電流が導体14を流れるとき、電流密度が導体14の表層で高く、表層から離れると低くなる現象のことである。周波数が高くなるほど電流が表層に集中し、導体14の交流抵抗は高くなる。かかる表皮効果の影響を受ける表層の深さ、すなわち電流密度の高い表層の深さδ[μm]は下記のスキンデプス計算式から導かれ、周波数f[kHz]が高くなるほど減少する。
下記式中、「ρ」は導体14の体積抵抗率[Ω・m]であり1.72×10-8Ω・mである。「μ」は導体14の比透磁率であり1である。
本実施形態ではかかる表皮効果に着目し、高周波の伝送特性が導体14の形態(単なる撚線、圧縮撚線および単線)にどの程度影響するかを下記実施例にて検討しており、導体14が断面円形状の単線か、または断面円形状の圧縮撚線で外接円90の円弧長さLに対する素線間距離dの総和Dの割合D/Lが71%以下のものである場合に高周波の伝送特性が優れることを見出している。
絶縁体16の厚さは好ましくは0.2~0.4mmである。
押巻き20の厚さは好ましくは0.02~0.1mmである。
なお、押巻き20は必須の部材ではなく省略されてもよい。
当該金属テープは金属箔と樹脂テープとが貼り合わされ構成されたテープであり、好ましくはアルミニウム箔とポリエチレンテレフタレートテープ(PETテープ)とが貼り合わされ形成されている。第1の遮蔽層40では金属箔が外周に露出するように重ね巻きされる。
当該金属テープの厚さは好ましくは0.02~0.05mmである。
他方、第2の遮蔽層50は複数本の金属線が編組され構成されている。第2の遮蔽層50は複数本の金属線が一定のピッチ以下で横巻きされ構成されてもよい。当該各金属線は好ましくはスズのメッキ層で軟銅線を被覆した、いわゆるスズメッキ軟銅線(TA;Tinned Annealed copper)である。
当該金属線の外径は好ましくは3.0~3.5mmである。
外被60の厚さは好ましくは0.2~0.6mmである。
これによれば、光の速度を100とするとケーブル対内を伝わる信号の速度は技術常識としておよそ70%である(NVP:Nominal Velocity of Propagation)。周波数を10GHzと設定すれば、対撚りピッチの当該上限値は理論的には下記式のとおりに導出されるのである。
対撚りピッチの上限値[mm]
=(波長)×(1/絶縁体16の誘電率)
=(光速×NVP/周波数)×(1/絶縁体16の誘電率)
=300,000,000[m/s]×0.7/10×109[Hz]×(1/絶縁体16の誘電率)×1,000[mm]
内被の厚さは好ましくは2.3~2.9mmである。
その後、導体14に対し絶縁性樹脂を押し出し被覆してこれに電子線を照射し架橋させ絶縁体16を形成し、絶縁電線12を製造する。
その後、2本の絶縁電線12を一定のピッチで撚り合わせる(対撚りする)。
その後、押巻き20に対し金属テープを重ね巻きし第1の遮蔽層40を形成し、複数本の金属線を編組し第2の遮蔽層50を形成する。
最後に、第2の遮蔽層50に対し外被用樹脂を押し出し被覆し外被60を形成し、通信ケーブル1を製造することができる。
(1.1)サンプル1
はじめに、直径0.15mmの軟銅線を7本撚り合わせ、外径0.45mmの導体を形成した。当該導体は単なる撚線である。
その後、当該導体に対しポリエチレンを押し出し被覆しこれに電子線を照射し架橋させ、架橋ポリエチレン(XLPE)から構成される厚さ0.2mmの絶縁体を形成し、外径1mmの絶縁電線を形成した。
その後、2本の絶縁電線をピッチ8mmで撚り合わせ(対撚りし)、対撚体を形成した。
その後、第2の遮蔽層として86本の直径0.1mmのスズメッキ軟銅線(TA)を準備し、第1の遮蔽層に対し当該スズメッキ軟銅線を編組し、外径3.1mmの第2の遮蔽層を形成した。
