A cable connection structure and method

Abstract

A cable connection structure and method, relating to the field of aircraft, the cable connection structure comprises a composite barrel and a flexible cable, the flexible cable is embedded in the composite barrel; one end of the flexible cable is connected with a front contact, the other end is connected with a rear contact and an electrical connector, the front contact is provided with a product front contact point, the product front contact point is electrically connected with the bundle cable through the printed circuit on the front contact; the flexible cable contains a printed circuit for transmitting electrical signals; one side of the rear contact is provided with a product rear contact point, the product rear contact point is electrically connected with the bundle cable through the printed circuit on the rear contact; the product front contact point and the product rear contact point protrude from the inner wall of the composite barrel, the product front contact point and the product rear contact point are in contact with the aircraft located in the composite barrel; a plurality of protruding copper points are arranged on the other side of the rear contact, the electrical connector is connected with the protruding copper points, and the electrical connector is used for connecting with the launch platform. The cable integration reliable laying and connection are realized.

Description

Technical Field

[0001] This invention belongs to the field of aircraft and relates to a cable connection structure and method. This method is mainly used in the integrated connection and forming process of flexible cables with embedded composite materials. Background Technology

[0002] During launch, the aircraft is positioned inside a composite material tube, which guides it. Traditionally, a bundle of cables is connected inside the composite material tube, which needs to be electrically connected to the aircraft to supply power or transmit signals. Each installation requires operators to plan the installation route, and the cables occupy a significant amount of space. Cable clamps are needed to secure the cables during installation, and after determining the fixing points, a threading process is required on the composite material cylinder, causing repeated processing. Repeated disassembly and reassembly of the cables easily causes damage, requiring the cables to be returned to the factory or even scrapped. One end of the bundled cable is connected to a product connector, which plugs into a socket on the aircraft. Before launch, the product connector is plugged into the socket; before launch, it is disconnected. Therefore, the product connector needs to be repeatedly plugged and unplugged. Each connection requires repeated checks and recording of both ends of the connector. If the connector is bent or otherwise damaged, the entire cable is scrapped, requiring rework and the installation of a new bundled cable. The reliability of the connector connection after plugging is poor, requiring the connectors to be wrapped with tape. The entire process is time-consuming, labor-intensive, repetitive, unreliable, and has low space utilization. Summary of the Invention

[0003] The technical problem solved by this application is to overcome the shortcomings of the prior art and provide a cable connection structure and method. It proposes to achieve reliable integrated laying and connection of cables by using a co-curing method of aircraft composite material protective cylinder and flexible cable, and adopting a riveting-like form for the connection point.

[0004] The technical solution provided in this application is as follows:

[0005] In a first aspect, a cable connection structure is provided, including a composite material cylinder and a flexible cable, the flexible cable being embedded within the composite material cylinder; one end of the flexible cable is connected to a front contact, and the other end is connected to a rear contact and an electrical connector; the front contact has a product front contact point, which is electrically connected to the bundled cable via a printed circuit on the front contact; the flexible cable contains a printed circuit for transmitting electrical signals; one side of the rear contact has a product rear contact point, which is electrically connected to the bundled cable via a printed circuit on the rear contact; the product front contact point and the product rear contact point protrude from the inner wall of the composite material cylinder and contact an aircraft located inside the composite material cylinder; the other side of the rear contact has multiple protruding copper points, and the electrical connector is connected to the protruding copper points for connection to a launch platform.

[0006] The electrical connector is provided with an annular ring, which is fitted around the outside of the protruding copper point; the electrical connector is fixed to the outer wall of the end of the composite material cylinder.

[0007] After the annular ring is fitted onto the outside of the protruding energized point, the end of the protruding copper point is thickened so that the top diameter of the protruding copper point is larger than the inner diameter of the annular ring.

[0008] The rear contact element is an arc shape that matches the shape of the composite material cylinder, so that the rear contact element is embedded in the cylinder wall of the composite material cylinder.

[0009] Both the front and rear contact members are provided with process holes, which are used to pre-fix the front and rear contact members to the composite material cylinder.

