EP3103122B1 - Data cable - Google Patents

Description

The invention relates to a data cable for transmitting data signals in the high-frequency range, for example in the megahertz or gigahertz range and a motor vehicle with such a data cable.

For data transmission, the so-called Ethernettechnologie is known, which is increasingly used in particular in motor vehicles. Automobile Ethernet lines usually consist of only one pair of wires, whereas in typical home installation lines, for example, the category CAT 5, CAT 6 typically four pairs are combined in a data cable. In the automotive sector, the data lines are often formed without a pair screen, that is, a respective pair of wires is not provided with a shield. A respective pair of wires is typically stranded together. In addition, so-called quad strands, in particular star quads are known in which four wires are stranded together.

In such unshielded cables, the high-frequency fields also propagate in the outer area, that is to say in particular in the jacket surrounding the respective wire pairs or the quad cables. This therefore influences the transmission quality and the transmission loss of a high-frequency data cable.

Disturbing these transmissions is also the unwanted transfer of energy from one cable to another cable, or the irradiation of high-frequency fields in the transmission system. This behavior is known in the art as crosstalk. As an extension of the well-known crosstalk you can see the "Alien-Next", which describes the radiation between different services or cables in the same wiring harness. A transmission system can only compensate for a limited amount of radiated energy without working erroneously.

Proceeding from this, the object of the invention is to specify a data cable with improved transmission properties.

From the US 2011/0005806 A1 a data cable is to be taken, which has four stranded pairs of wires. The wire pairs are arranged in a wire core, which additionally has a separating element. The wire pairs are separated by the separating element in particular electrically shielding from each other.

The US 2006/0169479 A1 describes a data line having a usually hollow and air-filled lead core and a surrounding the core core coat. Both the lead core and the cladding extend along a length of the data line. Within the line core two wire pairs are arranged. The jacket has a plurality of radially oriented to the center of the line core ribs. Due to the hollow formation of the lead core and the ribs of the shell, contact of the wire pairs with the jacket is reduced.

Of the DE 199 40 229 A1 is to take a two-wire line for use in a motor vehicle having an outer shell formed as a tube. The two-wire line is attached by means of a double-sided adhesive tape inside the tube.

The object is achieved by a data cable with the features of claim 1. Preferred developments are laid down in the dependent claims.

The data cable has a transmission core, which is formed by only one stranded pair of wires or alternatively by a quad stranding of four wires stranded together, in particular as star quads. Each of the wires consists of a conductor and a surrounding core insulation. The transmission core is in particular unshielded. To reduce transmission losses and / or to reduce external interference the transmission core is surrounded by a jacket with a high proportion of air / gas content. This jacket with a high proportion of air is formed by a foamed jacket or by at least one spacer which defines a jacket annulus around the transfer core with open air spaces.

Conveniently, the shroud is mounted concentric with the transfer core, sheath and transfer core are therefore arranged strictly coaxial with each other. This high symmetry positively influences the transmission properties.

In particular, it is preferably an automotive Ethernet line, which are usually formed by a single pair of wires, which is surrounded directly by an insulating jacket (outer jacket). The standard stretchers for such a data cable are usually comparatively small in size and require a small cable diameter, ie the diameter of the outer sheath in the range of only a few millimeters, for example 3 mm.

In one embodiment, the sheath with the high air content is arranged with the interposition of an intermediate sheath and forms an outer sheath. In the present case, the outer sheath is understood as meaning, in particular, the outermost sheath which concentrically surrounds the transfer core. Therefore, no further concentric layer or layer is arranged around the outer jacket. The cable with a structure which is closed by the outer jacket forms a prefabricated unit. In principle, it is possible to combine this prefabricated cable with other cables to form a complete cable or wiring harness. The high proportion of air is preferably generated by the fact that the sheath is foamed.

This embodiment is based on the fundamental idea to ensure a necessary distance, for example, to an adjacent data cable over this jacket formed as an outer sheath so as to minimize, for example, crosstalk effects. Such problems occur in particular in low-cost applications, for example in the automotive sector, where usually expensive shielding measures, etc. are dispensed with in order to reduce such effects.

By attaching the jacket with a high proportion of air adjacent data cables are therefore kept at a sufficiently large distance. At the same time, the material used for this sheathing is comparatively low due to the high proportion of air. The same applies to the weight of the data cable. Overall, this unnecessary material consumption is avoided and the costs are kept low.

