A branch type shipboard cable and its manufacturing method

Abstract

The present invention relates to the field of cable technology, and discloses a branch-type shipboard cable, comprising: single-core groups, the number of which is at least two; single-core shielding groups, the number of which is at least twenty-four, each single-core shielding group uses tinned copper wire to weave a shielding layer on the outer layer of the conductor; twisted pairs groups, the number of which is at least six and is equally divided into three groups, each twisted pair group is composed of at least two twisted core wires; twisted pair shielding groups, the number of which is at least eight and is equally divided into four groups, each twisted pair shielding group is composed of at least two twisted core wires, and each twisted pair core wire has a twisted core wire insulation layer coated on the conductor and a braided shielding layer coated on the two twisted core wires after being twisted; and tape layers, the number of which is at least two, which are wrapped before braiding and after braiding respectively. The purpose of the branch-type shipboard cable and its manufacturing method is to solve the defects of the existing branch-type shipboard cables in terms of structural design, material properties, cable core protection, and adaptability to application environments.

Description

Technical Field

[0001] The invention relates to the technical field of cables, in particular to a branch-type shipboard cable and a manufacturing method thereof. Background Art

[0002] Branching marine cable is a high-performance cable designed for ship power systems. It integrates multi-core conductors, multiple shielding and special sheath layer structure to meet the high reliability and safety requirements in complex marine environments. The cable uses tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA) as insulation material, and has excellent temperature resistance, corrosion resistance and flame retardant properties. Through fine twisting, braided shielding and multi-layer twisting technology, it effectively reduces electromagnetic interference and signal attenuation, ensuring the stability and clarity of power and signal transmission. The specially designed branching structure facilitates flexible branching in the complex wiring inside the ship, and the branch is vulcanized to enhance the mechanical strength and waterproof performance of the cable. The outer total braided shielding layer and sheath layer provide additional protection to resist the erosion of the marine environment and extend the service life of the cable. Branching marine cable has become an indispensable component of modern ships with its excellent comprehensive performance.

[0003] Existing branch-type marine cables have some significant defects. First, their structure is often relatively simple and lacks multi-level design, which leads to limited transmission efficiency and insufficient mechanical properties. They are easily interfered with by transmission parameters between coaxial cables, affecting signal stability and clarity. Secondly, traditional cables are insufficient in protecting the cable core from damage by the external environment. The selection of wrapping materials and process treatment are not sophisticated enough, which makes the cables easily damaged in the complex and changeable ship environment, reducing their service life. In addition, the insulation layer materials of existing cables have limited performance and cannot simultaneously meet multiple requirements such as chemical corrosion resistance, high temperature resistance, and radiation resistance, which limits the application of cables under extreme conditions. The selection of braiding materials often ignores the improvement of corrosion resistance and welding performance, affecting the overall performance of the cable. Summary of the invention

[0004] The purpose of the present invention is to solve the defects of the existing branch type shipboard cable in terms of structural design, material performance, cable core protection and adaptability to application environment, and to propose a branch type shipboard cable and a manufacturing method thereof.

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

[0006] A branch type shipboard cable, comprising:

[0007] Single core group, the number is at least two;

[0008] Single-core shielding groups, the number of which shall be at least twenty-four, each of which shall use tinned copper wire to form a braided shielding layer on the outer layer of the conductor;

[0009] The number of twisted pairs is at least six and is divided into three groups, each of which is composed of at least two twisted pairs of core wires;

[0010] Twisted shielding groups, the number of which is at least eight and is equally divided into four groups, each of which is composed of at least two twisted core wires, and each twisted core wire has a twisted core wire insulation layer coated on the conductor and a braided sub-shielding layer coated after the two twisted core wires are twisted;

[0011] The number of the wrapping tape layers is at least two, and the wrapping tape is performed before weaving and after weaving respectively;

[0012] The overall braided shielding layer covers the outermost layer of all cable core structures;

[0013] The overall sheath layer is covered on the outside of the overall braided shielding layer;

[0014] Among them, the cable is branched in a straight line to form branch one and branch two. Branch one consists of two single-core groups and is covered with a wave-proof sleeve and a polyurethane sheath. Branch two consists of six twisted-pair groups, six twisted-pair shielded groups, and twenty-four single-core shielded groups and is covered with a wave-proof sleeve and a polyurethane sheath. The branch lines are vulcanized.

[0015] Based on the above technical solution, the present invention can also be improved as follows.

[0016] Furthermore, the cable comprises a three-layer cable core structure;

[0017] The first layer of cable core structure is composed of a group of twisted shielded cable cores and twelve single-core shielded cable cores.

[0018] The first layer of cable core structure is further twisted with another twelve single-core shielding groups and seven low-density polyester tapes, and then wrapped with a layer of polyester tape to form a second layer of cable core structure;

[0019] The second-layer cable core structure is twisted with four twisted-pair groups, seven twisted-pair shielded groups and two single-core groups, and after the twisting is completed, a layer of non-woven fabric is wrapped around it to form a third-layer cable core structure.

