A high-strength tethered cable and a method for preparing the same

Abstract

The present invention discloses a high-strength tethered cable, comprising an optical unit part, an electrical unit part and a reinforcement unit part. The optical unit part comprises an optical fiber core layer, and an optical fiber tight sleeve layer and a metal armor layer sequentially wrapped around the optical fiber core layer; the electrical unit part comprises a multi-core copper alloy conductor, and a first insulating layer and a second insulating layer sequentially wrapped around the multi-core copper alloy conductor; the reinforcement unit part comprises a filling layer, a braided armor layer and a protective layer; the filling layer, the optical unit part and the electrical unit part are geometrically formed into a circle and are recorded as a semi-finished product, and the filling layer is filled outside the optical unit part and the electrical unit part; the braided armor layer is woven outside the semi-finished product, and the protective layer is wrapped around the braided armor layer. The high-strength tethered cable of the present invention has good heat dissipation performance, high temperature resistance, and high tensile strength, which is conducive to improving the flight altitude of the unmanned aerial vehicle, while ensuring long-term stable operation. The present invention also provides a preparation method of a high-strength tethered cable with a simple process.

Description

Technical Field

[0001] The present invention relates to the technical field of electric wires and cables, and in particular to a high-strength tethered cable and a preparation method thereof, which are suitable for data and energy transmission of unmanned aircraft or aircraft. Background Art

[0002] With the continuous development of science and technology, the demand for drones and low-altitude aircraft in various fields is increasing day by day. Conventional tethered drones use tethered cables as energy supply and signal transmission. Their flight altitude and flight duration are limited by the length and structure of the tethered cables. The higher the aircraft, the longer the cable, which means greater heat generation under DC power supply and heavier overall weight.

[0003] Conventional tethered cables are generally composed of wires for transmitting electrical energy and optical fiber cables for transmitting signals: the conductor material of the wire is generally tinned copper wire, and the insulation material is generally PE; the optical fiber is ordinary single-mode optical fiber, and the sheath is made of TPU material. The molding method is generally extrusion. Due to the limitations of the material itself, its temperature resistance level does not exceed 80℃, its effective distance is short, and its heat power is large under long-term use, which affects the flight altitude and use time of the aircraft. Summary of the invention

[0004] In order to overcome the shortcomings of the prior art, the primary purpose of the present invention is to improve the temperature resistance level of the cable, reduce the weight and volume of the cable, use a unique structural design, increase the effective transmission distance of the cable, and provide effective guarantee for the flight time and flight altitude of the UAV. To this end, the present invention provides a high-strength tethered cable. The optical cable structure has good heat dissipation performance, the conductor temperature resistance can reach 260°C, and the cable has high overall tensile strength, which is beneficial to improving the flight altitude of the UAV while ensuring long-term stable operation.

[0005] A second object of the present invention is to provide a method for preparing a high-strength tethered cable with a simple process.

[0006] One of the purposes of the present invention is achieved by the following technical solution:

[0007] A high-strength moored cable comprises at least one optical unit part, at least two electrical unit parts and a reinforcement unit part, wherein the optical unit part is a ring structure, comprising an optical fiber core layer, and an optical fiber tight sleeve layer and a metal armor layer wrapped around the optical fiber core layer in sequence; the electrical unit part is a ring structure, comprising a multi-core copper alloy conductor, and a first insulating layer and a second insulating layer wrapped around the multi-core copper alloy conductor in sequence; the optical unit part and the electrical unit part are arranged in parallel; the reinforcement unit part comprises a filling layer, a braided armor layer and a protective layer; the filling layer, the optical unit part and the electrical unit part are geometrically formed into a circle and are recorded as a semi-finished product, and the filling layer is filled in the area outside the optical unit part and the electrical unit part; the braided armor layer is woven outside the semi-finished product, and the protective layer is wrapped around the braided armor layer.

[0008] Furthermore, for the optical unit part, the optical fiber core layer is a polyimide-coated single-mode optical fiber; the optical fiber tight sleeve layer is a polytetrafluoroethylene raw tape wrapping layer, the single layer thickness of the polytetrafluoroethylene raw tape is 0.01-0.20 mm, the width is 2.2-19.2 mm, and the total thickness of the optical fiber tight sleeve layer after wrapping is 0.1-0.50 mm.

[0009] Furthermore, for the optical unit part, the metal armor layer is a stainless steel wire sheath, the outer diameter of the stainless steel wire is 0.05-1.5 mm, the stainless steel wire is extruded into a flat tape and then spirally wrapped around the optical fiber tight sleeve layer, the spiral angle is 17-60°, the spiral pitch is 0.08-0.15 mm, preferably 0.05 mm.