[0010] Secondly, a cable connection method is provided, including:

[0011] S1: The composite material cylinder includes a semi-finished outer cylinder and an inner cylinder. The semi-finished outer cylinder is located outside the inner cylinder. The semi-finished outer cylinder is formed first.

[0012] S2: Pre-fix the flexible cable with front and rear contacts that has qualified conductivity to the inner wall of the semi-finished outer cylinder, fix the electrical connector to the outer wall of the end of the semi-finished outer cylinder, and then connect the electrical connector to the flexible cable.

[0013] S3: Continue to form an inner cylinder on the inside of the semi-finished outer cylinder and the flexible cable to obtain an integrated composite material cylinder, thus obtaining the cable connection structure as described in any one of claims 1-6.

[0014] In step S1, a cable installation groove is reserved on the inner wall of the semi-finished outer cylinder. The cable installation groove is used to install flexible cables. The end of the semi-finished outer cylinder is provided with an installation slot that penetrates the wall thickness of the semi-finished outer cylinder so that the electrical connector for the flexible cable can be installed in the installation slot.

[0015] In step S2, the flexible cable is pre-fixed to the inner wall of the semi-finished outer cylinder, including: using screws or pins to pass through the process holes of the front contact and the rear contact and insert them into the semi-finished outer cylinder.

[0016] In step S2, after the flexible cable is pre-fixed to the inner wall of the semi-finished outer cylinder, the product front contact point on the front contact surface and the product rear contact point on the rear contact surface are protected with a protective film.

[0017] In step S3, after the molded inner cylinder becomes an integrated composite material cylinder, the protective film at the front contact point and the rear contact point of the product is removed.

[0018] In step S3, connecting the electrical connector to the flexible cable includes: fitting the annular ring of the electrical connector over the corresponding protruding copper point, and then thickening the copper point so that its top diameter is larger than the inner diameter of the annular structure connecting the electrical connector lead wire.

[0019] This invention proposes a cable connection structure and method for protective casings (i.e., composite material casings) on the outside of aircraft. The method first involves preliminary molding of the composite material casing and testing the conductivity of the flexible cable. Then, the conductive flexible cable is laid into a pre-set groove inside the composite material casing, positioned using process holes. The contact points inside the casing are protected with a protective film. A ring structure for the electrical connector lead is fitted onto the corresponding protruding copper connection point of the flexible cable (both with the same diameter). The copper point is thickened so that its top diameter is larger than the ring structure connecting the electrical connector lead, while ensuring a reliable connection between the copper point and the electrical connector lead, and conductivity is tested. The composite material casing is then further cured and molded, embedding the connection point between the copper point and the electrical connector lead into a liner, and curing it within the liner. The process positioning holes are then completed. Finally, the protective film on the contacts is removed, and the product is finished and cleaned.

[0020] This invention utilizes a composite material and flexible cable co-curing method for integral molding. The flexible cable can be bent multiple times without damage, has high space utilization, and greatly saves installation space. The flexible cable is easy to assemble and can be embedded in a tube to achieve high current, high-speed transmission, shielding, and strong interference protection wiring. By integrating the cable structure and the tube structure, stress concentration is reduced, and weight reduction is maximized while meeting strength and stiffness requirements, achieving lightweight design. A novel connection structure for cable contacts and connectors is adopted, with the connection points using a riveting-like method and co-cured within the tube structure, solving the problem of low reliability at the connection between the flexible cable contacts and connectors.

[0021] In summary, this application includes at least the following beneficial technical effects:

[0022] This invention and patented product are integrally molded using a co-curing method of composite materials and flexible cables. The flexible cables can be bent multiple times without damage, and the cable space utilization rate is high, greatly saving installation space.

[0023] This invention patents flexible cable products are easy to assemble. Embedded inside the tube, they can achieve high current, high speed transmission, shielding, and strong interference protection for wiring. By integrating the cable structure and the tube structure into one, stress concentration is reduced, and weight reduction is maximized while meeting strength and stiffness requirements, thus achieving lightweight design.

