A monolithic high temperature thermal protection cable assembly

Abstract

The application discloses a whole high-temperature heat protection cable assembly, which comprises a wire bundle and a plurality of branch wire bundles separated from the wire bundle, connectors arranged at the ends of the wire bundle and the branch wire bundles, corresponding high-temperature resistant sleeves sleeved on the wire bundle and the branch wire bundles, heat-proof covers sleeved on the connectors, the wire bundle and the branch wire bundle near the junction of the wire bundle and the branch wire bundle forming a bifurcation part, the wire bundle and the branch wire bundle of the bifurcation part being wound with two or more layers of silicon-based heat-proof cloth, and organic silicone glue coating being arranged between the silicon-based heat-proof cloth. Compared with the prior art, the application adopts integrated high-temperature resistant sleeves, heat-proof covers special for the connectors and integrated, winds the silicon-based heat-proof cloth at the bifurcation part and applies the organic silicone glue, so that the assembly efficiency and reliability are improved, and the weight is light. Meanwhile, the process forming applicability is good, the softness is high, the total assembly laying and fixing of the cable assembly are facilitated, the heat-proof layer of the assembly can realize seamless connection, and the heat flow resistance is obviously improved.

Description

Technical Field

[0001] This invention relates to a cable assembly, specifically to an integrated high-temperature thermal protection cable assembly. Background Technology

[0002] When an aircraft flies in the atmosphere, aerodynamic heating is extremely severe. A heat protection system with ablation resistance is an essential element to ensure the safe and successful completion of flight missions. Therefore, the cable assembly must be able to resist heat flow erosion as a whole, and the cable must be flexible and reliable.

[0003] To achieve overall resistance to thermal runaway, current technology primarily employs a method of first wrapping thermal insulation material around the outer surface of the cable conductors, followed by wrapping with heat-resistant material. For structural details, please refer to [link to relevant documentation]. Figure 1 and Figure 2 The cable harness is divided into multiple branches, with connectors installed at the ends of both the main cable harness and the branches. A shielding layer, a heat insulation layer, and a heat-resistant layer are sequentially wrapped around the outside of the main cable harness and the branches. The shortcomings of the existing technology are: the cable is wound in a strip-like manner, and to achieve better heat protection and ensure the gaps at the branch points are protected as much as possible, multiple layers of heat insulation and heat-resistant layers are required, which is laborious and time-consuming; moreover, the increased diameter, stiffness, and weight of the cable increase the load on the aircraft; after the cable hardens, it is not easy to bend and fix, and during use, bending the cable can easily cause the heat insulation and heat-resistant layers to loosen or crack, leading to unreliable factors; the connectors are irregularly shaped, and the branched cable harness makes it difficult to achieve a good seal even with multiple wrappings, ultimately failing to achieve a good heat protection effect. Summary of the Invention

[0004] To address the technical problems of complex processing, heavy weight, high rigidity, and poor heat protection of the aforementioned cable assemblies, this invention provides an integrated high-temperature heat protection cable assembly.

[0005] The objective of this invention is achieved through the following technical solution. According to this invention, an integrated high-temperature heat-protected cable assembly includes a conductor bundle and multiple branch conductor bundles branching from the conductor bundle. Connectors are provided at the ends of the conductor bundle and branch conductor bundles. Corresponding high-temperature resistant sleeves are fitted onto the conductor bundle and branch conductor bundles. Heat shields are fitted onto the connectors. The conductor bundles and branch conductor bundles near the junction of the conductor bundle and branch conductor bundles form a bifurcation section. The conductor bundles and branch conductor bundles at the bifurcation section are wrapped with two or more layers of silicone-based heat-resistant fabric, with an organic silicone coating between the layers of the silicone-based heat-resistant fabric.

[0006] Furthermore, the silicon-based heat-resistant cloth includes alkali-free glass fiber cloth and quartz fiber cloth. A shielding layer is provided on the outside of the wire bundle and branch wire bundle. From the inside to the outside of the shielding layer of the wire bundle and branch wire bundle at the bifurcation point, alkali-free glass fiber cloth is wrapped, an organic silicone coating is applied, and quartz fiber cloth is wrapped.