[0010] Furthermore, for the electrical unit part, the multi-core copper alloy conductor is formed by bundling multi-core nickel-plated copper alloy conductors, and the pitch ratio is 10-16.

[0011] Furthermore, for the electrical unit part, the first insulating layer is a polytetrafluoroethylene-polyimide-polytetrafluoroethylene composite tape wrapping layer with an overlap width of 30% to 80%; the second insulating layer is a polytetrafluoroethylene raw tape wrapping layer with an overlap width of 30% to 80%, and the single layer thickness of the polytetrafluoroethylene raw tape is 0.01 to 0.20 mm, and the width is 1.8 to 32 mm.

[0012] Furthermore, for the reinforcement unit part, the braided armor layer includes a bulletproof aramid wire core layer composed of a plurality of bulletproof aramid wires, and a hollow silver-plated copper wire layer wrapped around the bulletproof aramid wire core layer; the number of braiding spindles of the braided armor layer is 8 to 144 spindles, and the braiding density is above 80%.

[0013] Furthermore, for the reinforcement unit part, the filling layer is an aramid filling layer with a pitch-to-diameter ratio of 8 to 14; the protective layer is a polytetrafluoroethylene raw tape wrapping layer, and the single-layer thickness of the polytetrafluoroethylene raw tape is 0.15 to 0.4 mm.

[0014] Furthermore, the number of the optical unit parts and the number of the electrical unit parts are both two, the two electrical unit parts are arranged side by side to form an electrical unit body, and the two optical unit parts are respectively arranged above and below the electrical unit body.

[0015] The second object of the present invention is achieved by adopting the following technical solution:

[0016] A method for preparing a high-strength tethered cable, comprising:

[0017] The steps of preparing the optical unit tight-buffered optical fiber are as follows: wrapping the optical fiber tight-buffered material around the optical fiber core layer to obtain the tight-buffered optical fiber;

[0018] Optical unit metal armoring step: placing the tight-buffered optical fiber on an armored pay-off frame, taking a metal armor material, extruding the metal armor material into a flat tape, and then spirally wrapping it on the tight-buffered optical fiber to obtain an optical unit part;

[0019] The steps of preparing the electrical unit conductor core are as follows: taking a plurality of copper alloy conductors and bundling them into a multi-core copper alloy conductor;

[0020] The electric unit insulation layer preparation step includes: taking a first insulation layer material, wrapping the first insulation layer material around the multi-core copper alloy conductor, then taking a second insulation layer material for wrapping, and then sintering to obtain an electric unit part;

[0021] Cabling step: taking the optical unit part and the electrical unit part, using an active back-twisting pay-off frame and a cantilever single twisting machine, and supporting the filling material flatly on the surface of the optical unit part and the electrical unit, and geometrically rounding the filling material, the optical unit part and the electrical unit part into a semi-finished product;

[0022] The braided armor layer preparation step is: using a single-spindle single-filament braiding device to braid the braided armor material outside the semi-finished product;

[0023] The protective layer preparation step is: taking the protective layer material, wrapping the protective layer material around the braided armor layer, and then semi-sintering it.

[0024] Furthermore, in the optical unit tight-buffered optical fiber preparation step, when wrapping the optical fiber tight-buffered material, the tension of the wrapping equipment is controlled to be 1 to 25N;

[0025] In the optical unit metal armoring step, the tight-buffered optical fiber is placed on an armored pay-off frame, and the pay-off tension is set to 0-40N; the helix angle of the metal armor material ranges from 17 to 60°, and the helix pitch is 0.05mm;

[0026] In the step of preparing the electrical unit conductor core, setting the pitch ratio to 10 to 16;

[0027] In the step of preparing the electrical unit insulation layer, when wrapping the first insulation layer material, the overlap width is set to 30% to 80%, and when wrapping the second insulation layer material, the overlap width is set to 30% to 80%;

[0028] In the cabling step, the pitch ratio is set to 8 to 14;

[0029] In the step of preparing the braided armor layer, the number of braiding spindles is set to 8 to 144, and the braiding density is controlled to be above 80%;

[0030] In the step of preparing the protective layer, the sintering temperature is controlled to be 320-370° C. during semi-sintering.

[0031] Compared with the prior art, the present invention has the following beneficial effects:

[0032] (1) The high-strength tethered cable provided by the present invention is also a high-temperature resistant lightweight tethered cable. It adopts a special heat dissipation structure design concept and uses lightweight new insulating materials and copper foil wire materials. On the basis of ensuring performance, the overall outer diameter and weight of the cable are reduced, which greatly improves the effective length and service life of the tethered cable, thereby increasing the working height and duration of the drone.