[0024] This invention patent adopts a novel connection structure for cable contacts and connectors. The connection points are riveted in a similar manner and are co-fixed within a cylindrical structure, thus solving the problem of low reliability at the connection between flexible cable contacts and connectors. Attached Figure Description

[0025] Figure 1 This is a schematic diagram of the preliminary forming of the composite material cylinder;

[0026] Figure 2 This is a schematic diagram of a flexible cable structure.

[0027] Figure 3 This is a schematic diagram of the installation process;

[0028] Figure 4 For flexible cables, protruding copper points are used.

[0029] Figure 5 The connector lead head has a ring structure;

[0030] Figure 6 To mount the electrical connector ring to the copper point;

[0031] Figure 7 This is a schematic diagram of the secondary co-curing molding of composite material cylinders.

[0032] Explanation of reference numerals: 1. Composite material cylinder; 2. Mounting slot; 3. Cable mounting slot;

[0033] 4. Front contact; 41. Front contact point of the product; 5. Flexible cable; 51. Rear contact; 52. Rear contact point of the product; 6. Process hole; 7. Protruding copper point;

[0034] 8. Electrical connector; 81. Lead wire; 82. Ring. Detailed Implementation

[0035] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments. Although various aspects of embodiments are shown in the accompanying drawings, the drawings are not necessarily drawn to scale unless specifically indicated otherwise.

[0036] This application discloses a cable connection structure and method, such as... Figures 1-3 As shown, the cable connection structure includes a composite material cylinder 1 and a flexible cable 5. The composite material cylinder 1 includes an integrally formed semi-finished outer cylinder and an inner cylinder. A cable installation groove 3 is reserved in the inner wall of the semi-finished outer cylinder. An installation slot 2 penetrating the wall thickness of the semi-finished outer cylinder is opened at the end of the semi-finished outer cylinder. The flexible cable 5 is set in the cable installation groove 3 in the inner wall of the semi-finished outer cylinder. The flexible cable 5 is connected to an electrical connector 8, which is fixed in the installation slot 2. The inner cylinder is formed inside the semi-finished outer cylinder and the flexible cable 5.

[0037] One end of the flexible cable 5 is connected to a front contact 4, and the other end is connected to a rear contact 51. The front contact 4 has a product front contact point 41, which is electrically connected to the bundled cable via a printed circuit on the front contact 4. The product front contact point 41 also makes electrical contact with the aircraft located inside the composite material cylinder 1. The flexible cable 5 contains a printed circuit for transmitting electrical signals. The rear contact 51 is arc-shaped, conforming to the shape of the inner wall of the semi-finished outer cylinder. Multiple protruding copper points 7 are provided on the outer circular surface of the rear contact 51, and these protruding copper points 7 are connected to the flexible cable 5 via a printed circuit on the rear contact 51. The multiple protruding copper points 7 are distributed sequentially along the axis of the rear contact 51, and are staggered in the circumferential direction of the rear contact 51, so that the multiple protruding copper points 7 are located on a spiral line. The rear contact point 52 is provided on the inner circular surface of the rear contact member 51. The rear contact point 52 is electrically connected to the bundled cable through the printed circuit on the rear contact member 51. The rear contact point 52 is electrically connected to the aircraft located inside the composite material cylinder 1.

[0038] Both the front contact 4 and the rear contact 51 are provided with process holes 6. By passing bolts or pins through the process holes 6 and inserting them into the semi-finished outer cylinder, the front contact 4 and the rear contact 51 can be fixed to the semi-finished outer cylinder.

[0039] Electrical connector 8 is electrically connected to protruding copper point 7. Electrical connector 8 is fixed to the outer circular surface of the end of the composite connecting cylinder and is used for electrical connection with the launch platform. The connector is equipped with a lead wire 81 and an annular ring 82. The lead wire 81 connects the annular ring 82 to the connector, and the annular ring 82 is fitted over the protruding copper point 7. After electrical connector 8 is fixed in the mounting slot 2, the annular ring 82 is fitted over the protruding copper point 7, and the copper point is thickened to complete the connection between electrical connector 8 and flexible cable 5. Then, the front contact 4 and rear contact 51 are fixed to the semi-finished outer cylinder through the process hole 6. Finally, the inner cylinder is formed inside the semi-finished outer cylinder.

