Cutting-resistant composite cable for aerospace and preparation method thereof

Abstract

The invention relates to the technical field of electrical equipment cables, and discloses a cutting-resistant composite cable for aerospace, which comprises a conductor, and further comprises at least one single core group; the number of the twisted-pair groups is at least one, and each twisted-pair group is composed of at least two twisted-pair core wires; the number of the shielding twisted-pair sheath groups is at least one, each shielding twisted-pair sheath group comprises a twisted-pair core wire insulating layer, a braided branch shielding layer and an inner protection layer, the twisted-pair core wire insulating layer wraps the conductor to form a twisted-pair core wire, and the two twisted-pair core wires are wrapped by the braided branch shielding layer and then wrapped by the inner protection layer after being twisted in pairs; the number of the wrapping tape layers is at least three, and the wrapping tape layers comprise two inner wrapping tape layers and an outer wrapping tape layer which are used for wrapping different cable core structures respectively; and a total braided shielding layer. The cutting-resistant composite cable for aerospace aims at solving the problems of cutting resistance, stretching resistance, flexibility, long-term use performance and the like of the cable in an aerospace environment.

Description

Technical Field

[0001] The present invention relates to the technical field of electrical equipment cables, in particular to a cutting-resistant composite cable for aerospace use and a preparation method thereof. Background Art

[0002] With the vigorous development of the aerospace industry and the continuous exploration of the boundaries of the universe, the performance requirements for aerospace components are increasing at an unprecedented rate. In the extreme and changeable aerospace environment, cables, as indispensable signal transmission and power supply carriers inside spacecraft, face particularly severe challenges. These challenges include but are not limited to extreme temperature fluctuations, from the extremely cold depths of space to the scorching solar radiation, as well as the ubiquitous cosmic radiation and vacuum environment. In order to meet the use requirements of spacecraft under complex working conditions, cables must have a series of excellent properties, among which high-strength cut resistance and tensile resistance are particularly critical. This not only requires the cable material itself to have excellent mechanical strength and toughness to resist cutting and pulling by external objects, but also requires the cable to maintain stable signal transmission and continuity of power supply after long-term stretching, bending and torsion.

[0003] In order to enhance the overall tensile strength, the traditional approach is to increase the thickness and strength of the cable sheath and internal structure, which greatly reduces the flexibility of the cable and increases the difficulty of wiring and installation. Especially in small and complex spaces, rigid cables are not only difficult to pass through, but may also damage other components. At the same time, the whole machine protection is unable to control some shear strength. In the aerospace environment, cables are easily hit by space debris or mechanically cut. Insufficient shear strength will directly cause signal interruption or power failure, endangering the operation of the spacecraft. In addition, under long-term use, the whole machine protection method is prone to cable performance degradation. The extreme conditions of the aerospace environment, such as radiation and oxidation, will weaken the mechanical and electrical properties of the cable, and there are certain defects. Summary of the invention

[0004] The purpose of the present invention is to solve the problems of cable's cut resistance, tensile strength, flexibility and long-term use performance in aerospace environment, and to propose a cut-resistant integrated cable for aerospace use and a preparation method thereof.

[0005] The technical solution of the present invention to solve the above technical problems is as follows:

[0006] A cutting-resistant composite cable for aerospace use, comprising a conductor and:

[0007] Single core group, the number of which is at least one;

[0008] There is at least one twisted pair group, wherein each twisted pair group is composed of at least two twisted core wires;

[0009] A shielded twisted pair sheath group, the number of which is at least one, each shielded twisted pair sheath group comprising a twisted core wire insulation layer, a braided sub-shielding layer and an inner sheath, the twisted core wire insulation layer is coated on the conductor to form a twisted core wire, and the two twisted core wires are twisted and then coated by the braided sub-shielding layer and then by the inner sheath;

[0010] The number of the tape layers is at least three, and the tape layers include two inner tape layers and one outer tape layer, which are used to respectively cover different cable core structures;

[0011] A total braided shielding layer, wherein the total braided shielding layer is coated on the outermost layer of all cable core structures;

[0012] A total protective layer, the total protective layer is coated on the outside of the total braided shielding layer;

[0013] The armor layers are respectively coated on the outside of the cable core structure.

[0014] Based on the above technical solution, the present invention can also be improved as follows.

[0015] Furthermore, the cable includes two cable core structures, namely cable core one and cable core two. Cable core one is formed by twisting a twisted pair group, a shielded twisted pair sheath group and aromatic polyamide fiber filling, and is covered by one of the inner tape layers. Cable core two is formed by twisting a single core group, another twisted pair group, another shielded twisted pair sheath group and aromatic polyamide fiber filling, and is covered by another inner tape layer. Cable core one and cable core two are twisted to form a preliminary structure of a multi-core cable, and an outer surface of the preliminary structure is coated with an outer tape layer, and the outer side of the outer tape layer is coated with a total braided shielding layer.

[0016] Furthermore, the conductor is a silver-plated copper conductor, and the cross-section of the conductor is between . and . square millimeters.

[0017] Furthermore, the insulation layer, inner sheath and overall sheath of the twisted core wire are all made of cross-linked fluoroplastic material, and the pitch used by the twisted pair group during the twisting process is at times of its outer diameter after twisting.

[0018] Furthermore, the braided sub-shielding layer and the overall braided shielding layer are both made of round copper wires plated with a silver layer, the single-filament diameter of these round copper wires is between .mm and .mm, and their braiding density reaches or exceeds the standard of %.