[0007] Furthermore, the alkali-free glass fiber cloth, silicone coating, and quartz fiber cloth cover the end of the high-temperature resistant sleeve near the bifurcation, with a coverage length of at least 30 mm, and the silicone coating covers the gap of the bifurcation.

[0008] Furthermore, the bifurcation section is wrapped with alkali-free glass fiber cloth and quartz fiber cloth in a 1 / 2 half-overlap manner. The end of the quartz fiber cloth is tied and fixed with alkali-free glass fiber rope, and the gap at the end of the quartz fiber cloth is coated with silicone.

[0009] Furthermore, the rear end of the heat shield is fitted onto the corresponding high-temperature resistant sleeve, and the front end of the heat shield is fitted onto the connector. The inner diameter of the front end of the heat shield is larger than the inner diameter of the rear end.

[0010] Furthermore, the heat shield consists of an aluminum-plated cloth layer, an organic silicone layer, and an alkali-free glass fiber layer, from the outside to the inside.

[0011] Furthermore, the high-temperature resistant sleeve is made of quartz fiber, organosilicon, and alkali-free glass fiber. The alkali-free glass fiber is woven into a tube, coated with organosilicon on the outside, and wrapped with quartz fiber on the outside of the organosilicon.

[0012] Furthermore, the rear end of the heat shield is fitted onto the end of the corresponding high-temperature resistant sleeve, and the heat shield and the high-temperature resistant sleeve are tied and fixed with steel cable ties. Organic silicone is brushed onto the gap at the joint between the heat shield and the high-temperature resistant sleeve.

[0013] Furthermore, the distance between the rear end of the heat shield and the end of the high-temperature resistant sleeve is at least 30 mm.

[0014] Compared with the prior art, the advantages of the present invention are:

[0015] Compared with existing technologies, this invention uses an integrated high-temperature resistant sleeve, a connector-specific and integrated heat shield, and wraps silicone-based heat shield cloth around the bifurcation point and applies silicone, which improves assembly efficiency and reliability, and is lightweight; at the same time, the process has good applicability and high flexibility, which facilitates the overall assembly, laying and fixing of cable assemblies; the heat shield layer of this component can achieve seamless connection, and the heat flow resistance is significantly improved.

[0016] The above description is merely an overview of the technical solution of the present invention. In order to better understand the technical means of the present invention and to implement it in accordance with the contents of the specification, and to make the above and other objects, features and advantages of the present invention more apparent and understandable, preferred embodiments are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0017] Figure 1 This is a schematic diagram of a cable assembly using existing technology.

[0018] Figure 2 for Figure 1 A schematic diagram of the cable layering in the cable assembly shown;

[0019] Figure 3 This is a schematic diagram of an embodiment of an integral high-temperature thermal protection cable assembly according to the present invention;

[0020] Figure 4 for Figure 3 A schematic diagram of the cable layering at the middle branch point;

[0021] Figure 5 for Figure 3 Schematic diagram of the central heat shield;

[0022] Figure 6 for Figure 5 The left view;

[0023] Figure 7 for Figure 5 A schematic diagram of the radial section at point A.

[0024] [Attached image labels]

[0025] 1-Connector, 2-Heat shield, 301-First high-temperature resistant sleeve, 302-Second high-temperature resistant sleeve, 4-Alkali-free fiberglass cloth, 5-Organic silicone coating, 6-Quartz fiber cloth, 7-Alkali-free fiberglass layer, 8-Aluminum-plated cloth layer, 9-Wire, 10-Shielding layer, 11-Heat insulation layer, 12-Heat protection layer, 13-Bifurcation part, 14-Organic silicone layer, 15-Wire harness, 16-Branch wire harness. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] An embodiment of an integral high-temperature thermal protection cable assembly of the present invention, hereinafter referred to as the assembly, is as follows: Figures 3 to 7 As shown. The component includes connector 1, integrated heat shield 2, integrated heat protection sleeve, silicone-based heat-resistant fabric, and wire 9.

[0028] The cable of this component contains multiple conductors 9, which form a conductor bundle 15. The conductor bundle branches into multiple conductors or conductor bundles at a fork 13, forming a branch conductor bundle 16. Both the conductor bundle 15 and the branch conductor bundle 16 are provided with a shielding layer on the outside, and a heat-insulating layer is provided outside the shielding layer. Connectors 1 are provided at the ends of the conductor bundle 15 and the ends of the branch conductor bundle 16.

