DisplayPort (DP) Cable Extrusion Line

DisplayPort Cable Extrusion Line

DisplayPort (abbreviated DP) is a digital video/audio interface standard developed by the Video Electronics Standards Association (VESA). It is primarily designed to connect source devices like computers and graphics cards to display devices such as monitors and projectors, providing high-quality audio and video signal transmission.

Main Features

High Bandwidth and High Resolution: DisplayPort has been committed to supporting higher resolutions and refresh rates since its inception. The latest DP 2.0/2.1 standard offers a theoretical bandwidth of up to 80 Gbps, easily supporting 8K@60Hz, 4K@240Hz, and even 10K resolution, making it ideal for high-end gaming, professional design, and future ultra-high-definition content.
Adaptive Sync Technology: Natively supports AMD FreeSync and NVIDIA G-SYNC Compatible technologies, effectively eliminating screen tearing and stuttering during gameplay for a smooth visual experience.
High Dynamic Range (HDR): Fully supports HDR content transmission, delivering a wider color gamut, higher contrast, and more vivid colors.
Powerful Audio Capabilities: Can simultaneously transmit multi-channel, high-fidelity digital audio signals without requiring a separate audio cable.
Daisy-Chaining: Through DisplayPort Multi-Stream Transport (MST) technology, a single cable can connect multiple monitors (the monitors must support DP output) from a computer, enabling a "daisy-chain" connection.
Sturdy Connection Design: The DP interface features a built-in latching mechanism (on some cables), ensuring a secure plug connection that is less prone to dislodging.
Open and Royalty-Free: As an open standard, manufacturers do not need to pay licensing fees, which helps reduce costs and promote adoption.

Interface and Cable Types

Standard DisplayPort Interface:
This is the most common form, widely used on desktop graphics cards, laptops, and monitors.
Mini DisplayPort Interface:
Introduced by Apple, it has a smaller size and is commonly found on ultra-thin devices like Apple MacBooks and Microsoft Surface devices. It can be easily converted to a standard DP or HDMI interface using an adapter.
DisplayPort Cable Specifications:
This is the most critical point to note when selecting a cable, as different versions support vastly different performances. Be sure to choose the appropriate cable based on your device and needs (such as target resolution/refresh rate).

DisplayPort Cable Extrusion Line

DisplayPort cable Extrusion Production Line refers to the complete set of automated equipment used for producing DisplayPort cables (especially the core part of the cable - the inner core). It evenly coats molten plastic (such as PVC, PE, foamed PE, etc.) onto the surface of a conductor (such as copper wire) to form an insulated core wire with specific insulation properties, dimensional accuracy, and electrical characteristics.

Process Characteristics:

Requires high precision, high stability, and high cleanliness. Compared to ordinary power cord extrusion, DP wire extrusion demands extremely high requirements for the uniformity of wire diameter, concentricity, and the purity of the insulating material.