[0019] Furthermore, the two inner tape layers and the outer tape layer are both made of polyimide tape, and the armor layer adopts a double-buckle stainless steel tube, the edges of which are chamfered in a circular arc.

[0020] A method for preparing a cutting-resistant composite cable for aerospace use, characterized by comprising the following steps:

[0021] S10, preparing a conductor, treating metal wires by drawing and annealing, then coating the surface with a layer of metal, and then twisting the treated metal wires into a conductor;

[0022] S20, extruding a cross-linked fluoroplastic insulation layer on the outside of the conductor, preheating the conductor, raising the temperature of the cross-linked fluoroplastic to a melt or viscous flow state, and extruding and coating the conductor through a cone to form a twisted core wire insulation layer on the outside of the conductor, and then irradiating the twisted core wire insulation layer to form a single core group; twisting multiple single core groups to form a twisted group core wire;

[0023] S30, coating the core wires of the twisted pair group with a braided shielding layer, and extruding an inner sheath, and then irradiating the core wires to form a shielded twisted pair sheath group;

[0024] S40, twisting the twisted pair group, the shielded twisted pair sheath group and the aromatic polyamide fiber to form a cable core 1, and wrapping the inner tape layer on the outside thereof; similarly, twisting the single core group, the twisted pair group, the shielded twisted pair sheath group and the aromatic polyamide fiber to form a cable core 2, and wrapping the inner tape layer on the outside thereof; then twisting the cable core 1 and the cable core 2 to form a multi-core cable, wrapping the outer tape layer again on the outside of the multi-core cable, and coating the overall braided shielding layer, extruding the overall sheath, and finally performing irradiation treatment to obtain a finished cable;

[0025] S50. Carry out branch armoring treatment on the finished cable. Strip the total sheath, total braided shielding layer and tape layer at one end of the cable, separate the cable cores, and put a cleaned and trimmed double-buckle stainless steel armor tube on the outside of each cable core. Use argon arc welding to weld and fix the joints of the armor tubes. Then, use the injection molding process to inject hot-melt fluoroplastic into the injection mold until the mold cavity is filled to a predetermined proportion. Finally, cool the injection mold to obtain a cut-resistant integrated cable for aerospace use.

[0026] Furthermore, during the extrusion process of the cross-linked fluoroplastic insulation layer in step S20, the degumming time is 30 to 45 minutes, and the rotation speed of the main machine is between 5 and 8 revolutions per minute. In steps S20 and S30, the irradiation treatment is performed by placing the insulation layer of the twisted core wire or the shielded twisted pair sheath group on the retractable line of the irradiation equipment, and setting corresponding irradiation parameters for irradiation.

[0027] Furthermore, in step S50, the injection molding process includes heating the fluoroplastic in the barrel to a flowing state, the flowing temperature of the fluoroplastic injection molding is 290 to 300°C, the nozzle temperature is lower than the maximum flowing temperature of the fluoroplastic of 300°C, and then the fluoroplastic is pushed into the injection mold by a screw, the filling injection pressure is 14 to 16 MPa, until 94% to 96% of the mold cavity is filled, the cooling time of the injection mold is 120 to 300 seconds, and the temperature in the mold cavity is lower than 150°C.

[0028] Furthermore, the irradiation dose of the prepared cable can be adjusted according to actual needs to ensure the performance of the cable, wherein the parameters of the irradiation dose are set between 7 and 11 Mrad.

[0029] Compared with the prior art, the technical solution of this application has the following beneficial technical effects:

[0030] 1. The present invention introduces the design of a single core group and a twisted pair group, and each twisted pair group is composed of at least two twisted core wires. Such a structure not only improves the transmission efficiency of the cable, but also enhances the cable's ability to resist electromagnetic interference. The design effectively reduces the interference of the external electromagnetic field on the internal signal transmission of the cable, and ensures the stability and reliability of the signal. Secondly, the design of the shielded twisted pair sheath group includes a twisted core wire insulation layer, a braided sub-shielding layer and an inner sheath, which provides additional protection for the cable. The braided sub-shielding layer can effectively resist cutting and pulling by external objects, while reducing electromagnetic interference inside the cable. The inner sheath further enhances the durability and stability of the cable, ensuring that the cable is not easily damaged during long-term use. Furthermore, by providing at least three tape layers, including two inner tape layers and one outer tape layer, the cable is more structurally sound. It is stable and can better protect the cable core structure from damage by the external environment. At the same time, such a design also improves the flexibility of the cable, making it more flexible when wiring inside the spacecraft and easy to pass through narrow and complex spaces. In addition, the use of the total braided shielding layer and the total sheath provides comprehensive external protection for the cable. The total braided shielding layer can further enhance the cable's ability to resist electromagnetic interference, while the total sheath can resist the extreme temperature and radiation in the aerospace environment, ensuring that the cable can still work normally under harsh conditions. Finally, the armor layers are respectively coated on the outside of the cable core structure, providing the cable with additional mechanical strength and cutting resistance. In the aerospace environment, the cable may encounter impact or mechanical cutting by space debris. The presence of the armor layer can greatly reduce the damage caused to the cable by these accidents, ensuring the integrity and functionality of the cable.