[0033] (2) The preparation method of the high-strength tethered cable provided by the present invention utilizes special armoring, insulation manufacturing and weaving processes. The optical cable structure has good heat dissipation performance and high temperature resistance. The overall tensile strength of the cable is high, which is beneficial to increasing the flight altitude of the UAV while ensuring long-term stable operation. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Figure 1 A schematic diagram of the structure of a high-strength tethered cable provided in an embodiment of the present invention;

[0035] Figure 2 An exploded schematic diagram of a braided armor layer in a high-strength tethered cable provided in an embodiment of the present invention.

[0036] In the figure: 1. Optical fiber core layer; 2. Optical fiber tight sleeve layer; 3. Metal armor layer; 4. Multi-core copper alloy conductor; 5. First insulation layer; 6. Second insulation layer; 7. Filling layer; 8. Braided armor layer; 81. Hollow silver-plated copper wire; 82. Bulletproof aramid wire; 9. Protective layer. DETAILED DESCRIPTION

[0037] The present invention is further described below in conjunction with the accompanying drawings and specific implementation methods. It should be noted that, under the premise of no conflict, the various embodiments or technical features described below can be arbitrarily combined to form a new embodiment.

[0038] A high strength tethered cable, such as Figure 1 As shown, it includes at least one optical unit part, at least two electrical unit parts and a reinforcement unit part. The optical unit part is a ring structure, including an optical fiber core layer 1, and an optical fiber tight sleeve layer 2 and a metal armor layer 3 wrapped around the optical fiber core layer 1 in sequence; the electrical unit part is a ring structure, including a multi-core copper alloy conductor 4, and a first insulation layer 5 and a second insulation layer 6 wrapped around the multi-core copper alloy conductor 4 in sequence; the optical unit part and the electrical unit part are arranged in parallel; the reinforcement unit part includes a filling layer 7, a braided armor layer 8 and a protective layer 9; the filling layer 7, the optical unit part and the electrical unit part are geometrically formed into a circle and are recorded as a semi-finished product, and the filling layer 7 is filled outside the optical unit part and the electrical unit part; the braided armor layer 8 is woven outside the semi-finished product, and the protective layer 9 is wrapped around the braided armor layer 8.

[0039] As a further implementation, for the optical unit part, the optical fiber core layer 1 uses a polyimide-coated single-mode optical fiber; specifically, a high-temperature resistant polyimide-coated G657D single-mode bend-insensitive optical fiber, which ensures the transmission distance and quality of the data signal.

[0040] As a further embodiment, the optical fiber tight jacket layer 2 is a polytetrafluoroethylene raw tape wrapping layer, the single layer thickness of the polytetrafluoroethylene raw tape is 0.01-0.20 mm, the width is 2.2-19.2 mm, and the total thickness of the optical fiber tight jacket layer 2 after multi-layer wrapping is 0.1-0.35 mm. The PTFE raw tape is wrapped on the surface of the optical fiber in multiple layers to achieve the purpose of waterproofing, heat insulation and mechanical protection buffering.

[0041] As a further embodiment, for the optical unit part, the metal armor layer 3 is a stainless steel wire sheath, the outer diameter of the stainless steel wire is 0.05-1.5mm, and most preferably 0.15mm. The stainless steel wire is extruded into a flat tape and then spirally wrapped around the optical fiber tight sleeve layer 2, with a spiral angle of 17-60°, preferably 45°, and a spiral pitch of 0.08-0.15mm, preferably 0.05mm. The soft metal armor layer 3 uses high-strength stainless steel wire to evenly spirally wrap around the optical fiber tight sleeve layer 2, which plays a role in heat dissipation, improving the tensile strength of the cable, mechanical protection, improving bending characteristics and lateral pressure resistance. In addition, such a setting can improve the optical fiber's resistance to the external environment and the lateral pressure of the outer layer structure, and reduce the overall outer diameter of the optical cable, ensure the bending performance of the cable, and dissipate heat more quickly.

[0042] As a further implementation, for the electrical unit part, the multi-core copper alloy conductor 4 is made of soft and lightweight multi-core nickel-plated copper alloy conductor bundles, which can improve the temperature resistance level, improve the bending characteristics and cable hardness, and have good heat dissipation while transmitting electrical energy; the pitch ratio is set to 10-16 to ensure that the conductor appearance is round and full. The multi-core copper alloy conductor 4 effectively reduces the outer diameter and weight of the cable, increases the tightness between the conductor filaments, ensures the conductivity of the conductive layer, and improves the heat dissipation performance.