[0020] Furthermore, the conductor is a silver-plated copper conductor, and the cross-section of the conductor is between 0.35 and 3.0 square millimeters.

[0021] Furthermore, the insulating layers in the single-core group, the single-core shielding group, the twisted-pair group, and the twisted-pair shielding group are all made of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer material.

[0022] Furthermore, the twisted pair shielding group, the single core shielding group and the overall braided shielding layer are all braided with tinned copper twisted wires, the braided wire diameter is 0.1 to 0.2 mm, and the braiding density is greater than or equal to 85%.

[0023] Furthermore, the total sheath layer is made of polyether polyurethane elastomer, the sheath thickness is 2.0 mm, and the thinnest thickness is 1.7 mm.

[0024] A method for manufacturing a branched marine cable comprises the following steps:

[0025] S10, covering the outer layer of the conductor with an insulating layer composed of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA) through an extrusion process, thereby preparing a single core group, and then twisting two single core groups to form a twisted pair group;

[0026] S20, performing a braided shielding process on the outer surface of the single core group to obtain a single core shielding group, and similarly, performing a braided shielding process on the outer surface of the twisted pair group to form a twisted pair shielding group;

[0027] S30, twisting the twisted shielding group and the single-core shielding group to form a first-layer cable core, then twisting the first-layer cable core with the single-core shielding group and the low-density raw tape, and wrapping a layer of polyester tape on the outer layer to form a tape layer, thereby obtaining a second-layer cable core, and then twisting the second-layer cable core with the twisted pair group, the twisted pair shielding group, the radio frequency group and the data line, and wrapping a layer of non-woven fabric on the outer layer, finally obtaining a third-layer cable core;

[0028] S40, weaving a total braided shielding layer on the outer surface of the third layer of cable core, and then wrapping a layer of non-woven fabric on the outer layer again, and finally, covering the outer layer of the non-woven fabric with a total sheath layer through an extrusion process, thereby obtaining a complete cable product;

[0029] S50. Perform branching treatment on the portion of the main cable line that needs to be branched, and perform vulcanization treatment on the branch after branching to enhance its performance.

[0030] Furthermore, in step S30, the wrapping specification of the polyester tape is 1*35*0.05mm, and the left-hand wrapping method is adopted, and the overlap rate is controlled between 20%-30%. At the same time, the wrapping specification of the non-woven fabric is 1*40*0.10mm, and the left-hand wrapping method is also adopted, and the overlap rate is also controlled between 20%-30%.

[0031] Furthermore, in the step S40, the weaving process uses tinned copper wire as the weaving material, the diameter of the weaving wire is 0.2 mm, and each ingot is weaved with 10 copper wires. At the same time, a 36-spindle weaving machine is used for weaving, the weaving pitch is set to 75.5 mm, and the weaving density must be greater than or equal to 85%. In addition, the wrapping specification of the non-woven fabric is still 1*40*0.10 mm, and a left-hand wrapping method is adopted, and the overlap rate is controlled between 20% and 30%.

[0032] Compared with the prior art, the technical solution of this application has the following beneficial technical effects:

[0033] The present invention designs a complex and delicate cable core structure including at least two single-core groups, twenty-four single-core shielding groups, six twisted-pair groups and eight twisted-pair shielding groups. Each single-core shielding group and twisted-pair shielding group adopts a tinned copper wire braided shielding layer, which effectively reduces electromagnetic interference and signal attenuation, and ensures high stability and clarity of power and signal transmission. In addition, the setting of the twisted-pair group and the twisted-pair shielding group further enhances the anti-interference ability of the cable, reduces the interference of transmission parameters between coaxial lines, and improves the signal quality. In terms of cable core protection, the present invention introduces at least two wrapping tape layers, which are wrapped before and after braiding, respectively, to provide an additional protective barrier for the cable core. At the same time, the setting of the total braided shielding layer and the total sheath layer further enhances the cable's resistance to the external environment, effectively prevents erosion by the marine environment, and extends the service life of the cable. The present invention has made innovations in the branching processing of the cable. The branches and sub-branches are composed of different numbers of single core groups, twisted pairs and twisted shielded pairs, and are covered with wave-proof sleeves and polyurethane sheaths. This design not only facilitates flexible branching in the complex wiring inside the ship, but also enhances the mechanical strength and waterproof performance of the branch. In addition, the branch line is vulcanized and packaged, which further improves the strength, wear resistance, thermal stability and oil resistance of the branch joint, reducing the risk of cable failure caused by damage to the joint.