[0031] 2. The present invention treats the metal wire by drawing and annealing in the process of preparing the conductor, and plates a layer of metal on the surface. Such treatment not only improves the electrical conductivity and mechanical strength of the conductor, but also enhances its corrosion resistance to the environment. Subsequently, the treated metal wires are twisted into conductors to ensure the stability and reliability of the cable when transmitting signals and electricity. Secondly, in the process of forming the insulation layer of the twisted core wires, cross-linked fluoroplastics are used as the insulating material, and through preheating, heating to a melt or viscous flow state, cone extrusion and other processes, the close bonding between the insulation layer and the conductor is ensured, thereby improving the insulation performance and temperature resistance of the cable. At the same time, the insulation layer of the twisted core wire is irradiated to further enhance its aging resistance and extend the service life of the cable. When preparing the shielded twisted pair sheath group, the core wires of the twisted pair group are coated with a braided sub-shielding layer and an extruded inner sheath, and then irradiated again. Such a design not only improves the cable's ability to resist electromagnetic interference, but also enhances its resistance to cutting and tensile strength. The introduction of the braided sub-shielding layer, When the cable is cut by external objects, it can more effectively resist the cutting force and protect the internal conductor from damage. In the process of forming the cable core and the finished cable, the twisted pair group, the shielded twisted pair sheath group and the aromatic polyamide fiber are twisted to form the cable core one and the cable core two, and the inner and outer tape layers are wrapped around the outer surface. Such a structure not only improves the softness and flexibility of the cable, but also enhances the stability and durability of its overall structure. At the same time, the addition of the total braided shielding layer and the extruded total sheath provides comprehensive external protection for the cable, further improving its resistance to cutting, tensile and environmental corrosion. Finally, in the branch armoring process of the finished cable, the high-strength cutting resistance and tensile resistance of the cable in the aerospace environment are ensured by stripping part of the outer layer structure, putting on the cleaned and trimmed double-buckle stainless steel armor tube, using argon arc welding for welding and fixing, and injection molding. This armoring treatment method not only improves the mechanical strength of the cable, but also makes it more adaptable to the extreme conditions and unexpected situations that may be encountered in the aerospace environment. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1 This is a schematic structural diagram of a cutting-resistant composite cable for aerospace use according to the present invention;

[0033] Figure 2 This is a schematic diagram of the connection structure of a cut-resistant integrated cable for aerospace use, a cable 1, a cable 2 and an armor layer of the present invention;

[0034] Figure 3 The present invention is a flow chart of a method for preparing a cut-resistant composite cable for aerospace use.

[0035] In the figure: 1. Conductor; 2. Single core group; 3. Twisted pair group; 4. Shielded twisted pair sheath group; 41. Twisted core insulation layer; 42. Braided sub-shielding layer; 43. Inner sheath; 5. Tape layer; 51. Inner tape layer; 52. Outer tape layer; 6. Overall braided shielding layer; 7. Overall sheath; 8. Armor layer; A. Cable core one; B. Cable core two. DETAILED DESCRIPTION

[0036] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0037] Combination Figure 1 to Figure 2 As shown, a cutting-resistant composite cable for aerospace use of the present invention comprises a conductor 1, and further comprises:

[0038] Single core group 2, the number of which is at least one;

[0039] A twisted pair group 3, the number of which is at least one, wherein each twisted pair group 3 is composed of at least two twisted core wires;

[0040] The shielded twisted pair sheath group 4, the number of which is at least one, each shielded twisted pair sheath group 4 comprises a twisted core wire insulation layer 41, a braided sub-shielding layer 42 and an inner sheath 43, the twisted core wire insulation layer 41 is coated on the conductor 1 to form a twisted core wire, and the two twisted core wires are twisted and coated by the braided sub-shielding layer 42 and then by the inner sheath 43;

[0041] The number of the tape layers 5 is at least three, and the tape layers 5 include two inner tape layers 51 and one outer tape layer 52, which are used to respectively cover different cable core structures;

[0042] A total braided shielding layer 6, the total braided shielding layer 6 is coated on the outermost layer of all cable core structures;

[0043] A total protective layer 7, the total protective layer 7 is coated on the outside of the total braided shielding layer 6;

[0044] The armor layers 8 are respectively coated on the outside of the cable core structure.

[0045] In a preferred embodiment, the present invention can be further configured as follows: Figure 1As shown; the cable includes two cable core structures, namely cable core 1 A and cable core 2 B. Cable core 1 A is formed by twisting a pair group 3, a shielded twisted pair sheath group 4 and aromatic polyamide fiber filling and twisting, and is covered by one of the inner tape layers 51. Cable core 2 B is formed by twisting a single core group 2, another twisted pair group 3, another shielded twisted pair sheath group 4 and aromatic polyamide fiber filling and twisting, and is covered by another inner tape layer 51. Cable core 1 A and cable core 2 B are twisted to form a preliminary structure of a multi-core cable. The outer surface of the preliminary structure is coated with an outer tape layer 52, and the outer side of the outer tape layer 52 is coated with a total braided Shielding layer 6, cable core 1 A is formed by twisting a pair group 3, a shielded twisted pair sheath group 4 and aromatic polyamide fiber filling and twisting. The twisted pair group 3 provides a basic signal transmission channel, while the shielded twisted pair sheath group 4 provides electromagnetic shielding and physical protection for it. The addition of aromatic polyamide fiber not only enhances the mechanical strength of cable core 1 A, but also improves its softness and wear resistance. This cable core structure is tightly wrapped by one of the inner tape layers 51 to ensure the stability and integrity of its structure. Cable core 2 B is composed of a single core group 2, another twisted pair group 3, another shielded twisted pair sheath group 4 and aromatic polyamide. The cable core 1A is filled with amine fibers and twisted. Similar to the cable core 1A, the cable core 2B also has excellent signal transmission capability, electromagnetic shielding effect and mechanical strength. It is also coated with another inner tape layer 51 to further consolidate its structure. After the cable core 1A and the cable core 2B are prepared, they will be twisted to form the preliminary structure of the multi-core cable. This step not only enhances the overall mechanical strength of the cable, but also improves its anti-electromagnetic interference capability and flexibility. The twisted cable core structure is more compact and stable, which is conducive to efficient signal transmission and power supply in aerospace environment. The outer surface is also coated with an outer tape layer 52, which not only provides additional physical protection for the cable, but also enhances its overall stability and durability. It fits tightly to the cable core structure, ensuring the stable performance of the cable during long-term use. Finally, the outer side of the outer tape layer 52 is coated with a total braided shielding layer 6, which provides comprehensive electromagnetic shielding protection for the cable and effectively reduces the interference of external electromagnetic fields on the internal signal transmission of the cable. This design ensures that the cable can maintain clear signal transmission and stable power supply in aerospace environments.