According to a preferred embodiment of the intermediate jacket is formed as a solid shell of a suitable insulating material, for example of TPE-S. Due to the design of the solid intermediate jacket, the desired mechanical properties such as tensile strength, etc. can be adjusted.

Alternatively, the intermediate jacket is also formed with a high proportion of air and preferably designed as a foamed jacket. In this particular case, therefore, two foam layers are formed as intermediate sheath and sheath.

The intermediate casing has a wall thickness preferably in the range of 0.3 mm to 1 mm and preferably of 0.5 mm. The wall thickness of the outer jacket is preferably in the range of 0.2 mm to 0.8 mm. In particular, the outer sheath has a smaller wall thickness than the intermediate sheath.

In a particularly expedient development, the sheath of the intermediate sheath is formed easily separable. For this purpose, suitably the sheath and the intermediate sheath made of different materials, which connect only slightly with each other and, for example, are polar or nonpolar. Alternatively or additionally, between the casing and the Intermediate coat a release agent, for example, introduced in liquid form or as a powder form, in particular in the form of stearates.

This embodiment is based on the consideration to arrange the casing only in intermediate areas between two ends of the cable and to remove the casing at the end regions in order to connect the data cable to standard plug can. As a result, there is the overall possibility, while maintaining the standard connector, which allow, for example, a maximum outer diameter of 3 mm to use data cable with a larger outer diameter for the transmission path, so that the individual transmission cores of two adjacent data cables are spaced as far as possible in a wiring harness. At the same time, the diameter is reduced to the required outside diameter only in the connector area.

Accordingly, it is expediently also provided that a plug is struck at the end, wherein the sheath is removed in the area in front of the plug and in the plug only the data cable with the intermediate sheath is inserted.

For this embodiment, it is not absolutely necessary that the intermediate jacket and the jacket are easily separable from each other. The separation of the casing or parts thereof to a desired remaining final diameter in the plug region can also be done by suitable peeling, for example by a peeling process, etc.

Conveniently, in the foamed embodiment, the foamed sheath is bounded on at least one side and preferably on both sides by a thin skin layer, so that the sheath is closed in particular to the outside and not open-pored. The skin layer preferably has a wall thickness in the range of only 0.25 μm to, for example, 100 μm. In contrast, the minimum wall thickness of the foamed material of the sheath is in the range of 0.2 mm.

According to a further embodiment, the sheath surrounds the transmission core directly.

This embodiment is based on the idea of arranging no massive jacket in the immediate vicinity of the pair of wires or the star quad, but rather a casing which has a high proportion of air / gas, so that the high-frequency fields entering into this vicinity of the casing in the data cable propagating signal as little disturbed and attenuated.

The sheathing can furthermore be surrounded by an additional outer sheath, in particular be sheathed directly. This is preferably solid and preferably formed from an HF-suitable material. The sheath is therefore designed in the manner of an intermediate sheath which is embedded between the transfer core and the outer sheath. The outer jacket serves as protection against external environmental influences.

In a preferred embodiment, however, forms the sheath that surrounds the transfer core directly, even the outer jacket. It is therefore only arranged the sheath with the high proportion of air. Further concentrically arranged on the transfer core coats are preferably not formed. As a result, good transmission properties can be obtained with low material usage.

The sheath is formed in one embodiment by the at least one spacer element, which is designed in the manner of a tubular element which surrounds the transfer core. This hose-like element thus has free air areas, so that the jacket-shaped annular space formed by the hose-like element encloses a high proportion of air.

Preferably, the tubular element is extruded onto the transfer core, so that a simple and inexpensive production is possible.

Conveniently, the tubular member is formed by a plurality of (plastic) strands or strands which are interconnected to form a braid, a web or a shield-like wrapping. In particular, it is an extruded web.

For the aforementioned embodiments, the following preferred developments apply equally.

Thus, preferably, the ratio between a dielectric value of the core insulation and a dielectric value of the cladding is in the range of 1.4 to 1.8, and more preferably about 1.5. In particular, the core insulation has a dielectric value in the range of 2.0 to 2.6 and the cladding has a dielectric value in the range of 1.4 to 1.7. By this measure, similar to a Goubau line, a suitable orientation of the so-called Poynting vector is achieved inwards, so that the data transmission is overall less lossy. The sheathing is in particular the foamed sheath.