[0034] The present invention adopts tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA) as the insulating material of the outer layer of the conductor. PFA has an extremely low friction coefficient, excellent electrical properties, outstanding chemical corrosion resistance, good creep resistance and compressive strength, and excellent radiation resistance. The selection of this material not only improves the insulation performance of the cable, but also enables it to withstand chemical corrosion and high temperature in extreme environments, thereby significantly extending the service life of the cable. Secondly, in terms of shielding treatment, the present invention performs braided shielding treatment on the outer surfaces of the single-core group and the twisted pair group to form a single-core shielding group and a twisted pair shielding group. This shielding treatment effectively reduces electromagnetic interference and signal attenuation, and improves the transmission efficiency and signal clarity of the cable. At the same time, the braided shielding layer also enhances the mechanical properties of the cable, enabling it to better resist damage from the external environment. In terms of the cable core structure, the present invention adopts a multi-level twisted design. By The cable core is twisted with a single-core shielding group to form a first layer of cable core, and the first layer of cable core is twisted with other components to form a second layer of cable core, and finally a third layer of cable core is obtained. This multi-layer twisted design not only improves the mechanical strength and stability of the cable, but also enables it to more flexibly adapt to the requirements of complex wiring inside the ship. In addition, the present invention arranges a total braided shielding layer and a total sheath layer on the outer layer of the cable core to provide an additional protective barrier for the cable. The total braided shielding layer further enhances the anti-interference ability of the cable, while the total sheath layer can resist the erosion of the marine environment, ensuring the normal operation of the cable under extreme conditions. Finally, in the branching treatment of the cable, the present invention adopts vulcanization treatment technology. By vulcanizing the branch, the strength, wear resistance, thermal stability and oil resistance of the branch joint are enhanced. This treatment not only improves the reliability of the cable at the branch, but also reduces the risk of cable failure due to damage to the joint. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] Figure 1 This is a schematic diagram of the cable connection structure of the present invention;

[0036] Figure 2 It is a schematic diagram of the connection structure between branch one and branch two of the present invention.

[0037] In the figure: 1, single core group; 2, single core shielded group; 3, twisted pair group; 4, twisted pair shielded group; 5, tape layer; 6, overall braided shielding layer; 7, overall sheath layer; 8, branch one; 9, branch two. DETAILED DESCRIPTION

[0038] 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.

[0039] Combination Figure 1-Figure 2 As shown, a branch type shipboard cable of the present invention comprises:

[0040] Single core group 1, the number is at least two;

[0041] Single-core shielding groups 2, the number of which is at least twenty-four, each single-core shielding group 2 uses tinned copper wire to braid a shielding layer on the outer layer of the conductor;

[0042] Twisted pair groups 3, the number of which is at least six and is equally divided into three groups, and each twisted pair group 3 is composed of at least two twisted pair core wires;

[0043] Twisted shielding groups 4, the number of which is at least eight and equally divided into four groups, each of which is composed of at least two twisted core wires, and each twisted core wire has a twisted core wire insulation layer coated on the conductor and a braided shielding layer coated after the two twisted core wires are twisted;

[0044] The number of the wrapping tape layers 5 is at least two, and the wrapping tape layers are respectively wrapped before weaving and after weaving;

[0045] The overall braided shielding layer 6 is coated on the outermost layer of all cable core structures;

[0046] A total sheath layer 7, covering the outside of the total braided shielding layer 6;

[0047] Among them, the cable is branched straightly to form branch one 8 and branch two 9. Branch one 8 consists of two single-core groups 1 and is covered with a wave-proof sleeve and a polyurethane sheath. Branch two 9 consists of six twisted-pair groups 3, six twisted-pair shielded groups 4, and twenty-four single-core shielded groups 2 and is covered with a wave-proof sleeve and a polyurethane sheath, and the branch lines are vulcanized and packaged.

[0048] First, the manufacturing process starts with single core groups 1, which are the basic units of the cable, and there are at least two of them. The outer layer of the conductor of each single core group 1 is covered with a layer of insulating material. Although the type of insulating material is not clearly stated in the claims, it can be inferred from the background technology that the insulating material may be tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA) to ensure good insulation performance and chemical corrosion resistance and high temperature resistance. Then, the single core group 1 is further shielded to form a single core shielding group 2. Each single core shielding group 2 is at least twenty-four, and tinned copper wire is used to shield the outer layer of the conductor. The tinned copper wire is braided to form a braided shielding layer. The tinned copper wire not only has good electrical conductivity, but also provides additional mechanical strength and corrosion resistance, thereby enhancing the overall performance of the cable. Subsequently, at least two single core groups 1 are twisted to form a twisted pair group 3. The number of twisted pair groups 3 is at least six and is equally divided into three groups. Each group contains at least two twisted core wires. The twisting process can reduce electromagnetic interference and improve the stability of signal transmission. Similarly, the twisted pair shielding group 4 is also composed of at least two twisted core wires, but each twisted core wire is additionally coated with a braided shielding layer after twisting. The number of twisted pair shielding groups 4 is at least There are eight of them, which are equally divided into four groups. This double shielding design further enhances the anti-interference ability and mechanical strength of the cable. In the process of constructing the cable core structure, a tape layer 5 is also introduced. The number of the tape layers 5 is at least two, which are wrapped before and after the braided shielding layer. The tape layer 5 can provide additional protection and support, and enhance the stability and durability of the cable core structure. After all the cable core structures are completed, a total braided shielding layer 6 will be coated on the outermost layer. The total braided shielding layer 6 further enhances the anti-interference ability of the cable and provides additional mechanical strength. Finally, a total braided shielding layer 6 is coated on the outside. The sheath layer 7, the total sheath layer 7 is usually made of wear-resistant and chemical-resistant materials to protect the cable from damage by the external environment. In the straight part of the cable, branching is performed as needed to form branch one 8 and branch two 9. Branch one 8 is composed of two single-core groups 1, and is covered with wave-proof sleeves and polyurethane sheaths to enhance its waterproof and wave-proof performance. Branch two 9 contains six twisted pair groups 3, six twisted pair shielded groups 4 and twenty-four single-core shielded groups 2, which are also covered with wave-proof sleeves and polyurethane sheaths. In the process of branching, the branch lines are vulcanized and packaged to improve the strength, wear resistance and waterproof performance of the branch joints.

