Heatproof integrated cable suitable for launch vehicle

Abstract

The application relates to a heat-proof integrated cable suitable for a carrier rocket and belonging to the field of cable heat-proof structure design; the cable comprises a high-temperature-resistant heat-proof integrated core wire and an alkali-free glass fiber heat-insulating sleeve pipe, the cable core wire adopts the high-temperature-resistant core wire, the heat environment adaptability of the cable itself is improved, the alkali-free glass fiber sleeve pipe is arranged outside the cable core wire bundle, the cable core wire bundle is kept in shape, and the wear resistance of the cable during use is improved. The application successfully solves the heat-proof problems of the second-stage bottom and the third-stage bottom cables of two types of carrier rockets, and simultaneously meets the requirements of heat-proof structure integration, structure lightening and high reliability.

Description

Technical Field

[0001] This invention relates to the field of thermal protection structures for electrical connectors, and more specifically, to an integrated thermal protection cable suitable for launch vehicles. Background Technology

[0002] Currently, some domestic launch vehicles adopt a thermal separation scheme for their first and second stages. For two-stage rockets, the second-stage engine ignites first during the separation process, followed by the connection and unlocking separation between the first and second stages. During the period from the second-stage engine ignition to the connection and unlocking separation, the flame from the second-stage engine directly sprays onto the front of the first stage, creating a rocket flame backflow to the tail section of the second stage. During this period, the electrical connectors inside the tail section of the second stage are subjected to the high-temperature, high-speed exhaust gas generated by the exhaust flame of the second-stage engine. The corresponding thermal scouring test conditions are a gas flow Mach number of 3, a gas flow temperature of 2000K, and a time of 1.0s. After the separation of the first and second stages, the second-stage engine continues to operate for hundreds to thousands of seconds. During this period, the thermal radiation conditions of the second-stage rocket engine are extremely severe, requiring very high thermal protection for the electrical connectors laid near the engine in the tail section of the rocket. In addition, for other configurations such as three-stage rockets, the final stage also has the characteristics of long operating time and severe thermal radiation conditions. Therefore, the tail section of the rocket's final stage generally requires a large number of thermal protection measures to ensure the normal operation of the tail section cables.

[0003] Currently, the main method for thermal protection of cables on domestic launch vehicles is to wrap them with rubber-based high-temperature insulation tape and polyimide aluminized film. The high-temperature insulation tape is used for thermal isolation, and the polyimide aluminized film is used to reflect the heat radiated to the cable surface. Since the cable needs to withstand the thermal scouring effect during the first and second stage separation, and the thermal environment in the tail section of the rocket in the subsequent flight phase is harsh, the current cable wrapping method is generally to wrap the high-temperature insulation tape twice with a semi-overlapping method, and then wrap the polyimide aluminized film three times with a semi-overlapping method. During the rocket assembly stage, a lot of manpower is required for cable wrapping. The manual semi-overlapping heat protection layer has poor processability, and it is difficult to guarantee the consistency of heat protection wrapping quality. After the cable is wrapped, due to the high density and low flexibility of the high-temperature insulation tape, the cable weight increases significantly and the flexibility is low. The increased cable weight will reduce the rocket's carrying capacity, and the low flexibility is unfavorable for cable laying and installation operations. At the same time, the heat protection layer using the semi-overlapping wrapping scheme is at risk of partial cable exposure and heat protection failure due to the interlayer movement of the protective material caused by vibration and thermal scouring during rocket flight. The overall reliability of cable heat protection is low. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and provide a solution that overcomes the problems of low operability and reliability of existing rocket cable heat protection wrapping technologies. This solution successfully addresses the thermal protection problem of launch vehicle tail section cables, achieving integrated cable production and heat protection. No additional heat protection wrapping is required during the cable delivery and use phase, thus meeting the requirements of integrated, lightweight, and highly reliable thermal protection structure.

[0005] To achieve the above objectives, the present invention provides a heat-resistant integrated cable suitable for launch vehicles, comprising a core wire with integrated insulation and heat protection design; and a sleeve fitted over the outside of the core wire, the sleeve constraining the shape of the core wire and increasing the abrasion resistance of the cable during use.

[0006] Preferably, the core wire comprises, from the inside out, a conductor, a high-temperature resistant insulation layer, an insulating adhesive, and a moisture-proof and wear-resistant layer.