[0029] To ensure the overall heat resistance of the cable assembly, a heat shield 2, a high-temperature resistant sleeve, and a silicone-based heat-resistant cloth are used as heat-resistant layers to protect the connector 1, the conductor 9, and the branch section 13, respectively. At least two layers of silicone-based heat-resistant cloth are provided, and an organic silicone coating 5 is provided between the two layers of silicone-based heat-resistant cloth, thereby achieving overall protection of the cable assembly.

[0030] The bifurcation section 13 is the portion of the conductor bundle 15 and branch conductor bundle 16 near the junction of the conductor bundle and the branch conductor bundle, such as... Figure 3 As shown, the lengths of the conductor bundle 15 and branch conductor bundle 16 in the bifurcation section 13 are determined based on their own outer diameter and the diameter of the high-temperature resistant sleeve, or according to the assembly process. The conductor bundle 15 and branch conductor bundle 16 in the bifurcation section 13 are protected with silicone-based heat-resistant cloth and an organic silicone coating 5 to ensure that the cable assembly can be bent and fixed normally at the bifurcation after the heat-resistant layer is installed. The conductor bundle 15 and branch conductor bundle 16 have different outer diameters, and high-temperature resistant sleeves of different diameters are used.

[0031] The silicon-based heat-insulating cloth includes alkali-free glass fiber cloth 4 and quartz fiber cloth 6. From the inside out, the silicon-based heat-insulating cloths wrapped around the shielding layer of the conductor bundle 15 and branch conductor bundle 16 at the bifurcation point 13 are alkali-free glass fiber cloth 4 and quartz fiber cloth 6, respectively. After the alkali-free glass fiber cloth 4 is wrapped, an organic silicone coating 5 is applied to the outside of the alkali-free glass fiber cloth 4 to form a high-temperature insulation layer. Then, quartz fiber cloth 6 is wrapped around the outside of the organic silicone coating 5. The quartz fiber cloth 6 prevents the entry of high-temperature, high-pressure combustion gases. Before the high-temperature insulation layer carbonizes, the alkali-free glass fiber cloth 4 blocks external heat flow, improves the reflectivity of the heat-insulating layer surface, and enhances the heat-insulating effect. The alkali-free glass fiber cloth 4 and quartz fiber cloth 6 are wrapped as close as possible to the boundary between the branch conductor bundle 16 and conductor bundle 15 in the bifurcation point. When applying the organic silicone, the organic silicone coating 5 covers the gaps in the bifurcation point 13. Due to the presence of the silicone coating 5, the gaps between the bifurcated conductors can be sealed, avoiding the gaps that occur at the bifurcated section when only silicone-based heat-insulating cloth is wrapped. Therefore, only one layer of alkali-free glass fiber 4 and quartz fiber cloth 6 is needed to seal the gaps at the bifurcated section, reducing the amount of wrapping, thereby reducing processing time, reducing the weight of the cable assembly, and reducing the load on the aircraft. Because the amount of silicone-based heat-insulating cloth wrapped is reduced, the silicone coating has better flexibility, which reduces the overall thickness of the heat-insulating layer on the outside of the conductor, making it easier to bend and ensuring the flexibility of the cable assembly. This avoids unreliable factors such as loosening and cracking when the cable assembly is bent and fixed. Furthermore, in the prior art, even if the heat insulation layer and heat-insulating layer are wrapped in multiple layers, it is still impossible to avoid the gaps at the bifurcated section. However, the use of silicone can completely seal the gaps at the bifurcated section. That is, the present invention can achieve the sealing of the bifurcated section with less wrapping and lighter weight, thereby achieving a better heat protection effect.

[0032] To address the connector protection issue, a heat shield is designed to match the connector's shape, ensuring a tight fit and providing thermal protection without affecting mating. The rear end of the heat shield 2 matches a corresponding high-temperature resistant sleeve, allowing it to be fitted over the sleeve. The front end of the heat shield 2 matches the outer contour of the connector 1, with the connector 1 nested within it. The inner diameter of the front end of the heat shield 2 is larger than that of the rear end, facilitating installation. During installation, the rear end of the connector 1 enters from the front end of the heat shield 2, ensuring complete nesting. The structure of the heat shield 2, from the outside in, consists of an aluminized cloth layer 8, an silicone rubber layer 14, and an alkali-free glass fiber layer 7. The aluminized cloth layer 8 reflects heat, while the silicone rubber layer 14 and the alkali-free glass fiber layer 7 provide thermal insulation, offering excellent thermal protection for the connector.