[0046] In a preferred embodiment, the present invention can be further configured as follows: Figure 1As shown; conductor 1 is a silver-plated copper conductor, and the cross-section of conductor 1 is between 0.08 and 3.0 square millimeters. Conductor 1 is a silver-plated copper conductor. The silver-plated copper conductor not only inherits the excellent electrical conductivity of the copper conductor, but also significantly improves its corrosion resistance and oxidation resistance due to the silver plating on the surface. This is very important for cables that work in aerospace environments for a long time. The silver plating layer can effectively prevent the increase in resistance of the copper conductor due to oxidation, thereby ensuring that the cable maintains stable signal transmission efficiency and power supply capabilities during long-term use. In addition, the cross-sectional size range of conductor 1 is specially specified, that is, between 0.08 and 3.0 square millimeters. If the cross-sectional size of conductor 1 is less than 0.08 square millimeters, although it can reduce the overall volume and weight of the cable, it may sacrifice its electrical conductivity and mechanical strength. Too small a cross-section will increase the conductor resistance and reduce the signal transmission efficiency. , in the aerospace environment, it may be damaged due to the inability to withstand external pressure or cutting force, thus affecting the reliability and service life of the cable. On the contrary, if the cross-sectional size of the conductor 1 exceeds 3.0 square millimeters, although the electrical conductivity and mechanical strength of the cable can be improved, the volume, weight and cost of the cable will be increased accordingly. An excessively large cross-section is not only not conducive to the flexible arrangement and lightweight design of the cable in the spacecraft, but may also have an adverse effect on the overall performance of the spacecraft due to its excessive volume and weight. Therefore, the cross-sectional size of the conductor 1 is precisely set between 0.08 and 3.0 square millimeters, which not only ensures that the cable has sufficient electrical conductivity and mechanical strength, but also ensures its reliability and lightweight design in the aerospace environment. This design enables the cable to efficiently and stably transmit signals and supply power in the aerospace environment, while meeting the strict requirements of the spacecraft on the volume, weight and cost of the cable.

[0047] In a preferred embodiment, the present invention can be further configured as follows: Figure 1As shown; the twisted core insulation layer 41, the inner sheath 43 and the total sheath 7 are all made of cross-linked fluoroplastic materials. The pitch of the twisted group 3 during the twisting process is 8 to 16 times the outer diameter after twisting. The twisted core insulation layer 41, the inner sheath 43 and the total sheath 7 in the cable are all made of cross-linked fluoroplastic materials. The cross-linked fluoroplastic material has excellent chemical corrosion resistance, high temperature resistance, radiation resistance and excellent mechanical properties. This material can not only effectively resist the extreme temperature and chemical corrosion in the aerospace environment, but also maintain stable performance under strong radiation conditions to ensure the long-term reliability of the cable. Specifically, the twisted core insulation layer 41 is made of cross-linked fluoroplastic material, which can ensure electrical isolation between the twisted cores and prevent signal interference and short circuit. The inner sheath 43 is also made of cross-linked fluoroplastic material, which provides additional mechanical protection and insulation barrier for the twisted group 3, thereby enhancing the durability and stability of the cable. The total sheath 7, as the outermost layer of the cable, is also made of cross-linked fluoroplastic material, which can resist physical and chemical erosion from the external environment to ensure the cable in the aerospace environment. In addition, the pitch range of the twisted pair group 3 during the twisting process is specifically specified, that is, the pitch is 8 to 16 times the outer diameter after twisting. If the pitch is less than 8 times the outer diameter after twisting, the twisting of the twisted pair group 3 will be too tight, which may cause excessive stress concentration when the cable is bent or stretched, thereby increasing the risk of cable damage. At the same time, too tight twisting may also affect the softness and flexibility of the cable, which is not conducive to the flexible arrangement and installation in the spacecraft. On the contrary, if the pitch exceeds 1 / 4 of the outer diameter after twisting, the twisting of the twisted pair group 3 will be too tight. 16 times, the twisting of twist pair group 3 will be too loose, which may increase electromagnetic interference during signal transmission and reduce the transmission efficiency of the cable. In addition, too loose twisting may also affect the mechanical strength and durability of the cable, making it unable to withstand the various challenges in the aerospace environment. Therefore, the twisting pitch of twist pair group 3 is precisely set between 8 and 16 times the outer diameter after twisting, which not only ensures the stable transmission and mechanical strength of the cable in the aerospace environment, but also ensures its softness and flexibility, meeting the strict requirements of spacecraft on cable performance.

