Multi-domain adaptive integrated cable and manufacturing method thereof

Abstract

The invention provides a multi-domain adaptive integrated cable and a manufacturing method thereof, a cable core comprises a signal unit and a radio frequency unit wrapping the outer side of the signal unit, an anti-interference layer and a sleeve are sequentially arranged on the outer side of an insulated wire group from inside to outside to form the signal unit, the insulated wire group is formed by twisting a plurality of insulated single wires, and the signal unit is arranged between the signal unit and the radio frequency unit. Each insulating single wire comprises a copper conductor, and the outer side of the copper conductor is sequentially provided with an inner skin layer, a reinforcing layer, an outer skin layer and a coating layer from inside to outside to form the insulating single wire. The radio frequency unit comprises a hollow inner conductor, and the outer side of the hollow inner conductor is sequentially provided with an inner insulating layer, an outer conductor, an outer insulating layer and a protective sleeve from inside to outside. The radio frequency unit and the signal unit are integrated, the space utilization rate and the system integration degree are improved, the interface compatibility risk problem is reduced, meanwhile, an electrically-interconnected composite shielding system is formed, and the anti-interference capacity is improved; and the cost is effectively controlled through the integrated design.

Description

Technical Field

[0001] The present invention relates to the technical field of cables, and in particular to a multi-domain adaptive integrated cable and a manufacturing method thereof. Background Art

[0002] As railways develop towards higher speeds and greater intelligence, the functions of railway communication and signaling systems are becoming increasingly complex. In terms of communication, not only must voice communication between trains and ground control centers be met, but also large amounts of data (such as train operating status data and dispatching instructions) must be transmitted in real time. In terms of signaling, train operation control relies on precise signal transmission, including track circuit signals and switch control signals. Single RF cables or signal cables are difficult to meet diverse needs, so a combination of the two is essential. For example, during high-speed rail operation, trains need to provide real-time feedback on speed, position, and other information to the control center, while also receiving precise dispatching instructions to ensure safe and efficient operation. RF cables can be used for high-speed data transmission, while signal cables are used for stable control signal transmission. The two work together to ensure the normal operation of the system. However, existing technologies have significant limitations. While existing wind turbine cables achieve multifunctional integration, their power and signal units remain in parallel configurations, failing to address the impedance matching challenges inherent in coaxial nesting. High-temperature resistant integrated cables employ a branched twisted structure, resulting in poor shielding effectiveness in electromagnetic compatibility testing. Furthermore, current railway communication systems require cables to meet both IEC 62290-2 (signal transmission) and EN 50117-1 (RF performance). This split design results in interface losses as high as 12%. Two major trends are emerging in the industry's technological development: On the one hand, existing cables utilize curved support structures to enhance mechanical protection, but this lacks multi-signal domain integration. On the other hand, existing cables lack true integration of signal transmission and RF functionality. Split-body designs pose interface compatibility risks in multi-device integration scenarios, increasing system failure rates and inefficient space utilization. Furthermore, it has recently been discovered that the majority of railway system failures stem from signal attenuation caused by electromagnetic interference in the cables, necessitating the development of integrated solutions with collaborative shielding capabilities. The disclosure of the above background technology content is only used to assist in understanding the inventive concept and technical solution of the present invention. It does not necessarily belong to the prior art of this patent application, nor does it necessarily provide technical guidance. In the absence of clear evidence that the above content has been disclosed before the filing date of this patent application, the above background technology should not be used to evaluate the novelty and creativity of this application. Summary of the Invention