Furthermore, the sheath has at least a wall thickness in the range of 0.25 mm to 2.2 mm. In particular, by the minimum wall thickness ensures that the penetrating into the sheath radio frequency fields as completely as possible only in the area of the sheath.

Conveniently, the sheath further comprises or is comprised of an RF-suitable material. This is in particular a non-polar material, for example, the casing on plastics such as PE, PP, TPE-S or FEP. The high proportion of air also mitigates the negative impact of polar materials.

In the present case, if HF-suitable material is used, this generally refers in particular to a material with only a low dielectric loss factor at high frequencies. In particular, the loss factor is (at 1 MHz) in the range of about less than 20 * 10 ^-4 ; in particular below 5 * 10 ^-4 or even below 1 * 10 ^-4 (according to IEC60250).

In an expedient embodiment, the sheath itself is formed as a foamed sheath. By this measure, therefore, a high proportion of air or gas is introduced by the foaming process in the sheath. Compared to a solid shell, this significantly improves the transmission properties.

Conveniently, it has a degree of foaming in the range of 25 to 80%. The term "degree of foaming" here means the ratio of the volume fraction of the enclosed air to the volume fraction of the material.

Furthermore, the foamed sheath has a density in the range of 0.3 to 0.75 g / cm ³ , especially for lighter materials such as PE, PP, or a density in the range of 0.65 to 1.8 g / cm ³ especially for heavier materials like FEP.

Preferably, the sheath of several zones, in particular two or three zones consisting of different (high) foamed plastics constructed, wherein preferably the (radially) inner zones are formed with a higher degree of foaming (lower density) than the outer zones. The different zones can also form an intermediate sheath and an outer sheath.

As an alternative to the embodiment of the sheath as a foamed sheath, the sheath has at least one spacing element which preferably directly surrounds the transmission core and typically also bears against it. The spacer itself is interrupted and has a high proportion of air, is therefore not designed as a solid tubular element or shell-shaped element. To this spacer element, the outer sheath may be attached, which in particular directly sheathed the spacer. The outer jacket is in turn in turn made of a solid Material. However, an additional outer sheath does not necessarily have to be designed. There is also the possibility that only the spacer element is arranged and / or that the spacer itself forms a jacket. The spacer itself consists of an HF-suitable material.

The spacer element is designed in the manner of a tubular element, for example a (rope) screen or braid, and arranged / laid around the transmission core. Preferably, the spacer element is designed in the manner of a C-screen.

The screen or the tubular element in this case has only a low degree of coverage in the range of preferably less than 75%. In particular, the degree of coverage is in the range of 10% to 60%.

The tubular element is a total of interconnected (plastic) threads or strands, preferably a braid shield, which is formed from individual plastic threads. The plastic threads in turn consist of the HF-suitable material.

In a further alternative embodiment, the spacing element is finally designed in the manner of a tubular, surrounding the transfer core webs. This consists preferably of solid or foamed plastic.

The at least one spacer element in general, and in particular the web, is expediently formed by extrusion and, in particular, is applied directly to the transfer core by an extrusion process. The web is, in particular, individual strands of plastic which form a kind of net by means of a special extrusion process. Such extruded webs are used, for example, as packaging materials.

In principle, other tube-like structures surrounding the transfer core can also be used, which have only a low degree of coverage and thus a high proportion of air. The thickness of the tube-like elements and thus the radial extent of the spacer element is in particular in the range of the wall thickness of the sheath given above, ie in particular in the range of 0.2 mm to 2.2 mm.

This thickness also applies to the following variants of the spacer.

This has, according to an alternative embodiment, at least one strand wound around the transfer core, in particular made of plastic from an HF-suitable material. The plastic strand is expediently formed in counterstrike to a stranding of the wire pair or of the transmission core, so that the strand does not get into the gusset region between the wires. The strand is preferably surrounded by an outer sheath, in particular a hose-shaped extruded sheath.

The preferably extruded spacer is generally solid or made of a foamed material. It is produced during production, for example in the case of a design as a coiled strand, in particular in that an extruder or an extrusion head rotates.

Conveniently, a lay length of the transfer core and a lay length of the coiled plastic strand are in the ratio of a prime number to each other. As a result, periodic disturbances are reliably avoided.