[0043] As a further implementation method, for the electrical unit part, the first insulating layer 5 is a wrapped layer of polytetrafluoroethylene-polyimide-polytetrafluoroethylene composite tape with an overlap width of 30% to 80%. The first insulating layer 5 is a part of the composite insulating dielectric layer and adopts a special polytetrafluoroethylene-polyimide-polytetrafluoroethylene composite tape, which is characterized by light weight and excellent insulation performance. It can withstand temperatures up to 500 degrees. Only a thin layer is needed to achieve excellent electrical insulation performance, which greatly reduces the outer diameter and volume of the cable.

[0044] As a further embodiment, the second insulating layer 6 is a polytetrafluoroethylene raw tape wrapping layer, the overlap width is 30% to 80%, the single layer thickness of the polytetrafluoroethylene raw tape is 0.01 to 0.20 mm, and the width is 1.8 to 32 mm. The second insulating layer 6 is another part of the composite insulating dielectric layer. The polytetrafluoroethylene raw tape produced by the process and formula is tightly wrapped on the surface of the composite material to play a role in auxiliary electrical insulation and waterproofing.

[0045] As a further implementation, for the reinforcement unit part, the filling layer 7 is an aramid filling layer 7 with a pitch-to-diameter ratio of 8 to 14; the aramid filling fills the pores of the cable, making the cable geometry round while improving the load-bearing and tensile strength of the cable. At the same time, the presence of the gap also improves the heat dissipation of the cable.

[0046] like Figure 2 As shown, as a further embodiment, for the reinforcement unit part, the braided armor layer 8 includes a bulletproof aramid wire core layer composed of a plurality of bulletproof aramid wires 82, and a layer of hollow silver-plated copper wire 81 wrapped around the bulletproof aramid wire core layer; the number of braided spindles of the braided armor layer 8 is 8 to 144 spindles, and the braiding density is more than 80%. Hollow silver-plated copper foil wires of different outer diameters can be selected according to the design of the actual product. The hollow structure ensures the heat dissipation of the long-distance high-power transmission cable, while also reducing the weight of the cable product, and plays a role in buffering and protection when subjected to air or physical side pressure and impact.

[0047] As a further embodiment, the protective layer 9 is a polytetrafluoroethylene raw tape wrapping layer, and the thickness of the single layer of the polytetrafluoroethylene raw tape is 0.15-0.4 mm. The PTFE raw tape is used to evenly wrap multiple layers on the surface of the braided armor layer 8. The PTFE material, known as the king of plastics, has extremely excellent resistance to harsh environments. The dense and porous structure between the molecules of the raw tape layer not only ensures heat dissipation and air permeability, but also ensures the penetration of moisture and water molecules, playing a protective and waterproof role.

[0048] As a further embodiment, Figure 1 As shown, there are two optical unit parts and two electrical unit parts, and the two electrical unit parts are arranged side by side to form an electrical unit body, and the two optical unit parts are respectively arranged above and below the electrical unit body.

[0049] The high-strength tethered cable provided in the embodiment of the present invention is also a high-temperature resistant lightweight tethered cable. It adopts a special heat dissipation structure design concept and uses lightweight new insulating materials and copper foil wire materials. On the basis of ensuring performance, it reduces the overall outer diameter and weight of the cable, greatly improves the effective length and service life of the tethered cable, thereby increasing the working height and duration of the drone.

[0050] A method for preparing a high-strength tethered cable, comprising:

[0051] The optical unit tight-buffered optical fiber preparation step is: wrapping the optical fiber tight-buffered material around the optical fiber core layer 1 to obtain the tight-buffered optical fiber;

[0052] Optical unit metal armoring steps: placing the tight-buffered optical fiber on an armored pay-off frame, taking a metal armor material, extruding the metal armor material into a flat tape, and then spirally wrapping it on the tight-buffered optical fiber to obtain an optical unit part;

[0053] The steps of preparing the electrical unit conductor core are as follows: a plurality of copper alloy conductors are bundled into a multi-core copper alloy conductor 4;

[0054] The steps of preparing the electrical unit insulation layer are as follows: taking the material of the first insulation layer 5, wrapping the material of the first insulation layer 5 on the multi-core copper alloy conductor 4, and then taking the material of the second insulation layer 6 for wrapping, and then sintering to obtain the electrical unit part;

[0055] Cabling steps: take the optical unit part and the electrical unit part, use an active back-twisting pay-off frame and a cantilever single twisting machine, and support the filling material flat on the surface of the optical unit part and the electrical unit part, and geometrically round the filling material, the optical unit part and the electrical unit part to form a semi-finished product;

[0056] Preparation steps of the braided armor layer 8: using a single-spindle single-filament braiding device to braid the braided armor material outside the semi-finished product;

[0057] Preparation steps of the protective layer 9: Take the material of the protective layer 9, wrap the material of the protective layer 9 around the braided armor layer 8, and then semi-sinter it.