[0049] In a preferred embodiment, the present invention may be further configured as follows: the cable includes a three-layer cable core structure;

[0050] The first layer of cable core structure is formed by twisting a group of 4 twisted shielded cable cores and twelve single-core shielded cable cores.

[0051] The first layer of the cable core structure is further twisted with another twelve single-core shielding groups 2 and seven low-density polyester tapes, and then wrapped with a layer of polyester tape to form a second layer of the cable core structure;

[0052] The second layer of the cable core structure is twisted with four twisted pair groups 3, seven twisted pair shielding groups 4 and two single core groups 1, and after the twisting is completed, a layer of non-woven fabric is wrapped around it to form the third layer of the cable core structure. On the outer layer of the third cable core structure, a total braided shielding layer 6 is woven; on the outer layer of the total braided shielding layer 6, a layer of non-woven fabric is wrapped; and on the outer layer of the non-woven fabric, a total sheath layer 7 is formed by an extrusion process. The first layer of the cable core structure is formed by twisting a group of twisted shielding group 4 cable cores with twelve single-core shielding group 2 cable cores. This design combines the advantages of the shielded twisted pair group and the single-core shielding group, which not only reduces electromagnetic interference, but also provides good mechanical strength and anti-interference capabilities. Then, the first layer of the cable core structure is further twisted with another twelve single-core shielding groups 2 and seven low-density polyester tapes. The low-density polyester tape not only provides additional mechanical support, but also helps to maintain the stability and consistency of the cable core structure. After the twisting is completed, a layer of polyester tape is wrapped to form the second layer of the cable core structure. The design of this layer further enhances the mechanical strength and durability of the cable core. Then, the second layer of the cable core structure is twisted with four twisted pair groups 3, seven twisted pair shielding groups 4 and two single-core groups 1 Twisting, this step combines more signal transmission unit twisted pairs and single core groups and shielded unit twisted shielded groups together to form a more complex cable core structure. After twisting is completed, a layer of non-woven fabric is wrapped to form the third layer of the cable core structure. The use of non-woven fabric not only provides additional protection, but also helps to maintain the integrity of the cable core structure. On the outer layer of the third layer of the cable core structure, there is a total braided shielding layer 6. This shielding layer further enhances the anti-interference ability of the cable and ensures the stability and clarity of signal transmission. On the outer layer of the total braided shielding layer 6, there is a layer of non-woven fabric wrapped. This layer of non-woven fabric provides additional protection and support, and also helps to maintain the shape and stability of the cable. Finally, on the outer layer of the non-woven fabric, a total sheath layer 7 is formed by an extrusion process. The total sheath layer 7 is usually made of wear-resistant and chemical-resistant materials to protect the cable from damage from the external environment. The design of this layer ensures the reliability and durability of the cable in harsh environments.

[0053] In a preferred embodiment of the present invention, the conductor can be further configured as follows: the conductor is a silver-plated copper conductor, and the cross-section of the conductor is between 0.35 and 3.0 square millimeters. In the branch-type marine cable, the conductor as the core component of current transmission adopts a silver-plated copper conductor. The silver-plated copper conductor is a high-performance material that combines the excellent conductivity of copper with the low resistivity, high corrosion resistance and good oxidation resistance of silver. The selection of this material enables the cable to have lower energy loss, higher efficiency and stronger corrosion resistance when transmitting electric energy, thereby extending the service life of the cable. In addition, the cross-sectional size range of the conductor is also specified, that is, between 0.35 and 3.0 square millimeters. The setting of this size range is based on the cable. Taking into account the transmission requirements, installation convenience and cost-effectiveness, a smaller cross-section such as 0.35 square millimeters is suitable for scenarios with lower current transmission, which helps to reduce material usage, reduce costs, and is easy to install in a small space; while a larger cross-section such as 3.0 square millimeters can carry higher currents and meet the power supply requirements of high-power equipment. In practical applications, according to the specific needs of the ship's power system, silver-plated copper conductors of different cross-sections can be selected to construct cables. For example, for main power lines that need to transmit a large amount of current, a conductor with a larger cross-section can be selected to ensure the stability and efficiency of current transmission; for signal transmission lines or control lines, a conductor with a smaller cross-section can be selected to reduce costs and installation difficulty.