In an alternative embodiment, the spacer elements are part of a jacket and are preferably arranged projecting radially inwards on an inner side of the jacket. They preferably have a sufficiently large radial length, so that viewed in the circumferential direction between two successive spacer elements sufficient free space is formed. Viewed in cross section, the spacer elements are, for example, semicircular, triangular or trapezoidal. Generally, they therefore rejuvenate towards the transmission core. By virtue of this refinement, the spacer elements therefore centrally center and hold the transmission core. The radial length of the spacer elements preferably corresponds again to the above-stated wall thickness of the sheath. It is preferably in the range of 0.2 to 0.8 times the maximum wall thickness of the jacket

In order to ensure the largest possible air entrapment, only a few spacer elements continue to be formed. In particular, only four, six or a maximum of eight spacer elements are arranged distributed around the inner circumference of the jacket. The spacers are preferably arranged distributed uniformly. For reasons of symmetry, the number of spacers is expediently even.

In order to ensure the highest possible concentric guidance of the transmission core, and in particular only a pair of wires relative to the jacket, the transmission core is guided twisted relative to the jacket with the integrally formed spacer elements. The individual cores are therefore guided in a helical manner within the sheath, so that they are periodically supported on the individual spacer elements and thereby reliably guided in a centric manner.

In a further alternative embodiment, the casing comprises a hollow tube in which the transfer core / pair of wires is not rectilinearly stretched, but instead is guided in waves or serrated, so that in particular periodically recurring support points of the transfer core are formed on the inner wall of the hollow tube. The transfer core is therefore only at vertices.

Fig. 1

in einer Querschnittsdarstellung ein Datenkabel mit einem geschäumten Außenmantel,

Fig. 2

eine Seitenansicht des in Fig. 1 dargestellten Datenkabels mit angedeutetem angeschlagenem Stecker,

Fig. 3A

eine Querschnittsdarstellung eines Datenkabels , bei dem ein Gespinst als Ummantelung mit hohem Luftanteil einen Übertragungskern unmittelbar umgibt und zugleich den Außenmantel definiert,

Fig. 3B

eine Seitenansicht des Datenkabels gemäß Fig. 3A,

Fig. 4A

eine weitere Ausführungsvariante mit einer unmittelbar um den Übertragungskern geschäumte Ummantelung mit zusätzlichem Außenmantel,

Fig. 4B

eine weitere Ausführungsvariante, bei der zur Ausbildung der Ummantelung mit hohem Luftanteil zwischen Übertragungskern und Außenmantel ein im Gegenschlag gewendelter Kunststoffstrang angeordnet ist sowie

Fig. 4C

eine Querschnittsdarstellung durch eine weitere Variante, bei der am Außenmantel radial nach innen gerichtete Abstandshalter angeformt sind, welche den Übertragungskern zentrieren.

Various configurations of a data cable will be explained in more detail with reference to the following description in conjunction with the following figures: These show in schematic diagrams in each case:

Fig. 1

in a cross-sectional representation of a data cable with a foamed outer jacket,

Fig. 2

a side view of the in Fig. 1 illustrated data cable with indicated battered plug,

Fig. 3A

a cross-sectional view of a data cable, in which a web as a jacket with high air content immediately surrounds a transfer core and at the same time defines the outer jacket,

Fig. 3B

a side view of the data cable according to Fig. 3A .

Fig. 4A

a further embodiment variant with a shell foamed directly around the transfer core with an additional outer shell,

Fig. 4B

a further embodiment in which the formation of the jacket with a high proportion of air between the transfer core and outer sheath a counter-wound coiled plastic strand is arranged as well as

Fig. 4C

a cross-sectional view through a further variant in which radially inwardly directed spacers are formed on the outer jacket, which center the transmission core.

All of the data cables 2 described below are preferably cables for a balanced signal transmission in which the signal is transmitted via one conductor of a line pair and an inverted signal is transmitted via the other conductor of a line pair. The data cable 2 is preferably an unshielded data cable 2, thus has no shielding. It has a comparatively simple structure. As a transmission core 4, the data cable 2 in the embodiments only a single pair of wires. The wire pair consists of two wires 6, which are each formed by a conductor 8 and a core insulation concentrically surrounding these 10. The two wires 6 are stranded together with a length of impact, so twisted together.