[0058] As a further implementation method, in the step of preparing the optical unit tight-cup optical fiber, when wrapping the optical fiber tight-cup material, the tension of the wrapping equipment is controlled to be 1 to 25N to avoid excessive tension during the production process, which causes the optical fiber to stretch and slightly bend, affecting the transmission efficiency. The wrapping equipment independently developed by our company is used, using a special wrapping head and mold as well as a motor speed control. The three cooperate with each other and adopt multiple layers and multiple wrapping, so that the PTFE raw tape is evenly attached to the surface of the optical fiber. The total thickness of the PTFE raw tape wrapping ranges from 0.1 to 0.35mm.

[0059] In the optical unit metal armoring step, the tight-buffered optical fiber is placed on the armored pay-off frame, and the pay-off tension is set to 0-40N; the helix angle of the metal armor material ranges from 17 to 60°, and the helix pitch is 0.05mm;

[0060] In the step of preparing the electrical unit conductor core, the pitch ratio is set to 10 to 16;

[0061] In the preparation step of the insulation layer of the electrical unit, we use the wrapping equipment independently developed by our company, special wrapping heads and molds, and motor speed control. The three cooperate with each other and adopt multiple layers and multiple wrapping. First, wrap the polytetrafluoroethylene-polyimide-polytetrafluoroethylene composite tape, accurately control the overlap width to 30% to 80%, and tightly wrap it around the surface of the conductor layer. Then wrap the PTFE raw tape, accurately control the overlap width to 30% to 80%, and tightly wrap it around the surface of the composite tape. According to the size of the wire diameter, select the tape with appropriate thickness (0.01 to 0.20mm) and width (1.8 to 32mm), or the raw tape and the composite tape cooperate with each other to ensure the insulation electrical performance of the wires in the electrical unit. Then carry out the sintering process, control the sintering line speed and sintering temperature, let the insulation tape tightly cover the conductor surface, form a fine insulation layer, and reduce the outer diameter and volume of the cable.

[0062] In the cabling step, the pitch ratio is set to 8 to 14;

[0063] In the preparation step of the braided armor layer 8, in order to ensure good heat dissipation characteristics, it is not necessary to perform wire doubling processing, and a single-spindle single-filament braiding device is used, and the number of spindles ranges from 8 to 144 spindles, preferably 120 spindles. When transmitting electrical energy over long distances, the hollow structure of the silver-plated copper wire itself and the special braiding structure of the single-spindle single-filament can ensure the overall heat dissipation characteristics of the cable. The main parameter of weaving is the weaving density, and its density range is controlled to be above 80%, preferably 85%, which not only ensures mechanical protection but also controls the weight of the cable; before the conventional weaving process, the material must be processed with wire doubling;

[0064] In the preparation step of the protective layer 9, in order to ensure the normal and stable long-term operation of the effective working unit inside the cable, PTFE raw tape is used for wrapping to form the protective layer 9. The wrapping equipment independently developed by our company is used, and a special wrapping head and mold and motor speed control are used. The three cooperate with each other and use multiple layers and multiple wrapping to make the tape evenly attached to the cable surface, and its thickness ranges from 0.15 to 0.4 mm. Then a specific semi-sintering process is used, and the sintering temperature is controlled at 320 to 370°C, which ensures the good heat dissipation performance of the cable.

[0065] The preparation method of the high-strength tethered cable provided in the embodiment of the present invention utilizes special armoring, insulation manufacturing and weaving processes. The optical cable structure has good heat dissipation performance and high temperature resistance. The overall tensile strength of the cable is high, which is beneficial to increasing the flight altitude of the UAV while ensuring long-term stable operation.

[0066] The following are specific embodiments of the present invention. Unless otherwise specified, the raw materials, equipment, etc. used in the following embodiments can be obtained by purchase.