[0054] In a preferred embodiment, the present invention can be further configured as follows: the insulating layers in the single core group 1, the single core shielding group 2, the twisted pair group 3, and the twisted pair shielding group 4 are all made of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer material. In the design of the branch type marine cable, in order to improve the electrical performance, mechanical strength and environmental corrosion resistance of the cable core assembly, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer material, hereinafter referred to as FEP / PFA copolymer material, is specially selected as the manufacturing material of the insulating layer in the single core group 1, the single core shielding group 2, the twisted pair group 3, and the twisted pair shielding group 4. The FEP / PFA copolymer material is a high-performance fluoroplastic that combines the excellent electrical insulation, low dielectric constant and loss, and good chemical corrosion resistance of tetrafluoroethylene FEP with the high temperature stability, radiation resistance and excellent mechanical strength of perfluoroalkyl vinyl ether PFA. The selection of this material makes the cable insulation The insulation layer can maintain stable electrical properties in a wide temperature range of -60℃ to +200℃, effectively prevent current leakage and short circuit, and ensure the clarity and accuracy of signal transmission. In single-core group 1 and single-core shielded group 2, the FEP / PFA copolymer insulation layer is tightly wrapped around the conductor, providing a solid barrier to prevent electrical interference between conductors and erosion by the external environment. At the same time, its good flexibility and wear resistance enable the cable to maintain good insulation performance when bent and stretched. In twisted pair group 3 and twisted pair shielded group 4, the FEP / PFA copolymer insulation layer not only plays a role in electrical isolation, but also reduces the capacitive coupling and electromagnetic interference between the wire pairs through its excellent dielectric properties, thereby improving the anti-interference ability and clarity of signal transmission. In addition, the thickness and uniformity of the insulation layer are also strictly controlled to ensure the electrical balance and transmission efficiency of the twisted pair.

[0055] In a preferred embodiment of the present invention, the twisted shielding group 4, the single-core shielding group 2 and the overall braided shielding layer 6 are all woven with tinned copper stranded wire, the braided wire diameter is 0.1 to 0.2 mm, and the braiding density is greater than or equal to 85%. In the branch type marine cable, in order to improve the electromagnetic shielding effect and enhance the mechanical strength and corrosion resistance of the cable, the tinned copper stranded wire weaving technology is particularly used to manufacture the twisted shielding group 4, the single-core shielding group 2 and the overall braided shielding layer 6. This technology not only utilizes the excellent conductivity and corrosion resistance of the tinned copper wire, but also forms a tight and uniform shielding layer by weaving the stranded wire, effectively blocking the transmission path of the electromagnetic wave and improving the anti-interference ability of the cable. The diameter of the braided wire is selected between 0.1 and 0.2 mm, which is a carefully calculated size range. The finer the braided wire, the tighter and more uniform the braiding structure can be formed, thereby improving the shielding effectiveness of the shielding layer. At the same time, this size range The braided wire not only ensures the shielding effect, but also takes into account the flexibility and processability of the cable, making the cable more convenient during installation and use. The requirement that the braiding density is greater than or equal to 85% further ensures the shielding effect and mechanical strength of the shielding layer. High braiding density means that the gaps between the braided wires are smaller, and electromagnetic waves are more difficult to penetrate, thereby improving the electromagnetic shielding performance of the cable. In addition, high braiding density can also enhance the mechanical strength and wear resistance of the shielding layer, so that the cable can still maintain good performance in harsh environments. In specific applications, the braided shielding layer in the twisted shielding group 4 is tightly wrapped around the twisted core wires, effectively reducing the electromagnetic interference between the wire pairs and the erosion of the external environment. The braided shielding layer in the single-core shielding group 2 provides additional protection for a single conductor, enhances the cable's anti-interference ability and mechanical strength, and the total braided shielding layer 6 serves as the outermost shield of the cable, further improving the electromagnetic shielding performance and mechanical strength of the entire cable system.