The core insulation 10 is preferably made of polypropylene and the conductor 8 is in particular a stranded conductor. The individual wires of the stranded conductor are designed in particular as copper wires and preferably tin-plated.

Alternatively, the transmission core 4 may be formed by a four-stranded network, in particular a so-called star quad, in which two diagonally opposite cores 6 define the pair of cores for the symmetrical data transmission. The four wires 6 are stranded together. The wires 6 are with their wire insulation 10 directly to each other. In the center, a Füllstrang be arranged to ensure the desired for a trouble-free signal transmission high symmetry.

Overall, with such a, unshielded data cable 2 high symmetry sought and realized to ensure trouble-free signal transmission.

When in the Fig. 1 illustrated variant of the transfer core 4 is initially surrounded immediately by an intermediate jacket 12, which is then surrounded by a foamed outer shell 14. Other layers preferably does not have the data cable 2. The intermediate casing 12 is preferably a solid intermediate casing 12. Alternatively, this may also be a foamed intermediate casing 12. Both the intermediate shell 12 and the outer shell 14 are preferably applied by an extrusion process.

The intermediate jacket consists for example of TPE-S. In the exemplary embodiment, the foamed outer jacket 14 is made of polypropylene.

Due to the foamed formation of the outer shell 14 forms a shroud with high air content. The degree of foaming is in particular at least about 50%.

The outer jacket 14 has a wall thickness w1 which is in the range of 0.2 to 0.8 mm and preferably in the range of 0.5 mm. The intermediate casing 12 has an average wall thickness w2 which is in the range of 0.3 to 1 mm and in particular about 0.5 mm. It is preferably slightly larger than the wall thickness w1 of the outer jacket 14. The average wall thickness w2 here means the difference between the radii of the transmission core 4 and the outer radius of the intermediate jacket 12, as is apparent Fig. 1 results. The intermediate casing 12 surrounds the transfer core 4 in a strictly concentric manner in view of the desired high symmetry. In this case, when extruding jacket material of the intermediate jacket 12 penetrates into the intermediate regions between the two wires 6. Also, the outer sheath 14 is arranged strictly concentric.

The entire data cable 2 has an outer diameter d1, which is defined by the outer diameter of the outer jacket 14. Furthermore, the intermediate casing 12 has a diameter d2 and the transmission core has a diameter d3. The latter is usually in the range between 1.5 and 2.2 mm and in particular about 1.8 mm. The diameter d2 of the intermediate sheath 12 is in the range of 2.8 to 3.4 mm, and preferably about 3 mm. The total outer diameter d1 is about 0.8 to 2 mm, and more preferably about 1 mm above, so that the overall total outer diameter d1 is from about 3.6 to 5.5 mm, and preferably about 4 mm.

Of particular importance now is that the diameter d2 of the intermediate sheath corresponds to a standard outer diameter, as is required for standard connector in such Ethernet lines, which are used in the automotive sector.

When assembling a plug 16, as in example Fig. 2 is indicated greatly simplified, initially only the outer sheath 14 is removed in the end of, for example, a few centimeters and the data cable 2 is inserted only with the intermediate sheath 12 in the plug 16. In this case, preferably the outer jacket 14 can be easily separated from the intermediate jacket 12 for the required assembly. This is for example due to different materials for these two coats 12, 14 and / or a separating layer between these two coats 12,14 achieved.

By in the Fig. 1 and 2 described data cable 2 overall, the particular advantage is achieved that is provided by the arrangement of the outer sheath 14 with the high air content and the special dimensions of the intermediate sheath 12 to the standard dimension of 3 mm improved in terms of signal transmission quality data cable 12 and at the same time on standard Confectioning as the connector 16 can be used. Due to the outer jacket 14 and the dimensioning and surface of the data cable 2 which is thereby increased, in particular an energy input from a source of interference coming from the outside is at least reduced. At the same time, the material requirement and the additional weight are kept as low as possible by the foamed outer shell 14. The sensitivity to the so-called alien-Next is therefore reduced.

The variants shown in the other figures show variants in which the jacket with the high air content is arranged directly around the transfer core 4 around.

In the embodiment of the FIGS. 3A and 3B At the same time, this sheathing forms an outer sheath 18. The entire data cable 2 is therefore formed only by the transfer core 4 and its outer sheath 18.