[0007] Preferably, the high-temperature resistant insulation layer includes a mica winding layer and a quartz filament layer. The mica winding layer is densely wound around the outside of the conductor to form a complete cover of the conductor, and the quartz filament layer is bound to the outside of the mica winding layer.

[0008] Preferably, the insulating adhesive is a high-temperature insulating varnish layer, which is uniformly coated on the outside of the quartz filament layer, and the high-temperature insulating varnish is made by mixing modified organosilicon and silicone insulating varnish.

[0009] Preferably, the moisture-proof and wear-resistant layer is a polytetrafluoroethylene film layer, which is used to prevent the mica winding layer from getting damp and at the same time improve the wear resistance of the cable.

[0010] Preferably, the sleeve is made of alkali-free glass fiber.

[0011] Preferably, it further includes a shielding layer disposed between the insulating adhesive and the moisture-proof and wear-resistant layer, for shielding the signals generated by the core wire.

[0012] Preferably, when the modified organosilicon is heated above 250°C, it thermally decomposes to form silicon dioxide, which adheres to the surface of the silicone insulating varnish, forming a dense whole for the core wire to resist high temperatures. Compared with the prior art, the technical solution proposed in this application has the following beneficial effects: The cable structure provided by this invention can directly withstand the thermal scouring of the engine flame during the thermal separation of the first and second stages of the rocket and the long-term heat radiation of the rocket engine, effectively protecting the integrity of the overall structure, while also possessing certain heat insulation and protection performance. Thermal protection is integrated synchronously during the cable production stage, resulting in a cable with strong overall thermal protection capability. It can adapt to the comprehensive thermal environment requirements of the thermal separation thermal scouring environment of the first and second stages of the rocket and the long-term heat radiation during flight, eliminating the need for heat-resistant wrapping work after the cable is delivered to the rocket assembly stage. Attached Figure Description

[0013] Other features, objects, and advantages of the present invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings:

[0014] Figure 1 This is a schematic diagram of the overall configuration of the heat-resistant integrated cable of the present invention;

[0015] Figure 2 This is a schematic diagram of the core wire structure of the present invention;

[0016] Figure 3 This is a schematic diagram of the core wire with a shielding structure according to the present invention;

[0017] In the diagram: 1. High-temperature resistant core wire, 2. Alkali-free glass fiber sheath, 3. Conductor, 4. Mica winding layer, 5. Quartz filament layer, 6. High-temperature insulating varnish layer, 7. Polytetrafluoroethylene film layer, 8. Shielding layer. Detailed Implementation

[0018] The technical solutions in the embodiments of the present invention will be clearly and completely described and discussed below with reference to the accompanying drawings. Obviously, what is described here is only a part of the examples of the present invention, not all of them. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without creative effort are within the protection scope of the present invention.

[0019] It should be noted that when a component is described as "fixed to" another component, it can be directly on the other component or may have a component in between. When a component is described as "connected to" another component, it can be directly connected to the other component or may have a component in between. When a component is described as "set on" another component, it can be directly set on the other component or may have a component in between. The terms "vertical," "horizontal," "left," "right," and similar expressions used in this document are for illustrative purposes only.

[0020] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0021] See Figure 1 , Figure 2 and Figure 3The present invention provides a heat-resistant integrated cable suitable for launch vehicles, specifically including an alkali-free glass fiber sheath 2 and a high-temperature resistant core wire 1. The alkali-free glass fiber sheath 2 is fitted on the outside of the high-temperature resistant core wire 1. The high-temperature resistant core wire 1 includes, from the inside out, a conductor 3, a mica winding layer 4, a quartz wire layer 5, a high-temperature insulating varnish layer 6, a polytetrafluoroethylene film layer 7, and a shielding layer 8.