最後に、当該第2の遮蔽層に対しポリ塩化ビニル(PVC)を押し出し被覆し、外径4mmの通信ケーブルを作製した。
サンプル1において主に、導体(単なる撚線)を、直径0.45mmの単線に変更した。
サンプル1において主に、導体(単なる撚線)を、外径0.45mmの3種の圧縮撚線に変更した。ここでは、素線径が互いに異なる3種の単なる撚線を、複数種類のダイスを通過させて圧縮し、最終的な外径が0.45mmの圧縮撚線に変更した(素線径を変えつつ外径が同じ3種の圧縮撚線を準備した。)。
サンプルごとに、圧縮撚線の外接円の円弧長さに対する素線間距離の総和を、キーエンス社製デジタルマイクロスコープVHX-6000を使用し算出したところ、下記のとおりであった。
各サンプルを5m切り出してこれに対し高周波帯域における挿入損失(IL;Insertion Loss)を測定した。測定結果を図3に示す。
なお、Multi-Gig Automotive Ethernet規格では、規格値が最大4GHzの高周波帯域までしか制定されていない。図3では、Multi-Gig Automotive Ethernet規格に記載された挿入損失(IL)の規格値たる下記計算式をもとに、4GHz以降の閾値を算出しこれを参考規格値としている。
図3に示すとおり、サンプル1は導体が単なる撚線であり、5GHz前後の帯域において伝送特性が参考規格値を下回っている。これに対しサンプル2-5は導体が単線または外接円の円弧長さに対する素線間距離の総和の割合が71%以下の圧縮撚線であり、4GHz超の帯域において伝送特性が参考規格値を満たしている。特にサンプル2-4は10GHzの帯域においても伝送特性が参考規格値を満たしている。
以上から、高周波データ伝送に対応した通信ケーブルを提供するうえで、導体として断面円形状の単線か、または断面円形状の圧縮撚線でその外接円の円弧長さに対する素線間距離の総和の割合が71%以下のものを適用することが有用であることがわかり、特に10GHzの帯域では当該割合が42%以下の圧縮撚線を適用することが有用であることがわかった。
なお、本実施例では導体が26AWG(American Wire Gauge)である例を示しているが、導体が24AWGまたは28AWGであっても、円弧長さL、素線間距離dおよび総和Dの値は変動するものの、その割合D/Lの値自体は導体が26AWGである場合とほぼ同様であり、その挿入損失(IL)も図3と同様の結果が得られる。
10 対撚体
10A~10B 第1~第2種線心
12 絶縁電線
14 導体
15 素線
15A 外周部の素線
15B 中心部の素線
16 絶縁体
20 押巻き
40 第1の遮蔽層
50 第2の遮蔽層
60 外被
90 外接円
100 湾曲部
102 変曲点
L 円弧長さ
d 素線間距離
D 総和
D/L 割合
Claims (4)
- 導体を絶縁体で被覆した絶縁電線を複数本撚り合わせた通信ケーブルであって、
前記導体が断面円形状の単線か、または断面円形状の圧縮撚線でその外接円の円弧長さに対する素線間距離の総和の割合が71%以下のもので構成されていることを特徴とする通信ケーブル。 - 請求項1に記載の通信ケーブルであって、
前記導体が断面円形状の圧縮撚線でその外接円の円弧長さに対する素線間距離の総和の割合が42%以下のもので構成されていることを特徴とする通信ケーブル。 - 請求項1または2に記載の通信ケーブルにおいて、
車載用途に使用されることを特徴とする通信ケーブル。 - 導体として断面円形状の単線か、または断面円形状の圧縮撚線でその外接円の円弧長さに対する素線間距離の総和の割合が71%以下のものを準備する工程と、
前記導体を絶縁体で被覆し絶縁電線を形成する工程と、
を備えることを特徴とする通信ケーブルの製造方法。
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