[0056] In a preferred embodiment, the present invention can be further configured as follows: the total sheath layer 7 adopts polyether polyurethane elastomer TPU, the sheath thickness is 2.0mm, and the thinnest thickness is 1.7mm. In the structure of the branch-type marine cable, the total sheath layer 7 is the outermost protective layer of the cable, and is responsible for resisting external mechanical damage, chemical corrosion and environmental aging. In order to meet these stringent requirements, polyether polyurethane elastomer TPU is specially selected as the manufacturing material of the total sheath layer. TPU material has become an ideal choice for cable sheaths with its excellent wear resistance, oil resistance, hydrolysis resistance and good elasticity. It can not only effectively protect the cable core structure inside the cable from damage by the external environment, but also maintain good flexibility and recovery during dynamic use such as cable bending and stretching, thereby ensuring the long-term stable operation of the cable. In terms of thickness design, the thickness of the total sheath layer 7 is set to 2.0mm This is based on the comprehensive consideration of the cable's use environment, mechanical strength requirements and cost-effectiveness. The thickness of 2.0mm can provide sufficient mechanical protection for the cable while maintaining the cable's lightness and easy installation characteristics. In addition, in order to ensure the uneven thickness that may occur during the manufacturing and installation process, it is also specifically stipulated that the thickness of the thinnest part of the total sheath layer shall not be less than 1.7mm. This provision ensures that even in the case of uneven thickness, the total sheath layer can still provide sufficient protection for the cable to prevent mechanical damage or environmental erosion caused by too thin thickness. In actual applications, the total sheath layer 7 is tightly wrapped around the outermost layer of the cable, forming a solid barrier that effectively resists external mechanical impact, chemical corrosion, environmental aging and other factors. At the same time, its good elasticity and wear resistance enable the cable to maintain excellent performance during long-term use, thereby extending the service life of the cable.

[0057] A method for manufacturing a branched marine cable comprises the following steps:

[0058] S10, covering the outer layer of the conductor with an insulating layer composed of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA) through an extrusion process, thereby preparing a single core group 1, and then twisting two single core groups 1 to form a twisted pair group 3;

[0059] S20, performing a braided shielding process on the outer surface of the single core group 1 to obtain a single core shielding group 2, and similarly, performing a braided shielding process on the outer surface of the twisted pair group 3 to form a twisted pair shielding group 4;

[0060] S30, twisting the twisted pair shielding group 4 and the single-core shielding group 2 to form a first layer of cable core, then twisting the first layer of cable core with the single-core shielding group 2 and the low-density raw tape, and wrapping a layer of polyester tape on the outer layer to form a tape layer 5, thereby obtaining a second layer of cable core, and then twisting the second layer of cable core with the twisted pair group 3, the twisted pair shielding group 4, the radio frequency group and the data line, and wrapping a layer of non-woven fabric on the outer layer, finally obtaining a third layer of cable core;

[0061] S40, weaving a total braided shielding layer 6 on the outer surface of the third cable core, and then wrapping a layer of non-woven fabric on the outer layer again, and finally covering the outer layer of the non-woven fabric with a total sheath layer 7 through an extrusion process, thereby obtaining a complete cable product;

[0062] S50. Perform branching treatment on the portion of the main cable line that needs to be branched, and perform vulcanization treatment on the branch after branching to enhance its performance.

[0063] In a preferred embodiment of the present invention, the following configuration can be further adopted: in step S30, the wrapping specification of the polyester tape is 1*35*0.05mm, the left-hand wrapping method is adopted, and the overlap rate is controlled between 20% and 30%. At the same time, the wrapping specification of the non-woven fabric is 1*40*0.10mm, the left-hand wrapping method is also adopted, and the overlap rate is also controlled between 20% and 30%. In step S30, the twisted shielding group 4 and the single-core shielding group 2 are firstly twisted to form the first layer of the cable core. Then, in order to further strengthen the cable core, In order to improve the mechanical strength and stability, this layer of cable core is twisted together with the additional single-core shielding group 2 and the low-density raw tape. In this process, a key step is to wrap a layer of polyester tape 5 on the outer layer to form a tape layer. According to the , the wrapping specification of the polyester tape is precisely set to 1350.05mm, which means that the width of the polyester tape is 35mm, the thickness is 0.05mm, and a single-layer wrapping method is adopted. At the same time, in order to ensure the tightness and uniformity of the wrapping, the polyester tape is wrapped in the left direction, that is, the wrapping direction is from the left To the right, in addition, the overlap rate, that is, the proportion of the overlapping parts between two adjacent circles of polyester tape, is strictly controlled between 20% and 30% to ensure the strength and stability of the wrapping layer. After the polyester tape is wrapped, in order to further provide additional protection and support, a layer of non-woven fabric is also needed to be wrapped on the outer layer. Similarly, the wrapping specifications of the non-woven fabric are also precisely set to 1400.10mm, that is, the width is 40mm and the thickness is 0.10mm. It also adopts a single-layer wrapping method. Like the polyester tape, the non-woven fabric is also The left-hand wrapping method is used to ensure the tightness and uniformity of the wrapping. At the same time, the overlap rate of the non-woven fabric is strictly controlled between 20% and 30% to ensure the strength and stability of the wrapping layer. By precisely controlling the wrapping specifications, wrapping methods and overlap rates of the polyester tape and non-woven fabric, the S30 step not only enhances the mechanical strength and stability of the cable core, but also provides a solid foundation for subsequent manufacturing steps. This design not only ensures the quality of the cable during the manufacturing process, but also improves the durability and reliability of the cable during long-term use.