[0033] High-temperature resistant sleeves are fitted over the wire harness 15 or branch wire harness 16 between the branch section 13 and the connector 1. The wire harness 15 is fitted with a first high-temperature resistant sleeve 301, and the branch wire harness 16 is fitted with a second high-temperature resistant sleeve 302. The high-temperature resistant sleeves are made of quartz fiber, silicone, and alkali-free glass fiber. The alkali-free glass fiber is woven into a tube, then coated with silicone on the outside, and then wrapped with quartz fiber on the outside. In use, the wire harness or branch wire harness is threaded through the corresponding high-temperature resistant sleeve to achieve thermal protection for the wire harness or branch wire harness.

[0034] The rear end of the heat shield 2 is fitted onto the end of the corresponding high-temperature resistant sleeve. The length of the high-temperature resistant sleeve end covered by the rear end of the heat shield 2 is at least 30mm. The heat shield 2 and the corresponding high-temperature resistant sleeve are tied and fixed with steel cable ties. The gap at the joint between the heat shield 2 and the high-temperature resistant sleeve is sealed with silicone. When the branch wire bundles 16 and 15 of the bifurcation section 13 are wrapped with alkali-free glass fiber cloth 4 and quartz fiber cloth 6, the alkali-free glass fiber cloth 4 and quartz fiber cloth 6 cover the end of the high-temperature resistant sleeve near the bifurcation section. When applying the silicone coating 5, it also covers the end of the high-temperature resistant sleeve near the bifurcation section, so that the wire bundles and branch wire bundles are completely sealed. The length of the alkali-free glass fiber cloth 4, quartz fiber cloth 6, and silicone coating 5 covering the end of the corresponding high-temperature resistant sleeve is at least 30mm.

[0035] Cable assembly process: The conductor bundle 15 and branch conductor bundle 16 are respectively threaded into their corresponding high-temperature resistant sleeves. Then, multiple heat shields 2 are respectively fitted onto the corresponding high-temperature resistant sleeves, with the front end of the heat shield 2 facing the end of the corresponding conductor bundle 15 or branch conductor bundle 16. Multiple connectors 1 are respectively connected to the corresponding conductor bundle 15 or branch conductor bundle 16. Then, the heat shield 2 is moved towards the connector 1, so that the connector 1 is nested inside the heat shield 2. The rear end of the heat shield 2 covers the end of the corresponding high-temperature resistant sleeve by a distance of 30mm. Then, the rear end of the heat shield is secured with steel cable ties. Organic silicone is applied to the gap at the junction of the heat shield and the high-temperature resistant sleeve to achieve sealing and heat protection at the junction of the connector and the corresponding conductor bundle or branch conductor bundle. The high-temperature resistant sleeve at the branching point and near the branching point adopts a 1 / 2 half-lap type. The alkali-free fiberglass cloth 4 is wound in the following manner: when winding the alkali-free fiberglass cloth, it is wound along the direction of the conductor bundle or branch conductor bundle. Each time it is wound, the previous turn of the alkali-free fiberglass cloth is covered by the next turn of the alkali-free fiberglass cloth, and the width of the cover is half the width of the alkali-free fiberglass cloth. After the alkali-free fiberglass cloth 4 covers the conductor bundle or branch conductor bundle at the bifurcation, an organic silicone coating 5 is brushed on. In this embodiment, the coating thickness is 2mm. Then, a layer of quartz fiber cloth 6 is wound on the outside of the organic silicone coating in a 1 / 2 half-overlap manner. The ends of the quartz fiber cloth 6 are tied and fixed with alkali-free fiberglass rope, and organic silicone is applied to the gaps at the ends of the quartz fiber cloth 6 and the gaps at the bifurcation to achieve sealing of the bifurcation, thereby achieving the overall sealing performance of the cable, resistance to heat flow erosion, and ensuring flexibility.