[0048] In a preferred embodiment, the present invention can be further configured as follows: Figure 1As shown; the braided sub-shielding layer 42 and the total braided shielding layer 6 are both made of round copper wires plated with a silver layer as materials. The diameter of the single wire of these round copper wires is between 0.08 mm and 0.20 mm, and their braiding density reaches or exceeds the standard of 85%. The braided sub-shielding layer 42 and the total braided shielding layer 6 of the cable are both made of round copper wires plated with a silver layer as braiding materials. The use of silver-plated copper wires not only inherits the excellent electrical conductivity of copper wires, but also significantly improves its corrosion resistance and oxidation resistance due to the silver plating on the surface. The silver plating layer can effectively prevent the increase in resistance of the copper wire due to oxidation, thereby ensuring that the cable maintains a stable electromagnetic shielding effect during long-term use. At the same time, the single wire diameter range of the round copper wire is specially specified, that is, between 0.08 mm and 0.20 mm. If the single wire diameter of the round copper wire is less than 0.08 mm, although the volume and weight of the braided shielding layer can be reduced, its braiding density and mechanical strength may be sacrificed. Too small a single wire diameter will lead to a decrease in the braiding density of the braided shielding layer and a weakened electromagnetic shielding effect. At the same time, it may not be able to withstand the aerospace environment. The cable may be damaged by external pressure or cutting force, thereby affecting the reliability and service life of the cable. On the contrary, if the monofilament diameter of the round copper wire exceeds 0.20 mm, although the mechanical strength of the braided shielding layer can be improved, the volume, weight and cost of the cable will be increased accordingly. The monofilament diameter that is too large is not only not conducive to the flexible arrangement and lightweight design of the cable in the spacecraft, but may also have an adverse effect on the overall performance of the spacecraft due to the excessive volume and weight. In addition, the importance of braiding density is also emphasized, requiring that the braiding density of the braided sub-shielding layer 42 and the total braided shielding layer 6 both reach or exceed the standard of 85%. The high braiding density can ensure that the braided shielding layer forms a tight electromagnetic shielding network, effectively blocking the interference of the external electromagnetic field, while providing additional mechanical protection and enhancing the durability of the cable. If the braiding density is lower than 85%, the electromagnetic shielding effect of the braided shielding layer will be greatly reduced, and it will not be able to effectively resist the interference of the external electromagnetic field, which may cause confusion and distortion of the signal transmission inside the cable. At the same time, the lower braiding density may also affect the mechanical strength of the cable, making it unable to withstand the various challenges in the aerospace environment.

[0049] In a preferred embodiment, the present invention can be further configured as follows: Figure 1As shown; two inner tape layers 51 and one outer tape layer 52 are both made of polyimide tape, and the armor layer 8 adopts a double-buckle stainless steel tube with arc chamfered edges. The two inner tape layers 51 and one outer tape layer 52 in the cable are both made of polyimide tape. Polyimide tape has become an ideal tape material for aerospace cables due to its excellent high temperature resistance, radiation resistance, high strength and excellent insulation performance. It can not only effectively protect the cable core structure inside the cable and prevent physical and chemical corrosion from the external environment, but also maintain stable performance under strong radiation conditions to ensure the long-term reliability of the cable. Specifically, the inner tape layer 51 is tightly wrapped around the cable core structure to fix the cable core, isolate external interference and provide mechanical protection. By adopting the polyimide tape, the inner tape layer 51 can withstand the high temperature and strong radiation in the aerospace environment while maintaining its good flexibility and strength to ensure the stability and durability of the cable during long-term use. 52 is located on the outside of the cable core structure after the initial twisting, which further enhances the mechanical strength and cutting resistance of the cable. The high-strength characteristics of the polyimide tape enable the outer tape layer 52 to resist physical impact and cutting from the external environment, providing an additional layer of protection for the cable. In addition, the armor layer 8 adopts a double-buckle stainless steel tube, which not only has excellent corrosion resistance and high strength, but also can effectively resist various physical and chemical erosions in the aerospace environment. More importantly, the edges of the double-buckle stainless steel tube are chamfered. This detailed design not only improves the installation convenience of the armor layer 8, but also reduces the potential risk of damage to the cable due to sharp edges during use. The circular chamfering makes the edge of the double-buckle stainless steel tube smoother, reduces friction and wear with other parts of the cable, thereby extending the service life of the cable. At the same time, the smooth edge is also more conducive to the flexible arrangement and installation of the cable in the spacecraft, improving the practicality and reliability of the cable.

[0050] Conductor 1 is the core part of signal transmission or power supply and is responsible for the basic functions of the cable. In order to improve the transmission efficiency and stability of the cable, the cable also includes at least one twisted pair group 3. Each twisted pair group 3 is composed of at least two twisted core wires. The twisted core wires are formed by covering the conductor 1 with a twisted core wire insulation layer 41. The two twisted core wires are twisted again to enhance the anti-interference ability of the signal. Such a design helps to reduce electromagnetic interference and improve the clarity and accuracy of signal transmission. Outside the twisted pair group 3, a shielded twisted pair sheath group 4 is provided, which includes a twisted core wire insulation layer 41, a braided sub-shielding layer 42 and an inner sheath 43. The braided sub-shielding layer 42 can effectively resist the interference of the external electromagnetic field and provide additional mechanical protection to prevent the cable from being cut or damaged. The inner sheath 43 further enhances the durability and stability of the cable to ensure that the cable maintains excellent performance during long-term use. In order to further improve the structural stability and flexibility of the cable Softness, the cable contains at least three tape layers 5, including two inner tape layers 51 and one outer tape layer 52, these tape layers 5 are respectively coated on different cable core structures, such as single core group 2, twisted pair group 3 and shielded twisted pair sheath group 4, etc., through tight twisting and coating, a stable cable core structure is formed, and the outermost layer of all cable core structures is provided with a total braided shielding layer 6, which provides comprehensive electromagnetic shielding protection and further enhances the cable's anti-electromagnetic interference capability, and the total sheath 7 is coated on the outside of the total braided shielding layer 6, providing the cable with additional physical protection and environmental corrosion resistance. Finally, in order to further improve the mechanical strength and cutting resistance of the cable, an armor layer 8 is also provided on the outside of the cable, and the armor layer 8 is respectively coated on the outside of the cable core structure, such as the shielded twisted pair sheath group 4, etc., through strong armor materials, such as stainless steel belts or steel wires, etc., to provide strong mechanical protection for the cable, so that it can withstand extreme conditions and accidents in the aerospace environment.