[0064] In a preferred embodiment of the present invention, the configuration may be further as follows: in step S40, the weaving process uses tinned copper wire as the weaving material, the diameter of the weaving wire is 0.2 mm, and each spindle uses 10 copper wires for weaving. At the same time, a 36-spindle weaving machine is used for weaving, the weaving pitch is set to 75.5 mm, and the weaving density needs to be greater than or equal to 85%. In addition, the wrapping specification of the non-woven fabric is still 1*40*0.10 mm, and the left-hand wrapping method is used. The overlap rate is controlled between 20% and 30%. In step S40, the weaving process is refined. The design and execution are carefully considered to ensure the best shielding performance of the cable. First of all, tinned copper wire is used as the braiding material. This material not only has good conductivity, but also can effectively resist corrosion from the external environment, thereby improving the durability of the cable. The diameter of the braided wire is precisely set to 0.2mm. This size selection not only ensures the braiding density and shielding effect, but also takes into account the flexibility and processability of the cable. During the braiding process, 10 copper wires are used for each spindle for weaving. This design can enhance the strength and stability of the braided layer. At the same time, a 36-spindle braiding machine is used for weaving, which means that during the braiding process, a total of 360 tinned copper wires are involved in the weaving at the same time, thus forming a tight and uniform braided layer, which effectively improves the shielding performance of the cable. The braiding pitch, that is, the distance between two adjacent circles of braided wire, is set to 75.5mm. The setting of this parameter is crucial to ensure the uniformity and stability of the braided layer. In addition, the braiding density, that is, the proportion of braided wires in the braided layer, is required to be greater than or equal to 85%. High braiding density means smaller gaps between braided wires, which is electromagnetic Waves are more difficult to penetrate, thereby further improving the shielding effect of the cable. After the braided layer is woven, a layer of non-woven fabric needs to be wrapped around the outer layer to provide additional protection and support. The wrapping specification of the non-woven fabric is still 1400.10mm, that is, the width is 40mm and the thickness is 0.10mm. Like the braided layer, the non-woven fabric also adopts the left-hand wrapping method, that is, the wrapping direction is from left to right, to ensure the tightness and uniformity of the wrapping. At the same time, the overlap rate of the non-woven fabric is strictly controlled between 20% and 30% to ensure the strength and stability of the wrapping layer.

[0065] In the initial stage of the manufacturing process, i.e., step S10, a high-performance material, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA), is firstly extruded to uniformly cover the outer layer of the conductor as a medium for current transmission to form a solid and insulating barrier, thereby obtaining a single core group 1. Subsequently, two such single core groups 1 are twisted to reduce electromagnetic interference and enhance the stability of signal transmission by using the twisted structure to form a twisted pair group 3. Then, in step S20, the outer surfaces of the single core group 1 and the twisted pair group 3 are respectively subjected to braided shielding treatment. This step is achieved by using tinned copper strands. Silk and other high-quality materials are tightly woven to form a shielding layer, which effectively blocks the interference of electromagnetic waves and protects the internal signal transmission from external influences, thereby obtaining a single-core shielding group 2 and a twisted-pair shielding group 4. In step S30, the manufacturing process enters the construction stage of the cable core structure. First, the twisted-pair shielding group 4 and the single-core shielding group 2 are twisted to form a first layer of cable core. Subsequently, this layer of cable core is twisted together with an additional single-core shielding group 2 and a low-density raw tape, and a layer of polyester tape is wrapped around the outer layer to form a tape layer 5 to enhance the mechanical strength and stability of the cable core, thereby obtaining a second layer of cable core. Next, The second layer of cable core is twisted with the twisted pair group 3, the twisted pair shielding group 4, the radio frequency group and the data line, and a layer of non-woven fabric is wrapped around the outer layer again to provide additional protection and support, and finally the third layer of cable core is obtained. In step S40, the outer surface of the third layer of cable core is braided to form a total braided shielding layer 6. This shielding layer further improves the electromagnetic shielding performance of the cable and ensures the clarity and accuracy of signal transmission. Then, a layer of non-woven fabric is wrapped around the outer layer again to enhance the overall structural stability and wear resistance of the cable. Finally, a layer of non-woven fabric is evenly covered on the outer layer of the non-woven fabric through an extrusion process. The total sheath layer 7 adopts high-performance materials such as polyether polyurethane elastomer TPU to provide the cable with ultimate mechanical protection and environmental corrosion resistance, thereby obtaining a complete cable product. In the final stage of the manufacturing process, that is, step S50, according to the specific needs of the ship's power system, branching is performed on the part of the main cable line that needs to be branched. This step ensures stable and safe current transmission at the branch through precise cutting and connection processes. At the same time, the branch is vulcanized after branching, and the vulcanization reaction is used to enhance the mechanical strength and electrical properties of the branch, thereby improving the overall durability and reliability of the cable.

[0066] 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.