[0067] Example 1

[0068] A high-strength moored cable comprises two optical unit parts, two electrical unit parts and a reinforcement unit part. The optical unit part is a ring layer structure, comprising an optical fiber core layer, an optical fiber tight jacket layer and a metal armor layer wrapped around the optical fiber core layer in sequence; the electrical unit part is a ring layer structure, comprising a multi-core copper alloy conductor, and a first insulation layer and a second insulation layer wrapped around the multi-core copper alloy conductor in sequence, the first insulation layer is a polytetrafluoroethylene-polyimide-polytetrafluoroethylene composite tape wrapping layer, and the second insulation layer is a polytetrafluoroethylene raw tape wrapping layer; the optical unit part and the electrical unit part are flat The reinforcing unit part includes an aramid filling layer, a braided armor layer and a polytetrafluoroethylene protective layer; the aramid filling layer, the optical unit part and the electrical unit part are geometrically formed into a circle as a whole, which is recorded as a semi-finished product, and the aramid filling layer is filled outside the optical unit part and the electrical unit part; the braided armor layer is braided outside the semi-finished product, and the polytetrafluoroethylene protective layer is wrapped outside the braided armor layer; the braided armor layer includes a bulletproof aramid wire core layer composed of a plurality of bulletproof aramid wires, and a hollow silver-plated copper wire layer wrapped outside the bulletproof aramid wire core layer. The high-strength mooring cable is prepared according to the following method:

[0069] Preparation of optical unit tight-buffered optical fiber: select high-temperature resistant polyimide-coated G657D single-mode bend-insensitive optical fiber, select PTFE raw tape with a thickness of 0.08mm and a width of 15mm, control the tension of the wrapping equipment at 22N, and use multiple layers of wrapping to make the tape evenly attached to the surface of the optical fiber, with a thickness of 0.2mm.

[0070] Preparation of optical unit optical fiber armor: Place the tight-buffered optical fiber obtained in the previous step on an armored pay-off frame, adjust the pay-off tension range to 40N, and use high-strength galvanized stainless steel wire with an outer diameter range of 0.65mm, extrude it into a flat belt, and spirally wrap it on the tight-buffered optical fiber, with a spiral angle range of 60° and a spiral pitch of 0.15mm;

[0071] Preparation of electrical unit conductor layer: Use multi-core light and soft copper alloy conductor with a specification of 0.5mm 2 , using 27×0.15mm bundled wire structure, its pitch-to-diameter ratio is 16;

[0072] Preparation of the insulating dielectric layer of the electrical unit: multi-layer and multiple wrapping is adopted, firstly wrapping the polytetrafluoroethylene-polyimide-polytetrafluoroethylene composite tape, selecting 0.05mm thickness and 6.5mm width, controlling the overlap degree to 55%, then selecting 0.05mm thickness and 7.8mm width PTFE raw tape, the overlap degree is 55%, and infrared sintering is carried out at 550℃ for 30 seconds;

[0073] Preparation of cable: adopt active back-twisting pay-off frame and imported cantilever single twisting machine, supplemented by 4 1500D aramid filling flat supports on the surface of electrical unit and optical unit, and the pitch-diameter ratio is preferably 12. Use 4-core cable structure with 2 armored optical fibers and 2 wires;

[0074] Preparation of braided armor layer: Select a vertical high-speed braiding device with 120 spindles, set its braiding density to 85%, and select the diameter of the copper foil wire to be 0.10 mm;

[0075] Preparation of cable fluoroplastic sheath: Use PTFE raw tape with a thickness of 0.20mm for wrapping, adopt a unique semi-sintering process, and control the sintering temperature at 340℃.

[0076] Example 2

[0077] A high-strength moored cable comprises two optical unit parts, two electrical unit parts and a reinforcement unit part. The optical unit part is a ring layer structure, comprising an optical fiber core layer, an optical fiber tight jacket layer and a metal armor layer wrapped around the optical fiber core layer in sequence; the electrical unit part is a ring layer structure, comprising a multi-core copper alloy conductor, and a first insulation layer and a second insulation layer wrapped around the multi-core copper alloy conductor in sequence, the first insulation layer is a polytetrafluoroethylene-polyimide-polytetrafluoroethylene composite tape wrapping layer, and the second insulation layer is a polytetrafluoroethylene raw tape wrapping layer; the optical unit part and the electrical unit part are flat The reinforcing unit part includes an aramid filling layer, a braided armor layer and a polytetrafluoroethylene protective layer; the aramid filling layer, the optical unit part and the electrical unit part are geometrically formed into a circle as a whole, which is recorded as a semi-finished product, and the aramid filling layer is filled outside the optical unit part and the electrical unit part; the braided armor layer is braided outside the semi-finished product, and the polytetrafluoroethylene protective layer is wrapped outside the braided armor layer; the braided armor layer includes a bulletproof aramid wire core layer composed of a plurality of bulletproof aramid wires, and a hollow silver-plated copper wire layer wrapped outside the bulletproof aramid wire core layer. The high-strength mooring cable is prepared according to the following method:

[0078] Preparation of optical unit tight-buffered optical fiber: select high-temperature resistant polyimide-coated G657D single-mode bend-insensitive optical fiber, select PTFE raw tape with a thickness of 0.15mm and a width of 19mm, control the tension of the wrapping equipment at 25N, and use multiple layers of wrapping to make the tape evenly attached to the surface of the optical fiber, with a thickness of 0.35mm.