The outer jacket 18 is, in particular, a tubular element in the form of a web 20 extruded onto the transfer core 4. This outer jacket 18 is therefore characterized by intersecting individual strands which are, for example, lattice-shaped and enclose free air spaces 22 between them. As a material for the web 20 in this case a solid or a foamed HF-suitable plastic is used. Such extruded webs are known as packaging materials. They are made by two counter-rotating perforated discs in an extruder generated. For training in particular two opposite so-called D-wrapping are glued together at the intersection points.

The wires 6 of the transmission core 4 are basically suitable to be used without a massive outer shell. This makes the variant of the Fig. 3A, 3B advantage, since additional protection by a solid outer sheath is not mandatory. At the same time an improved data transmission due to a lower signal attenuation is achieved by the formed as a sheath with high air content outer jacket 18.

The dimensions of the data cable 2 are again comparable to those according to the Fig. 1 , In this case, the transfer core 4 is identical and the outer shell 18 has a diameter d2, which the diameter d2 of the intermediate shell 12 in the embodiment of the Fig. 1 equivalent. The outer jacket 18 according to the Fig. 3A Therefore, it has a diameter d2 of about 3 mm, so that the data cable 2 is suitable for standard plug 16.

Through the web 20 a spacer element is formed as a whole. By this web 20 so a spacer for example, adjacent data cables 2 or basic potentials (body) and other components is formed. By forming the outer shell 18 as a web material and weight is saved in comparison to massive outer shells.

In the further embodiment according to the FIGS. 4A, 4B, 4C the sheathing with high air content is additionally surrounded by a particular solid outer shell 24.

In the embodiment according to the Fig. 4A In this case, a foamed intermediate shell 26 is applied concentrically to the transfer core 4 before it is surrounded by a preferably solid outer shell 24.

In the Fig. 4B is to form the jacket with the high air content, a plastic strand 28 is attached, which is helical around the transfer core 4 is arranged and thus keeps the outer jacket 24 at a distance from the transfer core 4. The space between the transfer core 4 and outer shell 24 is formed by the free air space 22. By applying the plastic strand 28 in the counterstrike to the stranding of the wires 6 a sinking of the plastic strand 28 is reliably avoided in a gusset region between the wires 6. This ensures the desired high symmetry. On this provided with the plastic strand 28 transfer core 4, the outer jacket 24 is then buffed as a prefabricated hose. Overall, in this embodiment, a very small use of material with a high proportion of air in the sheath allows.

As an alternative to the design of the plastic strand 28 as a spacer element, a hose-like element, similar to, for example, the web 20, is attached to the transfer core 4 in a manner not shown here. This may be the in Fig. 3B shown webs 20 or even a braid or other tubular structure with free air spaces 22 act. In particular, a so-called C-screen is applied as a braid made of plastic threads. Again, the outer jacket 24 is preferably applied in a hose or half-tube extrusion.

Fig. 4C shows a variant in which individual spacer elements 30 are integrally formed on the outer casing 24 extending radially inwardly. The spacer elements 30 taper in the direction of the transmission core 4, so that they have a preferably rounded tip, so that they contact the wires 6 as possible only punctiform. To form the spacer elements 30, corresponding bulges are incorporated in an extrusion die which is used for the extrusion of the outer jacket 24. These bulges remain in the same place during the manufacturing process. At the same time, the wire pair rotates due to the stranding, so that the twisting of the wire pair causes it to be guided exactly in the middle of the outer casing 24. It can not slip into the gaps in the outer shell 24.

In order to achieve the highest possible proportion of air, expediently only a few spacer elements 30, in particular a maximum of eight and preferably only four spacer elements 30 are used. In view of the desired high symmetry while an even number is used. This embodiment can be manufactured on conventional extruders, is characterized by a high mechanical stability as well as good processability, since no additional work steps are required for the assembly of a plug 16. The diameter of the outer jacket 24 preferably corresponds again to the standard diameter of about 3 mm.

Finally, in an alternative, not shown here embodiment variant of the outer sheath be designed as a hollow tube, in which the stranded cores wave or zigzag is filed. As a result, the transfer core 4 rests against the outer jacket only at the vertices of the recurrent deformation.