[0067] 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 branched shipboard cable, characterized in that: include: Single core group (1), the number is at least two; Single-core shielding groups (2), the number of which is at least twenty-four, each single-core shielding group (2) using tinned copper wire to braid a shielding layer on the outer layer of the conductor; The number of twisted pair groups (3) is at least six and is equally divided into three groups, and each twisted pair group (3) is composed of at least two twisted pair core wires; Twisted shielding groups (4), the number of which is at least eight and is equally divided into four groups, each of which is composed of at least two twisted core wires, and each twisted core wire has a twisted core wire insulation layer coated on the conductor and a braided shielding layer coated after the two twisted core wires are twisted; The number of the wrapping tape layers (5) is at least two, and the wrapping tape layers (5) are respectively wrapped before weaving and after weaving; An overall braided shielding layer (6), covering the outermost layer of all cable core structures; A total sheath layer (7), covering the outside of the total braided shielding layer (6); The cable is branched in a straight line to form branch one (8) and branch two (9). Branch one (8) is composed of two single core groups (1) and is covered with a wave-proof sleeve and a polyurethane sheath. Branch two (9) is composed of six twisted pair groups (3), six twisted pair shielded groups (4), and twenty-four single core shielded groups (2) and is covered with a wave-proof sleeve and a polyurethane sheath. The branch lines are vulcanized and packaged.

2. A branched shipboard cable according to claim 1, characterized in that: The cable comprises a three-layer cable core structure; The first layer of cable core structure is formed by twisting a group of twisted shielded group (4) cable cores and twelve single-core shielded group (2) cable cores; The first layer of cable core structure is further twisted with another twelve single-core shielding groups (2) and seven low-density polyester tapes, and then wrapped with a layer of polyester tape to form a second layer of cable core structure; The second layer of the cable core structure is then twisted with four twisted pair groups (3), seven twisted pair shielding groups (4) and two single core groups (1), and after the twisting is completed, a layer of non-woven fabric is wrapped around it to form a third layer of the cable core structure.

3. A branched shipboard cable according to claim 1, characterized in that: The conductor is a silver-plated copper conductor, and the cross section of the conductor is between 0.35 and 3.0 square millimeters.

4. A branched shipboard cable according to claim 1, characterized in that: The insulating layers in the single core group (1), the single core shielding group (2), the twisted pair group (3) and the twisted pair shielding group (4) are all made of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer material.

5. A branched shipboard cable according to claim 1, characterized in that: The twisted pair shielding group (4), the single core shielding group (2) and the overall braided shielding layer (6) are all braided with tinned copper strands, the braided wire diameter is 0.1 to 0.2 mm, and the braiding density is greater than or equal to 85%.

6. A branched shipboard cable according to claim 1, characterized in that: The total sheath layer (7) is made of polyether polyurethane elastomer, the thickness of the sheath is 2.0 mm, and the thickness at the thinnest part is 1.7 mm.

7. A method for manufacturing a branched shipboard cable according to any one of claims 1 to 6, characterized in that: The following steps are involved: S10, covering the outer layer of the conductor with an insulating layer composed of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer by an extrusion process, thereby obtaining a single core group (1), and then twisting two single core groups (1) to form a twisted pair group (3); S20, performing a braided shielding process on the outer surface of the single core group (1) to obtain a single core shielding group (2); similarly, performing a braided shielding process on the outer surface of the twisted pair group (3) to form a twisted pair shielding group (4); S30, twisting the twisted pair shielding group (4) and the single core shielding group (2) to form a first layer of cable core, then twisting the first layer of cable core together with the single core shielding group (2) and the low-density raw tape, and wrapping a layer of polyester tape on the outer layer to form a tape layer (5), thereby obtaining a second layer of cable core, and then twisting the second layer of cable core with the twisted pair group (3), the twisted pair shielding group (4), the radio frequency group and the data line, and wrapping a layer of non-woven fabric on the outer layer, finally obtaining a third layer of cable core; S40, weaving a total braided shielding layer (6) on the outer surface of the third cable core, then wrapping a layer of non-woven fabric around the outer layer again, and finally, covering the outer layer of the non-woven fabric with a total sheath layer (7) through an extrusion process, thereby obtaining a complete cable product; S50. Perform branching treatment on the portion of the main cable line that needs to be branched, and perform vulcanization treatment on the branch after branching to enhance its performance.

8. The method for manufacturing a branched shipboard cable according to claim 7, characterized in that: In step S30, the wrapping specification of the polyester tape is 1*35*0.05mm, and the left-hand wrapping method is adopted, and the overlap rate is controlled between 20%-30%. At the same time, the wrapping specification of the non-woven fabric is 1*40*0.10mm, and the left-hand wrapping method is also adopted, and the overlap rate is also controlled between 20%-30%.

9. The method for manufacturing a branched shipboard cable according to claim 7, characterized in that: In step S40, the weaving process uses tinned copper wire as the weaving material, the diameter of the weaving wire is 0.2 mm, and each ingot is weaved with 10 copper wires. At the same time, a 36-spindle weaving machine is used for weaving, the weaving pitch is set to 75.5 mm, and the weaving density needs to be greater than or equal to 85%. In addition, the wrapping specification of the non-woven fabric is still 1*40*0.10 mm, and a left-hand wrapping method is adopted, and the overlap rate is controlled between 20% and 30%.

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