[0079] Preparation of optical unit optical fiber armor: Place the tight-buffered optical fiber obtained in the previous step on an armored pay-off frame, adjust the pay-off tension range to 35N, and use high-strength galvanized stainless steel wire with an outer diameter range of 0.25mm, extrude it into a flat belt, and spirally wrap it on the tight-buffered optical fiber, with a spiral angle range of 45° and a spiral pitch of 0.08mm;

[0080] Preparation of the electrical unit conductor layer: Use multi-core lightweight soft copper alloy conductor with a specification of 13mm 2 , using 161×0.32mm bundled wire structure, its pitch-to-diameter ratio is 12;

[0081] Preparation of the insulating dielectric layer of the electrical unit: multi-layer and multi-wrap, first wrap the polytetrafluoroethylene cutting tape, select 0.03mm thickness and 13mm width, overlap degree 35%, then wrap the polytetrafluoroethylene-polyimide-polytetrafluoroethylene composite tape, select 0.05mm thickness and 17.2mm width, control the overlap degree to 52%, finally select 0.064mm thickness and 22mm width PTFE raw tape for wrapping, overlap degree 70%, infrared sintering at 680℃ for 50 seconds;

[0082] Preparation of cable: Active back-twisting pay-off frame and imported cantilever single twisting machine are used, supplemented by 6 1500D aramid filling flat supports on the surface of the electrical unit and optical unit. The pitch-diameter ratio is preferably 14. A 4-core cable structure with 2 armored optical fibers and 2 wires is used;

[0083] Preparation of braided armor layer: Select a vertical high-speed braiding device with 144 spindles, set its braiding density to 85%, and select the diameter of the copper foil wire to be 0.20 mm;

[0084] Preparation of cable fluoroplastic sheath: Use PTFE raw tape with a thickness of 0.25mm for wrapping, adopt a unique semi-sintering process, and control the sintering temperature at 340℃.

[0085] Effect evaluation and performance testing

[0086] According to conventional testing methods in the field, the tethered cables obtained in Examples 1-3 were subjected to performance testing, and the testing indicators included outer diameter, weight, breaking force, temperature resistance level, bending, length, maximum operating voltage and maximum transmission current. In addition, a tethered cable (2 optical fibers, 2 24AWG wires) of conventional materials and structures on the market was taken as Comparative Example 1. The test results are shown in Table 1 below.

[0087] Table 1 Comparison of performance test results of Examples 1-3 and Comparative Example 1

[0088]

[0089] It can be seen from Table 1 that the performance of the high-strength tethered cables of Examples 1-3 is better than that of Comparative Example 1.

[0090] The above-mentioned embodiments are only preferred embodiments of the present invention and cannot be used to limit the scope of protection of the present invention. Any non-substantial changes and substitutions made by technicians in this field on the basis of the present invention shall fall within the scope of protection required by the present invention.

Claims

1. A high-strength tethered cable, characterized in that: It comprises at least one optical unit part, at least two electrical unit parts and a reinforcement unit part, wherein the optical unit part is a ring structure, comprising an optical fiber core layer, and an optical fiber tight sleeve layer and a metal armor layer wrapped around the optical fiber core layer in sequence; the electrical unit part is a ring structure, comprising a multi-core copper alloy conductor, and a first insulation layer and a second insulation layer wrapped around the multi-core copper alloy conductor in sequence; the optical unit part and the electrical unit part are arranged in parallel; the reinforcement unit part comprises a filling layer, a braided armor layer and a protective layer; the filling layer, the optical unit part and the electrical unit part are geometrically formed into a circle and are recorded as a semi-finished product, and the filling layer is filled in the place outside the optical unit part and the electrical unit part; the braided armor layer is woven outside the semi-finished product, and the protective layer is wrapped around the braided armor layer; The optical fiber tight jacket layer is a polytetrafluoroethylene raw tape wrapped layer, the single layer thickness of the polytetrafluoroethylene raw tape is 0.01-0.20 mm, the width is 2.2-19.2 mm, and the total thickness of the optical fiber tight jacket layer after wrapping is 0.1-0.50 mm; The metal armor layer is a stainless steel wire wrapping layer, the outer diameter of the stainless steel wire is 0.05-1.5 mm, the stainless steel wire is extruded into a flat belt and then spirally wrapped around the optical fiber tight sleeve layer, the spiral angle is 17-60°, and the spiral pitch is 0.08-0.15 mm; The second insulating layer is a polytetrafluoroethylene raw tape wrapping layer with an overlap width of 30% to 80%. The single layer thickness of the polytetrafluoroethylene raw tape is 0.01 to 0.20 mm and the width is 1.8 to 32 mm.