[0003] In order to solve the technical problems that existing cables have not yet achieved integrated integration of signal transmission and radio frequency functions, and signal attenuation caused by electromagnetic interference of cables, the present invention proposes a multi-domain adaptive integrated cable and a manufacturing method thereof, which realizes the integrated integration of radio frequency unit and signal unit, not only improving space utilization and system integration, but also reducing interface compatibility risk issues, while forming a composite shielding system of electrical interconnection, and improving anti-interference capability; the integrated design also reduces repeated construction, facilitates later maintenance and management, and realizes effective cost control from the perspective of the entire life cycle. In order to achieve the above object, the technical solution of the present invention is as follows: On the one hand, the present invention provides a multi-domain adaptive integrated cable, comprising: a cable core, the cable core comprising: a signal unit and a radio frequency unit coated on the outside of the signal unit, the signal unit comprising: an insulated wire group, the outside of the insulated wire group is provided with an anti-interference layer and a sleeve in sequence from the inside to the outside to form a signal unit, the insulated wire group is formed by twisting multiple insulated single wires, the insulated single wire comprising: a copper conductor, the outside of the copper conductor is provided with an inner skin layer, a reinforcement layer, an outer skin layer and a coating layer in sequence from the inside to the outside to form an insulated single wire; the radio frequency unit comprises: a hollow inner conductor, the outside of the hollow inner conductor is provided with an inner insulating layer, an outer conductor, an outer insulating layer and a protective cover in sequence from the inside to the outside. The present invention proposes a multi-domain adaptive integrated cable and a manufacturing method thereof, which realizes the integrated integration of the radio frequency unit and the signal unit, which not only improves space utilization and system integration, but also reduces interface compatibility risk issues, and at the same time forms an electrically interconnected composite shielding system, thereby improving anti-interference capability; the integrated design also reduces repeated construction, facilitates subsequent maintenance and management, and realizes effective cost control from the perspective of the entire life cycle. As a preferred technical solution, the copper conductor is a silver-plated copper conductor, the reinforcement layer is a physical foaming insulation reinforcement layer, and the coating layer is a polyimide coating layer. As a preferred technical solution, the hollow inner conductor is arranged outside the sleeve, and the gap between the sleeve and the hollow inner conductor is filled with heat dissipation paste. As a preferred technical solution, the thermal paste includes the following components in percentage by mass: Base oil, 16.7% to 20%, the base oil comprising: special silicone oil; Filler, 66.8% to 80%, wherein the mass ratio of the filler to the base oil is 4:1, and the filler comprises: a mixture of zinc oxide, aluminum nitride and silicon carbide, wherein the mass ratio of zinc oxide, aluminum nitride and silicon carbide is (3-5):(2-4):(1-3); The additives include: 0.5% to 2% of a structural stabilizer, 0.3% to 1.5% of an anti-corrosion agent, and 0.5% to 3% of a viscosity regulator. As a preferred technical solution, the anti-interference layer is a copper wire braided shielding layer, which is woven with copper wires or tinned copper wires with a diameter of ≥0.1 mm, and its braiding density is ≥90%. As a preferred technical solution, the inner insulation layer is an inner foam insulation layer, the outer insulation layer is an outer foam insulation layer, and an "eight"-shaped slot is provided on the outer conductor. As an optimal technical solution, it includes: a protective layer, which is coated on the outside of the cable core, and the protective layer includes: a cable core tape layer, and the outside of the cable core tape layer is provided with a thermal insulation layer, a metal shielding layer, an inner lining layer, a pressure-resistant shielding layer, an isolation layer and an outer sheath from the inside to the outside to form a protective layer. As a preferred technical solution, the metal shielding layer is a corrugated aluminum sheath with a thickness of ≥1.2mm; The compressive shielding layer is a double steel belt armor layer, which includes: galvanized steel belt, which is wrapped with a left-hand spiral gap through a double steel belt wrapping process to form a double steel belt armor layer. The left-hand spiral gap of the double steel belt wrapping process is controlled at 40% to 50% of the bandwidth, and the thickness of the galvanized steel belt is 0.2 to 0.8 mm. As a preferred technical solution, the isolation layer is a carbon fiber reinforced composite material layer, and the carbon fiber reinforced composite material layer includes the following components in mass percentage: Matrix material: synthetic resin, accounting for 30% to 70% of the total mass of the composite material; Reinforcement: carbon fiber, accounting for 30% to 70% of the total mass of the composite material. On the other hand, the present invention also provides a method for manufacturing a multi-domain adaptive integrated cable, which manufactures the multi-domain adaptive integrated cable as described in any one of the above items, comprising the following steps: The inner layer, reinforcement layer and outer layer are extruded onto the surface of the copper conductor at one time by using the skin-foam-skin physical foaming three-layer co-extrusion process, and then the outer surface of the outer layer is sprayed to form a coating layer to