In the embodiments described here, an HF-suitable material is selected for the respective sheathing. In the embodiments with the foamed jacket, gas or air is introduced as inclusions either by chemical or physical foaming processes. In particular, in the embodiment of the Fig. 1 the foamed outer casing 14 at least still a thin skin layer against mechanical stresses. This skin layer is dense. To produce the foamed shell, an extrusion line with the possibility of physical foaming or a blowing agent coated jacket material is used in the extrusion.

The data cable 2 described here is used - for example, with other cables or lines in a common harness - in a motor vehicle as part of the electrical system.

LIST OF REFERENCE NUMBERS

2

data cable

4

transmission core

6

veins

8th

ladder

10

wire insulation

12

intermediate casing

14

outer sheath

16

plug

18

outer sheath

20

web

22

free airspace

24

outer sheath

26

foamed intermediate coat

28

Plastic strand

30

spacer

d1

outer diameter

d2

diameter

w1

Wall thickness

w2

Wall thickness

Claims (15)

1. Data cable (2) with a transmission core (4), which has a single stranded conductor pair or four conductors stranded together to form a quad stranding and each conductor (6) comprises a line (8) which is sheathed by conductor insulation (10), wherein the transmission core (4) is surrounded by a sheathing (14, 18, 26, 20) with a high proportion of air, characterized

   - in that the sheathing (14, 18, 20, 26) is formed with a high proportion of air by a foamed sheath (14, 26), wherein the foamed sheath (14, 26) is either arranged as an outer sheath (14) with an intermediate sheath (12) interposed or is provided directly around the transmission core (4) and is surrounded by an additional outer sheath or

   - in that the sheathing (18, 20) is formed with a high proportion of air by at least one spacer element (18, 20), which defines an annular sheath space with air gaps (22) around the transmission core (4) and is formed as a tube-like element (20), which surrounds the transmission core (4).
2. Data cable (2) according to the preceding claim, in which the sheathing (14) can be stripped from the intermediate sheath (12) and for this purpose the sheathing (14) and the intermediate sheath (12) consist of different materials which do not bond to one another, or only a little, and/or a release agent is incorporated between the sheathing (14) and the intermediate sheath (12).
3. Data cable (2) according to one of the preceding claims, in which a connector (16) is fitted at the end and the sheathing (14) ahead of the connector (16) is removed and only the intermediate sheath (12) is led into the connector (16).
4. Data cable (2) according to one of the preceding claims, in which the foamed sheathing (14, 26) has a closed skin layer, at least on an outer side.
5. Data cable (2) according to one of the preceding claims, in which the tube-like element (20) forms an outer sheath (18).
6. Data cable (2) according to one of the preceding claims, in which the tube-like element (20) is extruded onto the transmission core (4) and in particular is formed as a spunbonded fabric extruded onto said transmission core.
7. Data cable (2) according to one of the preceding claims, in which the ratio between a dielectric value of the conductor insulation (10) and the sheathing lies in the range from 1.4 to 1.8 and in particular at approximately 1.5.
8. Data cable (2) according to one of the preceding claims, in which the conductor insulation (10) has a dielectric value in the range from 2.0 to 2.6 and the sheathing (18, 26) has a dielectric value in the range from 1.4 to 1.7.
9. Data cable (2) according to one of the preceding claims, in which the sheathing (14, 18, 26) has a wall thickness (w1) in the range from 0.25 mm to 2.2 mm.
10. Data cable (2) according to one of the preceding claims, in which the sheathing (14, 26) has a degree of foaming in the range from 25% to 80%, in particular of approximately 50%.
11. Data cable (2) according to one of the preceding claims, in which the sheathing (14, 18, 26) consists of an HF-compatible, nonpolar material, for example of PE, PP, TPES, FEP.
12. Data cable (2) according to the preceding claim, in which the foamed sheath has a density in the range from 0.3 to 0.75 g/cm³ for relatively lightweight materials such as PE, PP, or a density in the range from 0.65 to 1.8 g/cm³ for relatively heavy materials such as FEP.
13. Data cable (2) according to one of the preceding claims, in which the sheath consists of a number of zones, in particular two or three zones, of differently foamed plastics, wherein the inner zones are preferably formed with a greater degree of foaming than the outer zones.
14. Data cable (2) according to the preceding claim, in which the tube-like element (20) has a small degree of coverage in the range of below 75%, in particular in the range from 10% to 60%, preferably below 50%.
15. Motor vehicle with a data cable (2) according to one of the preceding claims.

Images