2. The high-strength tethered cable according to claim 1, characterized in that: For the optical unit part, the optical fiber core layer is a polyimide-coated single-mode optical fiber.

3. The high-strength tethered cable according to claim 1, characterized in that: For the electrical unit part, the multi-core copper alloy conductor is formed by bundling multi-core nickel-plated copper alloy conductors, and the pitch ratio is 10-16.

4. The high-strength tethered cable according to claim 1, characterized in that: For the electrical unit part, the first insulating layer is a polytetrafluoroethylene-polyimide-polytetrafluoroethylene composite tape wrapping layer, and the overlap width is 30% to 80%.

5. The high-strength tethered cable according to claim 1, characterized in that: For the reinforcement unit part, the braided armor layer includes a bulletproof aramid wire core layer composed of a plurality of bulletproof aramid wires, and a hollow silver-plated copper wire layer wrapped around the bulletproof aramid wire core layer; the number of braiding spindles of the braided armor layer is 8 to 144 spindles, and the braiding density is above 80%.

6. The high-strength tethered cable according to claim 1, characterized in that: For the reinforcement unit part, the filling layer is an aramid filling layer, and the pitch-to-diameter ratio is 8-14; the protective layer is a polytetrafluoroethylene raw tape wrapping layer, and the single-layer thickness of the polytetrafluoroethylene raw tape is 0.15-0.4 mm.

7. The high-strength tethered cable according to claim 1, characterized in that: The number of the optical unit parts and the number of the electrical unit parts are both two, and the two electrical unit parts are arranged side by side to form an electrical unit body, and the two optical unit parts are respectively arranged above and below the electrical unit body.

8. A method for preparing a high-strength tethered cable according to any one of claims 1 to 7, characterized in that: include: The steps of preparing the optical unit tight-buffered optical fiber are as follows: wrapping the optical fiber tight-buffered material around the optical fiber core layer to obtain the tight-buffered optical fiber; Optical unit metal armoring step: placing the tight-buffered optical fiber on an armored pay-off frame, taking a metal armor material, extruding the metal armor material into a flat tape, and then spirally wrapping it on the tight-buffered optical fiber to obtain an optical unit part; The steps of preparing the electrical unit conductor core are as follows: taking a plurality of copper alloy conductors and bundling them into a multi-core copper alloy conductor; The electric unit insulation layer preparation step includes: taking a first insulation layer material, wrapping the first insulation layer material around the multi-core copper alloy conductor, then taking a second insulation layer material for wrapping, and then sintering to obtain an electric unit part; Cabling step: taking the optical unit part and the electrical unit part, using an active back-twisting pay-off frame and a cantilever single twisting machine, and supporting the filling material flatly on the surface of the optical unit part and the electrical unit, and geometrically rounding the filling material, the optical unit part and the electrical unit part into a semi-finished product; The braided armor layer preparation step is: using a single-spindle single-filament braiding device to braid the braided armor material outside the semi-finished product; The protective layer preparation step is: taking the protective layer material, wrapping the protective layer material around the braided armor layer, and then semi-sintering it.

9. The method for preparing a high-strength tethered cable according to claim 8, characterized in that: In the optical unit tight-buffered optical fiber preparation step, when wrapping the optical fiber tight-buffered material, the tension of the wrapping equipment is controlled to be 1 to 25N; In the optical unit metal armoring step, the tight-buffered optical fiber is placed on an armored pay-off frame, and the pay-off tension is set to 0-40N; the helix angle of the metal armor material ranges from 17 to 60°, and the helix pitch is 0.05mm; In the step of preparing the electrical unit conductor core, setting the pitch ratio to 10 to 16; In the step of preparing the electrical unit insulation layer, when wrapping the first insulation layer material, the overlap width is set to 30% to 80%, and when wrapping the second insulation layer material, the overlap width is set to 30% to 80%; In the cabling step, the pitch ratio is set to 8 to 14; In the step of preparing the braided armor layer, the number of braiding spindles is set to 8 to 144, and the braiding density is controlled to be above 80%; In the step of preparing the protective layer, the sintering temperature is controlled to be 320-370° C. during semi-sintering.

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