[0051] A method for preparing a cutting-resistant composite cable for aerospace use comprises the following steps:

[0052] S10, preparing conductor 1, treating metal wires by drawing and annealing, then plating a layer of metal on the surface, and then twisting the treated metal wires into conductor 1;

[0053] S20, extruding a cross-linked fluoroplastic insulation layer on the outside of the conductor 1, preheating the conductor 1, raising the temperature of the cross-linked fluoroplastic to a melt or viscous flow state, and extruding and coating the conductor 1 through a cone to form a twisted core wire insulation layer 41 on the outside of the conductor 1, and then irradiating the twisted core wire insulation layer 41 to form a single core group 2; twisting a plurality of single core groups 2 to form a twisted group 3 core wires;

[0054] S30, coating the 3 core wires of the twisted pair group with a braided shielding layer 42, and extruding an inner sheath 43, and then performing irradiation treatment to form a shielded twisted pair sheath group 4;

[0055] S40, twisting the twisted pair group 3, the shielded twisted pair sheath group 4 and the aromatic polyamide fiber to form a cable core 1 A, and wrapping the inner tape layer 51 on the outside thereof; similarly, twisting the single core group 2, the twisted pair group 3, the shielded twisted pair sheath group 4 and the aromatic polyamide fiber to form a cable core 2 B, and wrapping the inner tape layer 51 on the outside thereof; then twisting the cable core 1 A and the cable core 2 B to form a multi-core cable, wrapping the outer tape layer 52 on the outside of the multi-core cable again, and coating the overall braided shielding layer 6, extruding the overall protective layer 7, and finally irradiating to obtain a finished cable;

[0056] S50. Carry out branch armoring treatment on the finished cable. Strip the total protective layer 7, the total braided shielding layer 6 and the tape layer 5 at one end of the cable, separate the cable cores, and put a cleaned and trimmed double-buckle stainless steel armor tube on the outside of each cable core. The armor tube joints are welded and fixed by argon arc welding. Then, the injection molding process is used to inject hot-melt fluoroplastic into the injection mold until the mold cavity is filled to a predetermined proportion. Finally, the injection mold is cooled to obtain a cut-resistant integrated cable for aerospace use.

[0057] In a preferred embodiment, the present invention can be further configured as follows: Figure 3 As shown; in the extrusion process of the cross-linked fluoroplastic insulation layer in step S20, the degumming time is 30 to 45 minutes, and the rotation speed of the main machine is between 5 to 8 revolutions per minute. In steps S20 and S30, the irradiation treatment is performed by placing the twisted core wire insulation layer 41 or the shielded twisted sheath group 4 on the retractable line of the irradiation equipment, and setting corresponding irradiation parameters for irradiation. In the extrusion process of the cross-linked fluoroplastic insulation layer, it is clearly stipulated that the degumming time is 30 to 45 minutes, and the rotation speed of the main machine is between 5 to 8 revolutions per minute. This setting is intended to optimize the extrusion process of the insulation layer and ensure the stable performance of the insulation layer material. By accurately controlling the degumming time and the rotation speed of the main machine, the extrusion temperature and extrusion pressure of the insulation layer can be effectively controlled, thereby avoiding the material from being damaged by temperature during the extrusion process. In addition, reasonable degumming time and rotation speed can also improve the cross-linking degree of the insulation layer, so that it has better heat resistance, chemical corrosion resistance and mechanical strength, so as to meet the high performance requirements of cables in aerospace environments. In terms of irradiation treatment, it is proposed to place the insulation layer 41 of the twisted core wire or the shielded twisted sheath group 4 at the retractable line of the irradiation equipment, and set the corresponding irradiation parameters for irradiation. By placing the material to be irradiated at the retractable line of the irradiation equipment, continuous irradiation treatment of the material can be achieved, avoiding the problem of uneven irradiation caused by improper placement of the material in the traditional irradiation method. At the same time, by accurately setting the irradiation parameters, such as irradiation dose, irradiation time, etc., it can be ensured that the material obtains the best cross-linking effect and performance improvement during the irradiation process.