[0040] When this cable connection structure is in use, the electrical connector 8 connected to the end of the composite material cylinder 1 is connected to the launch platform. The aircraft is inserted into the composite material cylinder 1. The aircraft is electrically connected to the front contact 4 and the rear contact 51 through the front contact point 41 and the rear contact point 52 of the product, respectively, so that the signal transmission during launch is: launch platform - electrical connector 8 - front contact 4 and rear contact 51 of flexible cable 5 - aircraft, realizing communication from the outside to the inside.

[0041] The cable connection structure of this application makes the electrical connection between the aircraft and the composite material cylinder 1 a contact type, avoiding plugging and unplugging, and also preventing the flexible cable 5 from being exposed, making the flexible cable 5 less prone to damage.

[0042] The cable connection method includes the following steps:

[0043] (1) Preliminary molding of composite material cylinder 1

[0044] The composite material cylinder 1 is initially formed. The initial forming of the composite material cylinder 1 only includes a portion of the outer diameter. A semi-finished outer cylinder is obtained. A cable installation groove 3 is reserved on the inner wall of the semi-finished outer cylinder. The cable installation groove 3 is used to install the flexible cable 5. The end of the semi-finished outer cylinder is provided with an installation slot 2 that penetrates the wall thickness of the semi-finished outer cylinder so that the electrical connector 8 connected to the flexible cable 5 can be installed in the installation slot 2.

[0045] (2) Testing the printing and conductivity of flexible cables.

[0046] The front contact point 41 of the product is used to contact the front end of the aircraft installed in the composite material cylinder 1. The flexible cable 5 contains printed circuits for transmitting electrical signals. The process hole 6 is used for positioning during the secondary co-curing of the composite material. The protruding copper point 7 is used to connect with the annular ring 82 of the electrical connector 8.

[0047] Measure the conductivity of flexible cable 5. If the conductivity is good, proceed to the next step.

[0048] (3) Lay the flexible cable 5 and install the electrical connector 8.

[0049] A flexible cable 5 with good conductivity is laid into the cable mounting groove 3 of the composite material cylinder 1, and positioned using the process holes 6 on the flexible cable 5. The front contact point 41 and the rear contact point 52 of the product are protected with a protective film. The electrical connector 8 is then installed into the mounting slot 2.

[0050] (4) The protruding copper point 7 is connected to the electrical connector 8.

[0051] like Figure 6 The annular ring 82 of the electrical connector 8 is fitted onto the corresponding protruding copper point 7 (the inner diameter of the annular ring 82 is the same as the diameter of the protruding copper point 7). The copper point is then thickened so that its top diameter is larger than the inner diameter of the annular structure connecting the lead wire 81 of the electrical connector 8, forming a riveted connection. The protruding copper point 7 is reliably connected to the lead wire 81 of the electrical connector 8, and the conductivity is tested.

[0052] (5) The composite material cylinder 1 is further cured and molded.

[0053] The composite material cylinder 1 is further cured and molded, that is, the inner cylinder is further molded inside the semi-finished outer cylinder and the flexible cable 5 to obtain an integrated composite material cylinder 1. The connection point of the protruding copper point 7 and the electrical connector 8 is embedded in the cylinder wall of the composite material cylinder 1 and cured into the composite material cylinder 1. At the same time, the process positioning hole is molded. After molding, the protective film at the front contact point 41 and the rear contact point 52 of the product is removed and cleaned.

[0054] The present application has been described in detail above with reference to specific embodiments and exemplary examples; however, these descriptions should not be construed as limiting the present application. Those skilled in the art will understand that various equivalent substitutions, modifications, or improvements can be made to the technical solutions and implementation methods of the present application without departing from the spirit and scope of the present application, and all such modifications and improvements fall within the scope of the present application. The scope of protection of the present application is determined by the appended claims.

[0055] The contents not described in detail in this application specification are common knowledge to those skilled in the art.