[0022] The high-temperature resistant core wire 1 of this invention possesses erosion resistance and high-temperature resistance, capable of withstanding the thermal erosion of the first and second stage separation of a rocket, as well as the thermal radiation from the engine exhaust plume during long-duration rocket flight. The inner layer of the core wire is a high-temperature resistant insulation layer, employing a mica winding layer 4 and a quartz fiber layer 5 with excellent insulation, high-temperature resistance, and heat insulation and fire resistance properties. A high-temperature insulating varnish layer 6 serves as the insulating adhesive, using modified organosilicon or silicone insulating varnish. Its characteristic lies in the fact that when the modified organosilicon or silicone insulating varnish reaches a temperature above 250°C, the material thermally decomposes to form silicon dioxide, which adheres to the surface of the inorganic material through the "island effect." The outer polytetrafluoroethylene film layer 7 is... The moisture-proof and wear-resistant layer primarily prevents the mica insulation layer on the inside of the wire, which is prone to absorbing water, from getting damp. At the same time, the PTFE moisture-proof and wear-resistant layer can improve the wear resistance of the wire during use and protect the high-temperature insulation layer inside the core wire. PTFE vaporizes and evaporates at high temperatures above 400℃, and the high-temperature insulation material on the outside of the core wire can ensure the normal operation of the core wire. According to the requirements of shielding the core wire in the electrical system, a shielding layer is set between the high-temperature insulating varnish layer 6 and the PTFE film layer 7 of the core wire. The outer insulation layer of the high-temperature resistant core wire uses high-temperature heat-insulating material. The core wire insulation layer and the high-temperature resistant layer are integrated into one design, achieving the goal of eliminating the need for additional wrapping of the cable product.

[0023] The outermost layer of the cable of this invention uses an alkali-free glass fiber sheath to maintain the cable's shape and increase its wear resistance during use. At the same time, it can withstand high temperatures of over 800°C, allowing it to directly withstand the thermal impact of the engine flame during the first and second stage thermal separation of the rocket and the heat radiation from the rocket engine during its long-term operation in the subsequent flight stage. This effectively protects the integrity of the overall structure and also provides a certain degree of thermal insulation and protection.

[0024] In this invention, the cable core uses a high-temperature resistant insulation layer that allows the insulation layer to remain intact after being subjected to a 1500℃ high-temperature heat flow for 3 seconds. It can pass the AC 300V / 5min withstand voltage test and insulation resistance test. At a temperature of 800℃, after 15 minutes, the external insulation coating remains intact and undamaged, and it can pass the AC 300V / 5min withstand voltage test and insulation resistance test. At a temperature of 500℃, after a working time of ≥100 hours, the external insulation coating remains intact and undamaged, and it can pass the AC 300V / 5min withstand voltage test and insulation resistance test. The thermal protection capability meets the requirements of the thermal separation and heat scouring environment of the first and second stages of the launch vehicle and the thermal radiation environment of the flight segment.

[0025] The cable of this invention uses a high-temperature resistant core wire and an alkali-free glass fiber sheath to achieve integrated heat protection. The heat protection is integrated simultaneously during the cable production stage, and the overall heat protection capability of the cable is strong. It can meet the comprehensive thermal environment requirements of the first and second stages of rockets, which are subjected to thermal separation and thermal scouring, as well as the long-term thermal radiation during the flight phase. This means that no heat protection wrapping work is required after the cable is delivered to the rocket assembly stage.

[0026] Specific embodiments of the present invention have been described above. It should be understood that the present invention is not limited to the specific embodiments described above, nor to combinations thereof. Those skilled in the art can make various changes, modifications, or combinations within the scope of the claims, which do not affect the essence of the present invention. Unless otherwise specified, the embodiments and features described in this application can be arbitrarily combined with each other.

Claims

1. A heat-resistant integrated cable suitable for launch vehicles, characterized in that, The utility model relates to a cable, which comprises a core wire, a sleeve, a shielding layer and a sheath. The core wire is made of a conductor, a high-temperature-resistant insulating layer, an insulating adhesive and a moisture-resistant wear-resistant layer. The high-temperature-resistant insulating layer comprises a mica winding layer and a quartz filament layer. The mica winding layer is tightly wound outside the conductor to form a complete covering for the conductor, and the quartz filament layer is tied outside the mica winding layer. The insulating adhesive is a high-temperature-resistant insulating paint layer, which is uniformly coated outside the quartz filament layer and is made of modified organic silicon and silicone insulating paint. The moisture-resistant wear-resistant layer is a polytetrafluoroethylene film layer, which is used to prevent the mica winding layer from being damp and improve the wear resistance of the cable. When the modified organic silicon is thermally decomposed into silicon dioxide at a temperature above 250℃, the silicon dioxide is deposited on the surface of the silicone insulating paint to form a dense whole for the core wire to resist high temperature. The sleeve is made of alkali-free glass fiber.

2. The integrated thermal protection cable for launch vehicles according to claim 1, wherein The shielding layer is arranged between the insulating adhesive and the moisture-resistant wear-resistant layer to shield the signal generated by the core wire.

3. The integrated thermal protection cable for launch vehicles according to claim 2, wherein ​

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