[0058] In a preferred embodiment, the present invention can be further configured as follows: Figure 3 As shown; in step S50, the injection molding process includes heating the fluoroplastic in the barrel to a flowing state, the flowing temperature of the fluoroplastic injection molding is 290 to 300°C, the nozzle temperature is lower than 300°C, the maximum flow temperature of the fluoroplastic, and then the fluoroplastic is pushed into the injection mold by a screw, the filling injection pressure is 14 to 16MPa, until 94% to 96% of the mold cavity is filled, the cooling time of the injection mold is 120 to 300 seconds, and the temperature in the mold cavity is lower than 150°C. In the injection molding process of step S50, it is clearly pointed out that the heating temperature of the fluoroplastic in the barrel should be controlled between 290 and 300°C. This temperature range ensures that the fluoroplastic can be fully softened to a flowing state, which is convenient for subsequent injection molding operations, and at the same time avoids material decomposition or performance degradation caused by excessive temperature. In addition, the nozzle temperature is set to be lower than 300°C, the maximum flow temperature of the fluoroplastic. This setting not only ensures the fluidity of the fluoroplastic at the nozzle, but also prevents the nozzle temperature from being too high. The material degradation caused by high temperature is ensured, and the quality of injection molding materials is ensured. During the injection molding filling process, the filling injection pressure is specified to be 14 to 16 MPa, and the fluoroplastics are required to be filled to 94% to 96% of the mold cavity. This precise control range ensures that the fluoroplastics can fill the mold cavity evenly and fully during the injection molding process, avoiding the problem of uneven thickness or gaps in the cable sheath layer caused by insufficient filling, and also prevents material waste and mold damage caused by overfilling. In the mold cooling link, it is pointed out that the cooling time of the injection mold should be 120 to 300 seconds, and the temperature in the mold cavity should be lower than 150°C. This cooling time and temperature control strategy ensures that the fluoroplastics can be quickly and evenly cooled and solidified in the mold, forming a cable sheath layer with a dense structure and stable performance. Reasonable cooling time and temperature not only improve the strength and wear resistance of the cable sheath layer, but also help to reduce quality problems such as deformation or cracking of the sheath layer caused by uneven cooling.

[0059] In a preferred embodiment, the present invention can be further configured as follows: Figure 3As shown; the irradiation dose of the prepared cable can be adjusted according to actual needs to ensure the performance of the cable, wherein the parameters of the irradiation dose are set between 7 and 11 Mrad. By setting the adjustable range of the irradiation dose to 7 to 11 Mrad, greater flexibility is provided for cable manufacturers. In the actual production process, the performance requirements of the cable may vary depending on the application scenario, working environment or customer requirements. By adjusting the irradiation dose, the manufacturer can accurately control the key performance indicators of the cable such as cross-linking degree, mechanical strength, heat resistance, and chemical corrosion resistance to meet the use requirements in different scenarios. This improvement in flexibility not only helps to improve the overall performance of the cable, but also effectively broadens the application field of the cable. Secondly, the set irradiation dose range is 7 to 11 Mrad. This range not only ensures that the cable can obtain sufficient cross-linking degree during the irradiation process, thereby improving its mechanical strength and heat resistance, but also avoids material damage or performance degradation caused by excessive irradiation dose. In actual operation, manufacturers can select appropriate irradiation doses within this range according to the specific performance requirements of the cable to achieve the best performance balance.

[0060] Based on the above-mentioned preparation method of the aerospace cut-resistant integrated cable, different preparation parameters are taken to prepare the aerospace cut-resistant integrated cable, as shown in Table 1.

[0061] Table 1

[0062]

[0063] As can be seen from the table above, the tensile strength and elongation at break of the cables obtained in Examples 3 and 4 are significantly better than those in Examples 1, 2, and 5. The reason is that irradiation is a process of molecular chain breaking and reorganization. For products of the same specification and the same material, the greater the irradiation dose, the greater the tensile strength and the smaller the elongation at break. However, if the irradiation dose is too large, over-crosslinking will occur, and Example 5 is an over-crosslinking phenomenon. Examples 1 and 2 have not yet been fully crosslinked and have not reached the required state. The elongation at break of Example 4 has decreased, and there is an over-crosslinking trend. According to Example 3, a comprehensive aerospace cut-resistant cable that can meet the performance index requirements can be obtained.

[0064] This aerospace cut-resistant composite cable is produced using cross-linked fluoroplastics. The product has a novel design and can meet the requirements of aerospace environments. It has the advantages of high and low temperature resistance, aging resistance, radiation resistance and high reliability. The cable itself contains a signal transmission unit and an electrical unit. It is suitable for installation and laying in harsh environments such as bending and shearing. The operating temperature is -100°C to 200°C, and can meet the shear strength requirements of 320MPa and the tensile strength requirements of 200MPa.

[0065] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0066] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A cut-resistant composite cable for aerospace use, comprising a conductor (1), characterized in that: Also includes: a single core group (2), the number of which is at least one; A twisted pair group (3), the number of which is at least one, wherein each twisted pair group (3) is composed of at least two twisted core wires; A shielded twisted pair sheath group (4), the number of which is at least one, each shielded twisted pair sheath group (4) comprising a twisted core wire insulation layer (41), a braided sub-shielding layer (42) and an inner sheath (43), the twisted core wire insulation layer (41) being coated on the conductor (1) to form a twisted core wire, and the two twisted core wires are twisted and then coated by the braided sub-shielding layer (42) and then by the inner sheath (43); The number of the tape layers (5) is at least three, and the tape layers (5) include two inner tape layers (51) and one outer tape layer (52), which are used to respectively cover different cable core structures; A total braided shielding layer (6), the total braided shielding layer (6) covering the outermost layer of all cable core structures; A total protective layer (7), wherein the total protective layer (7) is coated on the outside of the total braided shielding layer (6); Armor layers (8), the armor layers (8) are respectively coated on the outside of the cable core structure.