Claims

1. A cable connection structure, characterized in that, It includes a composite material cylinder (1) and a flexible cable (5), with the flexible cable (5) embedded inside the composite material cylinder (1); One end of the flexible cable (5) is connected to a front contact (4), and the other end is connected to a rear contact (51) and an electrical connector (8). The front contact (4) is provided with a product front contact point (41), which is electrically connected to the bundled cable through the printed circuit on the front contact (4). The flexible cable (5) contains a printed circuit for transmitting electrical signals. One side of the rear contact (51) is provided with a product rear contact point (52), which is electrically connected to the bundled cable through the printed circuit on the rear contact (51). The product front contact point (41) and the product rear contact point (52) protrude from the inner wall of the composite material cylinder (1) and are in contact with the aircraft located inside the composite material cylinder (1). The other side of the rear contact (51) is provided with multiple protruding copper points (7), and the electrical connector (8) is connected to the protruding copper points (7). The electrical connector (8) is used to connect to the launch platform. The rear contact member (51) is an arc shape that matches the shape of the composite material cylinder (1) so that the rear contact member (51) is embedded in the cylinder wall of the composite material cylinder (1); Both the front contact (4) and the rear contact (51) are provided with process holes (6), which are used to pre-fix the front contact (4) and the rear contact (51) to the composite material cylinder (1).

2. The cable connection structure according to claim 1, characterized in that, The electrical connector (8) is provided with an annular ring (82), which is sleeved on the outside of the protruding copper point; the electrical connector (8) is fixed to the outer wall of the end of the composite material cylinder (1).

3. The cable connection structure according to claim 2, characterized in that, After the annular ring (82) is fitted onto the outside of the protruding energized part, the end of the protruding copper point (7) is thickened so that the top diameter of the protruding copper point (7) is larger than the inner diameter of the annular ring (82).

4. A cable connection method, characterized in that, include: S1: Composite material cylinder (1) includes a semi-finished outer cylinder and an inner cylinder. The semi-finished outer cylinder is located outside the inner cylinder. The semi-finished outer cylinder is formed first. S2: Pre-fix the flexible cable (5) with front contact (4) and rear contact (51) that has qualified conductivity to the inner wall of the semi-finished outer cylinder, fix the electrical connector (8) to the outer wall of the end of the semi-finished outer cylinder, and then connect the electrical connector (8) to the flexible cable (5). S3: Continue to form an inner cylinder inside the semi-finished outer cylinder and the flexible cable (5) to obtain an integrated composite material cylinder (1) and obtain the cable connection structure as described in any one of claims 1-3.

5. A cable connection method according to claim 4, characterized in that, In step S1, a cable installation groove (3) is reserved on the inner wall of the semi-finished outer cylinder. The cable installation groove (3) is used to install the flexible cable (5). The end of the semi-finished outer cylinder is provided with an installation slot (2) that penetrates the wall thickness of the semi-finished outer cylinder so that the electrical connector (8) connected to the flexible cable (5) can be installed in the installation slot (2).

6. A cable connection method according to claim 4, characterized in that, In step S2, the flexible cable (5) is pre-fixed to the inner wall of the semi-finished outer cylinder, including: using screws or pins to pass through the process holes (6) of the front contact (4) and the rear contact (51) and insert them into the semi-finished outer cylinder.

7. A cable connection method according to claim 4, characterized in that, In step S2, after the flexible cable (5) is pre-fixed to the inner wall of the semi-finished outer cylinder, the product front contact point (41) on the surface of the front contact member (4) and the product rear contact point (52) on the surface of the rear contact member (51) are protected with a protective film. In step S3, after the molded inner cylinder is made into an integrated composite material cylinder (1), the protective film at the front contact point (41) and the rear contact point (52) of the product is removed.

8. A cable connection method according to claim 4, characterized in that, In step S3, connecting the electrical connector (8) to the flexible cable (5) includes: fitting the annular ring (82) of the electrical connector (8) onto the corresponding protruding copper point (7), and then thickening the copper point so that its top diameter is greater than the inner diameter of the annular structure of the lead wire (81) of the electrical connector (8).

Images