Core Components

A complete DP cable extrusion production line consists of the following major systems, arranged according to the process flow:
Pay-off System
Function: Smoothly releases the bare copper wire (usually very fine tinned or bare copper wire) that serves as the conductor.
Requirements: Tension must be very stable and adjustable. Excessive or fluctuating tension can thin the copper wire, leading to impedance changes and affecting electrical performance. Active tension-controlled pay-off stands are typically used.
Preheating System
Function: Moderately heats the copper wire before it enters the extruder head.
Purpose:
Removes moisture from the copper wire surface.
Brings the copper wire temperature closer to the temperature of the molten plastic, reducing internal stress in the insulation layer caused by temperature differences, and improving adhesion (bonding) between the plastic and conductor as well as concentricity.
Extruder System
a. Extruder:
Composition: Mainly consists of a drive motor, screw, barrel, and heating/cooling system.
Function: Melts solid plastic pellets via electric heating and screw shear friction heat, and pushes the formed uniform, bubble-free melt towards the die head through the rotation of the screw.
Requirements: Screw design must be suitable for specific plastics (e.g., foamed PE). Temperature control accuracy must be high.
b. Die Head and Mold:
Die Head: The place where the molten plastic and conductor converge.
Mold: Includes a tip (determines the inner diameter) and a die (determines the outer diameter). Their combination determines the thickness and concentricity of the insulation layer. The machining precision of the mold is extremely high and is key to ensuring cable quality.
Cooling System
* Function: Rapidly cools and sets the core wire, freshly coated with molten plastic as it exits the die head.
* Form: Typically a long cooling water trough, divided into multiple stages where water temperature can be controlled segmentally. Gradual cooling is crucial for preventing crystallization and reducing internal stress.
Online Diameter Gauge
Function: The "eyes" of high-speed wire production. Uses laser principles to measure the outer diameter of the core wire in real-time (thousands of times per second) and instantly feeds the data back to the control system.
Purpose: Achieves closed-loop control, ensuring wire diameter fluctuation is at the micron (μm) level, which is key to controlling characteristic impedance (e.g., 85Ω ±5%).
Spark Tester
Function: Applies high voltage to the cooled and set core wire.
Purpose: Detects defects in the insulation layer such as scratches or pinholes. If breakdown occurs, the equipment will alarm or automatically mark/stop, ensuring insulation integrity of the product.
Capstan / Puller
Function: Provides smooth, constant pulling force to continuously draw the core wire from the pay-off end through the entire production line.
Requirements: Speed must be extremely stable and synchronized with the extruder's output speed, otherwise uneven wire diameter will result. Dual-wheel capstans are often used to prevent slipping.
Take-up System
Function: Neatly winds the finished core wire onto a spool.
Requirements: Take-up tension must be smooth, and winding must be even to avoid damaging the core wire. Various forms exist, such as spool take-up and overhead take-up.
Central Control System
Function: Integrates PLC (Programmable Logic Controller) and a touchscreen HMI (Human-Machine Interface) to centrally control all parameters of the production line (speed, temperature, tension, etc.) and record production data, enabling automated production and traceability.

DisplayPort Cable Extrusion Line Datasheet

Model	30	40	50	60	70	80	90
Screw Diameter (mm)	φ30	φ40	φ50	φ60	φ70	φ80	φ90
Screw L/D Ratio	25:1	25:1	26:1	26:1	26:1	26:1	26:1
Extrusion Amount (kg/hr)	25	40	70	100	140	200	250
Outlet Wire (mm)	0.2-1	0.4-3	0.8-5	1-8	2-15	3-25	5-35
Total Power (KW)	18	20	25	33	40	55	63
Traction Power (KW)	2.2	2.2	4	4	4	5.5	5.5
Production Speed (m/min (Max.))	600	600	600	500	500	300	300
Take-up Spool (mm)	φ200-400	φ300-500	φ400-630	φ400-630	φ500-630	φ800-1000	φ1000-1250

DisplayPort Cable Extrusion Line Application

The DisplayPort cable extrusion production line is a high-precision, advanced manufacturing system that integrates mechanical, electrical, material, and automatic control technologies. This high-precision extrusion production line is specifically used for manufacturing the inner cores of various high-frequency, high-speed data cables. Details are as follows:

Main Product Applications

DisplayPort cable inner core: Produces the insulated core wires for the internal differential pairs of DP cables. This is the most direct application.
HDMI cable inner core: The process and requirements are very similar to those for DP cables.
USB Type-C / Thunderbolt cable inner core: Especially for cables supporting high-speed data transmission (USB 3.2/4, Thunderbolt 3/4).
SAS / SATA data cables: Inner cores used for servers and storage devices.
Automotive Ethernet cables: High-speed data cables for in-vehicle networks.

Production Line Type Breakdown

Depending on the product structure, the extrusion production line may vary slightly:
Single-pair extrusion line: Produces one independent insulated core wire at a time. The two core wires are later twisted into a pair by a twisting machine.
Dual-pair simultaneous extrusion line: A more advanced configuration. It can extrude two core wires simultaneously and immediately complete the twisting process after the die head. This "simultaneous" production method better maintains twist consistency and symmetry, which is highly beneficial for improving high-frequency performance.