2. The aerospace cut-resistant composite cable according to claim 1, characterized in that: The cable comprises two cable core structures, namely cable core one (A) and cable core two (B). Cable core one (A) is formed by twisting a pair group (3), a shielded pair twisted sheath group (4) and aromatic polyamide fiber filling, and is covered by one inner tape layer (51). Cable core two (B) is formed by twisting a single core group (2), another pair twisted group (3), another shielded pair twisted sheath group (4) and aromatic polyamide fiber filling, and is covered by another inner tape layer (51). Cable core one (A) and cable core two (B) are twisted to form a preliminary structure of a multi-core cable. An outer tape layer (52) is coated on the outer surface of the preliminary structure, and the outer side of the outer tape layer (52) is coated with a total braided shielding layer (6).

3. A cut-resistant composite cable for aerospace use according to claim 1 or 2, characterized in that: The conductor (1) is a silver-plated copper conductor, and the cross-section of the conductor (1) is between 0.08 and 3.0 square millimeters.

4. The aerospace cut-resistant composite cable according to claim 1, characterized in that: The twisted core wire insulation layer (41), inner protective layer (43) and overall protective layer (7) are all made of cross-linked fluoroplastic material. The pitch of the twisted pair group (3) during the twisting process is 8 to 16 times the outer diameter after twisting.

5. The aerospace cut-resistant composite cable according to claim 1, characterized in that: The braided shielding layer (42) and the overall braided shielding layer (6) are both made of round copper wires plated with a silver layer. The diameter of the single wire of the round copper wires is between 0.08 mm and 0.20 mm, and their braiding density reaches or exceeds the standard of 85%.

6. The aerospace cut-resistant composite cable according to claim 1, characterized in that: The two inner wrapping tape layers (51) and the outer wrapping tape layer (52) are both made of polyimide tape, and the armor layer (8) is a double-buckle stainless steel tube, the edges of which are chamfered in a circular arc.

7. A method for preparing the aerospace cut-resistant composite cable according to any one of claims 1 to 6, characterized in that: The following steps are involved: S10, preparing a conductor (1), treating metal wires by drawing and annealing, then coating the surface of the metal wires with a layer of metal, and then twisting the treated metal wires into a conductor (1); S20, extruding a cross-linked fluoroplastic insulation layer on the outside of the conductor (1), preheating the conductor (1), raising the temperature of the cross-linked fluoroplastic to a melt or viscous flow state, and extruding and coating the conductor (1) through a cone to form a twisted core wire insulation layer (41) on the outside of the conductor (1), and then irradiating the twisted core wire insulation layer (41) to form a single core group (2); twisting a plurality of single core groups (2) to form a twisted group (3) core wire; S30, coating the core wires of the twisted pair group (3) with a braided shielding layer (42), and extruding an inner sheath (43), and then performing irradiation treatment to form a shielded twisted pair sheath group (4); S40, twisting the twisted pair group (3), the shielded twisted pair sheath group (4) and the aromatic polyamide fiber to form a cable core 1 (A), and wrapping the inner tape layer (51) around the outer side of the cable core; similarly, twisting the single core group (2), the twisted pair group (3), the shielded twisted pair sheath group (4) and the aromatic polyamide fiber to form a cable core 2 (B), and wrapping the inner tape layer (51) around the outer side of the cable core; then twisting the cable core 1 (A) and the cable core 2 (B) to form a multi-core cable, wrapping the outer tape layer (52) around the outer side of the multi-core cable again, and covering the overall braided shielding layer (6), extruding the overall protective layer (7), and finally irradiating to obtain a finished cable; S50, the finished cable is subjected to branch armoring treatment, the total protective layer (7), the total braided shielding layer (6), and the tape layer (5) are stripped off at one end of the cable, the cable cores are separated, and a cleaned and trimmed double-buckle stainless steel armor tube is sheathed on the outside of each cable core. The joints of the armor tubes are welded and fixed by argon arc welding, and then the injection molding process is used to inject hot-melt fluoroplastic into the injection mold until the mold cavity is filled to a predetermined proportion. Finally, the injection mold is cooled to obtain a cut-resistant integrated cable for aerospace use.

8. The method for preparing a cutting-resistant composite cable for aerospace use according to claim 7, characterized in that: During the extrusion process of the cross-linked fluoroplastic insulation layer in step S20, the debonding time is 30 to 45 minutes, and the rotation speed of the main machine is between 5 and 8 revolutions per minute. In steps S20 and S30, the irradiation treatment is performed by placing the twisted core wire insulation layer (41) or the shielded twisted pair sheath group (4) at the retractable line of the irradiation equipment and setting corresponding irradiation parameters for irradiation.

9. The method for preparing a cutting-resistant composite cable for aerospace use according to claim 1, characterized in that: The injection molding process in step S50 includes heating the fluoroplastic in the barrel to a flowing state, the flowing temperature of the fluoroplastic injection molding is 290 to 300°C, the nozzle temperature is lower than the maximum flowing temperature of the fluoroplastic of 300°C, and then the fluoroplastic is pushed into the injection mold by a screw, the filling injection pressure is 14 to 16MPa, until 94% to 96% of the mold cavity is filled, the cooling time of the injection mold is 120 to 300 seconds, and the temperature in the mold cavity is lower than 150°C.

10. A method for preparing a cutting-resistant composite cable for aerospace use according to any one of claims 6 to 9, characterized in that: The irradiation dose of the prepared cable can be adjusted according to actual needs to ensure the performance of the cable, wherein the parameters of the irradiation dose are set between 7 and 11 Mrad.

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