This application claims priority to Chinese Patent Application No. 201710833864.5 filed on Sep. 15, 2017.
The present invention relates to a tinsel wire structure and a manufacturing method thereof, and more particularly, to a tinsel wire structure having a metal cladding layer and a manufacturing method thereof.
Most of current electronic products support various types of wireless communication protocols and thus are capable of signal or data transmission in a wireless way. However, in actual use, the transmission quality of wireless transmission is still likely to be compromised due to factors such as insufficient transmission bandwidth, interferences from other signals or obstacles on the transmission path or the like. Therefore, transmission of signals or data in a wired way is still a transmission scheme that is frequently selected by users.
When signals or data are transmitted in a wired way, the resistance of the material of the wire selected is closely related to the transmission quality of the wire. Generally speaking, a larger resistance of the material of the wire tends to cause a larger obstacle for the transmission of the signal or the data, and thus makes it easier for the signal to be distorted or to influence the transmission speed.
Moreover, as can be known from the resistance formula of Resistance (R)=Resistance constant (p)×Length (L)/Sectional area (A), the Resistance (R) is positively proportional to the Length (L) and the Resistance (R) is inversely proportional to the Sectional area (A) when the Resistance constant (p) is a constant value. In other words, the longer the distance (i.e., the length) that the signal (or the current) travels during the transmission is, the larger the resistance is; and the smaller the sectional area that the signal (or the current) passes through during the transmission is, the larger the resistance is.
For the tinsel wire structures being used currently, the conductive layer thereof is spirally wound on a core. Therefore, when a signal (or current) is transmitted from one end of the tinsel wire structure to the other end of the tinsel wire structure, the distance (length) that the current travels through the conductive layer spirally wound is much larger than a straight line distance between the two ends of the tinsel wire structure, thereby increasing the resistance and adversely affecting the signal transmission.
On the other hand, the heat generated as the resistance increases during the transmission process will soften the conductive layer and reduce the flexibility thereof. When a tinsel wire structure of a small wire diameter (the diameter of the wire) is adopted, a small sectional area defined by the small wire diameter will result in a larger resistance. Therefore, when the tinsel wire structure operates under a relatively high operating temperature due to the high resistance and being bent for several times, the conductive layer of the tinsel wire structure is likely to be broken and thus fails the signal transmission. Therefore, such tinsel wire structures of a small wire diameter have a defect of being not resistant to bending.
Accordingly, an urgent need exists in the art to provide a tinsel wire structure which has a low impendence and is resistant to bending with a limited wire diameter.
An objective of the present invention is to provide a tinsel wire structure and a manufacturing method thereof, which enables the tinsel wire structure to maintain a lower resistance and a higher bending-resistant characteristic while having a small wire diameter so as to meet customized requirements of different manufactures.
To achieve the aforesaid objective, a tinsel wire structure of the present invention comprises a core, a conductive layer and a metal cladding layer. The core has an outer surface and defines a length direction, the conductive layer is spirally wound along the length direction on the outer surface of the core, and the metal cladding layer is provided on the periphery of the conductive layer to cover the core and the conductive layer. The conductive layer is spirally wound on the outer surface of the core in a non-overlapping manner to define a gap so that the gap is spirally wound on the outer surface of the core in a non-overlapping manner, and when the metal cladding layer covers the core and the conductive layer, the metal cladding layer covers the gap at the same time.
To achieve the aforesaid objective, a manufacturing method of a tinsel wire structure according to the present invention comprises the following steps of: step S1: providing a core that has an outer surface and defines a length direction; step S2: spirally winding a conductive layer along the length direction of the core on the outer surface of the core; and step S3: forming a metal cladding layer on the periphery of the conductive layer to cover the core and the conductive layer; wherein the conductive layer is spirally wound on the outer surface of the core in a non-overlapping manner to define a gap so that the gap is spirally wound on the outer surface of the core in a non-overlapping manner, and when the metal cladding layer covers the core and the conductive layer, the metal cladding layer covers the gap at the same time.
The detailed technology and preferred embodiments implemented for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention.
As shown in
As shown in the embodiment of
In detail, as shown in cross-sectional views of
In the tinsel wire structure 10 of the present invention, the core 20 is a fibrous core so that the core 20 has a characteristic of being resistant to high temperature and bending, while the conductive layer 30 is a metal foil. Still referring to
In a preferred embodiment of the present invention, as shown in
In order to make the metal cladding layer 40 provided on the periphery of the tinsel wire structure 10 really and completely cover the core 20, the conductive layer 30 and the gap 32, the metal cladding layer 40 of the present invention is provided to cover the periphery of the conductive layer 30 through a hot dipping process, and a liquid metal used in the hot dipping process is liquid tin.
Therefore, as shown in
On the other hand, after the transmission path of the signal is reduced, the heat generated during the transmission process will accordingly be reduced so that the tinsel wire structure 10 of the present invention may also have the following advantage of: being capable of effectively preventing the softening of the conductive layer 30 and increasing the flexibility thereof.
As shown in
Like the above description of the tinsel wire structure 10, in the manufacturing method of the tinsel wire structure 10, the core 20 is a fibrous core so that the core 20 has a characteristic of being resistant to high temperature and bending, while the conductive layer 30 is a metal foil. The metal foil for forming the conductive layer 30 is preferably a copper alloy foil, and the copper alloy foil is a tin-copper alloy foil, a silver-copper alloy foil or an iron-copper alloy foil.
On the other hand, in order to make the metal cladding layer 40 provided on the periphery of the tinsel wire structure 10 really and completely cover the core 20, the conductive layer 30 and the gap 32, the metal cladding layer 40 of the present invention is provided to cover the periphery of the conductive layer 30 through a hot dipping process, and a liquid metal used in the hot dipping process is liquid tin.
According to the above descriptions, by the arrangement of the metal cladding layer in the tinsel wire structure and a manufacturing method thereof disclosed in the present invention, the signal can be transmitted in a nearly linear manner, thereby reducing the generation of waste heat and effectively preventing the softening of the conductive layer to increase the flexibility thereof. Furthermore, the metal cladding layer provided through the hot dipping process can also effectively avoid the increase in the overall wire diameter of the tinsel wire structure so that the overall wire diameter of the tinsel wire structure still remains at a relatively small size to meet customized requirements of different manufacturers.
The above disclosure is related to the detailed technical contents and inventive features thereof. People skilled in this field may proceed with a variety of modifications and replacements based on the disclosures and suggestions of the invention as described without departing from the characteristics thereof. Nevertheless, although such modifications and replacements are not fully disclosed in the above descriptions, they have substantially been covered in the following claims as appended.
Number | Date | Country | Kind |
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201710833864.5 | Sep 2017 | CN | national |