[0036] Compared with existing technologies, this invention employs an integrated high-temperature resistant sleeve, a connector-specific heat shield, and wrapping coating at the bifurcation point, improving assembly efficiency and reliability. It is also lightweight, with good process applicability and high flexibility, facilitating the overall assembly, laying, and fixing of cable assemblies. The heat shield layer of this assembly can achieve seamless connection, significantly improving heat flow resistance. Notably, the silicon-based heat shield cloth in this invention only requires two layers to achieve the heat flow erosion resistance performance achieved by wrapping multiple layers of heat insulation and heat shield in existing technologies. This invention achieves the heat flow resistance performance of existing technologies while improving production efficiency and reducing product weight.

[0037] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An integral high-temperature thermal protection cable assembly, comprising a conductor bundle and multiple branch conductor bundles branching from the conductor bundle, wherein connectors are provided at the ends of the conductor bundle and the branch conductor bundles, characterized in that: The lead wire harness and branch lead wire harness are fitted with corresponding high-temperature resistant sleeves, and the connector is fitted with a heat shield. The lead wire harness and branch lead wire harness near the junction of the lead wire harness and branch lead wire harness form a bifurcation section. The lead wire harness and branch lead wire harness at the bifurcation section are wrapped with two or more layers of silicone-based heat-resistant cloth, and an organic silicone coating is applied between the silicone-based heat-resistant cloths. The silicone-based heat-resistant cloth includes alkali-free glass fiber cloth and quartz fiber cloth. A shielding layer is provided on the outside of the lead wire harness and branch lead wire harness, and is wrapped sequentially from the inside to the outside of the shielding layer of the lead wire harness and branch lead wire harness at the bifurcation section. Alkali-free glass fiber cloth, coated with silicone coating, and wrapped with quartz fiber cloth; after the alkali-free glass fiber cloth (4) is wrapped, silicone coating (5) is applied to the outside of the alkali-free glass fiber cloth (4) to form a high-temperature insulation layer, and then quartz fiber cloth (6) is wrapped around the outside of the silicone coating (5); when applying silicone to the alkali-free glass fiber cloth (4) and quartz fiber cloth (6) near the junction of the branch wire bundle (16) and the wire bundle (15) in the bifurcation part, the silicone coating (5) covers the gap of the bifurcation part (13).

2. The integral high-temperature thermal protection cable assembly according to claim 1, characterized in that: The alkali-free glass fiber cloth, silicone coating, and quartz fiber cloth cover the end of the high-temperature resistant sleeve near the bifurcation, with a coverage length of at least 30mm, and the silicone coating covers the gap at the bifurcation.

3. The integral high-temperature thermal protection cable assembly according to claim 1, characterized in that: The bifurcation section is wrapped with alkali-free glass fiber cloth and quartz fiber cloth in a 1 / 2 half-overlap manner. The end of the quartz fiber cloth is tied and fixed with alkali-free glass fiber rope, and the gap at the end of the quartz fiber cloth is coated with silicone.

4. The integral high-temperature thermal protection cable assembly according to claim 1, characterized in that: The rear end of the heat shield is fitted onto the corresponding high-temperature resistant sleeve, and the front end of the heat shield is fitted onto the connector. The inner diameter of the front end of the heat shield is larger than the inner diameter of the rear end.

5. The integral high-temperature thermal protection cable assembly according to claim 4, characterized in that: The heat shield consists of an aluminum-coated cloth layer, an organic silicone layer, and an alkali-free glass fiber layer, from the outside to the inside.

6. The integral high-temperature thermal protection cable assembly according to claim 1, characterized in that: The high-temperature resistant sleeve is made of quartz fiber, organosilicon, and alkali-free glass fiber. The alkali-free glass fiber is woven into a tube, coated with organosilicon on the outside, and wrapped with quartz fiber on the outside of the organosilicon.

7. The integral high-temperature thermal protection cable assembly according to claim 1, characterized in that: The rear end of the heat shield is fitted onto the end of the corresponding high-temperature resistant sleeve, and the heat shield and the high-temperature resistant sleeve are tied and fixed with steel cable ties. Organic silicone is brushed onto the gap at the joint between the heat shield and the high-temperature resistant sleeve.

8. The integral high-temperature thermal protection cable assembly according to claim 7, characterized in that: The distance between the rear end of the heat shield and the end of the high-temperature resistant sleeve is at least 30 mm.

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