obtain an insulated single wire. The multiple insulated single wires produced are twisted into an insulated wire group using a twisting process, an anti-interference layer is coated on the outside of the insulated wire group using a braiding process, and a sleeve is extruded outside the anti-interference layer using an extrusion process to obtain a signal unit; A hollow inner conductor is coated on the outside of the multiple signal units by a continuous argon arc welding process, and a heat dissipation paste is simultaneously filled into the gap between the hollow inner conductor and the sleeve by a filling process. An inner insulating layer is extruded on the outside of the hollow inner conductor by a foaming extrusion process. An outer conductor is coated on the outside of the inner insulating layer by a copper strip welding corrugation process and a slotting process. An outer insulating layer is coated on the outside of the outer conductor. A protective sleeve is coated on the outer insulating layer by an extrusion process to obtain a radio frequency unit containing a signal unit; Twisting multiple radio frequency units containing signal units through a cabling process to obtain a cable core; The cable core is coated with a cable core tape layer, a thermal insulation layer, a metal shielding layer, an inner lining layer, a pressure-resistant shielding layer, an isolation layer and an outer sheath in sequence from the inside to the outside of the cable core to obtain a multi-domain adaptive integrated cable. The present invention provides a multi-domain adaptive integrated cable and a manufacturing method thereof, which has the following beneficial effects: 1) The present invention provides a multi-domain adaptive integrated cable and a manufacturing method thereof, which realizes the integrated integration of the radio frequency unit and the signal unit, not only improving space utilization and system integration, but also reducing interface compatibility risks. At the same time, it forms a composite shielding system for electrical interconnection and improves anti-interference capabilities. The integrated design also reduces repeated construction and facilitates subsequent maintenance and management, achieving effective cost control from a full life cycle perspective. 2) The present invention provides a multi-domain adaptive integrated cable and a manufacturing method thereof. The RF unit directly covers the signal unit to form a coaxial nested integrated architecture, achieving true integrated integration of signal transmission and RF functions, significantly reducing space occupancy. The RF unit and signal unit are better connected and integrated as a whole in multi-device integration scenarios, reducing interface compatibility risks and improving space utilization and system integration. The hollow inner conductor design (RF unit) works in conjunction with the signal unit to meet both the IEC 62290-2 standard (signal) and the EN 50117-1 standard (RF), effectively solving interface compatibility issues. The signal unit's protection (anti-interference layer and casing) and the RF unit's double insulation layer (inner and outer insulation layers) form an electrically interconnected composite shielding system, improving shielding effectiveness and reducing cross-interference. The insulated single-wire design with copper conductors and reinforcement layers further ensures high-speed transmission stability and improves anti-interference capabilities, meeting the stringent impedance matching requirements of high-speed railway communications. The integrated design reduces duplication of construction (reducing excavation costs) and also facilitates subsequent maintenance and management. The modular structure improves maintenance efficiency. The heat dissipation of the hollow conductor and the high-temperature resistant coating extend the cable life, reducing overall costs and effectively controlling the cost of the entire life cycle. 3) The present invention provides a multi-domain adaptive integrated cable and its manufacturing method, which integrates the radio frequency unit and the signal unit into one, realizing high-speed data and signal transmission through one cable. The combined use of the radio frequency unit and the signal unit improves the integration of the system. They can be better connected and integrated with other equipment and / or subsystems in the railway communication and signal system as a whole, reducing interface problems and compatibility risks, making the operation of the entire system more stable and efficient. The protection of the signal unit (anti-interference layer and sleeve) and the double insulation layer of the radio frequency unit (inner insulation layer and outer insulation layer) constitute an electrical interconnection composite shielding system, forming a more powerful shielding system, reducing the impact of mutual and external electromagnetic interference on the signal transmission quality, and ensuring the stable operation of the railway communication and signal system. In addition, by integrating the radio frequency unit and the signal unit into one, the repeated construction costs caused by laying radio frequency cables and signal cables separately can be avoided, including engineering costs such as excavation, laying, and backfilling, reducing the waste of manpower and material resources, reducing the difficulty of construction, and facilitating later maintenance and management, achieving effective cost control from the perspective of the entire life cycle. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 A schematic structural diagram of a multi-domain adaptive integrated cable provided by the present invention; Among them, 1-insulated single wire; 2-copper conductor; 3-inner skin layer; 4-reinforcement layer; 5-outer skin layer; 6-coating layer; 7-anti-interference layer; 8-sleeve; 9-signal unit; 10-heat dissipation paste; 11-hollow inner conductor; 12-inner insulation layer; 13-outer conductor; 14-outer insulation layer; 15-protective sleeve; 16-RF unit; 17-cable core tape layer; 18-thermal insulation layer; 19-metal shielding layer; 20-inner lining layer; 21-pressure-resistant shielding layer; 22-isolation layer; 23-outer sheath. DETAILED DESCRIPTION The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. like Figure 1 As shown, the present invention provides a multi-domain adaptive integrated cable, comprising: a cable core, the cable core comprising: a signal unit 9 and a radio frequency unit 16 coated on the outside of the signal unit, the signal unit 9 comprising: an insulated wire group, the outside of the insulated wire group is provided with an anti-interference layer 7 and a sleeve 8 in sequence from the inside to the outside to form the signal unit 9, the insulated wire group is twisted by multiple insulated single wires 1, the insulated single wire 1 comprises: a copper conductor 2, the outside of the copper conductor 2 is provided with an inner skin layer 3, a reinforcement layer 4, an outer skin layer 5 and a coating layer 6 in sequence from the inside to the outside to form the insulated single wire 1; the radio frequency unit 16 comprises: a hollow inner conductor 11, the outside of the hollow inner conductor 11 is provided with an inner insulating layer 12, an outer conductor 13, an outer insulating layer 14 and a protective cover 15 in sequence from the inside to the outside. The present invention proposes a multi-domain adaptive integrated cable and a manufacturing method thereof, which realizes the integrated integration of the radio frequency unit and the signal unit, which not only improves space utilization and system integration, but also reduces interface compatibility risk issues, and at the same time forms an electrically interconnected composite shielding system, thereby improving anti-interference capability; the integrated design also reduces repeated construction, facilitates subsequent maintenance and management, and realizes effective cost control from the perspective of the entire life cycle. Preferably, the copper conductor 2 is a silver-plated copper conductor, the reinforcement layer 4 is a physical foaming insulation reinforcement layer, and the coating layer 6 is a polyimide coating layer; The copper conductor 2 is preferably a silver-plated copper conductor, which has excellent electrical conductivity, thermal conductivity, corrosion resistance and high-temperature oxidation resistance, ensuring stable and reliable cable signal transmission; The reinforcing layer 4 is preferably a physical foaming insulation reinforcing layer, which can increase the insulation resistance of the cable, reduce the transmission loss of the cable, and reduce the working capacitance of the cable, thereby greatly improving the safety and reliability of the cable. The coating layer 6 is preferably a polyimide coating layer. The polyimide coating layer has excellent cold resistance, allowing the cable to work for a long time in the temperature range of -190°C to +300°C. In addition, it also has the characteristics of high temperature resistance, radiation resistance, and good dielectric properties. Preferably, the hollow inner conductor 11 is arranged outside the sleeve 8, and the gap between the sleeve 8 and the hollow inner conductor 11 is filled with heat dissipation paste 10; The gap between the sleeve 8 and the hollow inner conductor 11 is tightly filled with a heat dissipation paste 10. The heat dissipation paste 10 preferably uses special silicone oil as a base oil, adds zinc oxide, aluminum nitride and silicon carbide as fillers, and then adds a structural stabilizer, an anti-corrosion agent and a viscosity regulator to form a uniform heat dissipation paste 10. The heat dissipation paste 10 thus prepared has high thermal conductivity. It can fill the tiny gaps in the heat dissipation contact surface, improve the heat conduction efficiency, prevent the cable performance from being attenuated, damaged or even malfunctioning due to high temperature, and can effectively prevent oxidation corrosion of the metal surface, thereby extending the service life of the cable. Preferably, the thermal paste 10 comprises the following components in percentage by mass: Base oil, 16.7% to 20%, the base oil comprising: special silicone oil; Filler, 66.8% to 80%, wherein the mass ratio of the filler to the base oil is 4:1, and the filler comprises: a mixture of zinc oxide, aluminum nitride and silicon carbide, wherein the mass ratio of zinc oxide, aluminum nitride and silicon carbide is (3-5):(2-4):(1-3); Additives include: structural stabilizer 0.5% to 2%, anti-corrosion agent 0.3% to 1.5%, viscosity regulator 0.5% to 3%; The base oil is preferably a special silicone oil, which serves as a heat transfer medium carrier, provides fluidity and fills interface microgaps: the special silicone oil has a wide temperature range stability (-50°C to 250°C), ensuring that the paste does not solidify or volatilize at extreme temperatures. Its low surface tension enhances wettability to the metal interface and reduces contact thermal resistance; the filler is preferably a mixture of zinc oxide, aluminum nitride and silicon carbide to form a heat-conducting core network, wherein the mass ratio of the filler to the base oil is 4:1: Zinc oxide is preferably used as a low-cost basic filler with a thermal conductivity of ~30W / (m·K), providing a basic thermal conductivity path. Aluminum nitride is preferably used as a low-cost basic filler with a thermal conductivity of ~30W / (m·K) and a high thermal conductivity of ~320W / (m·K), which makes up for the shortcomings of zinc oxide and improves vertical thermal conductivity. Silicon carbide is preferably used as a high-hardness particle to enhance mechanical strength, prevent the filler layer from collapsing under pressure, and maintain the stability of the thermal conductive structure. The gradient combination of zinc oxide, aluminum nitride, and silicon carbide can achieve a comprehensive thermal conductivity of 5-8W / (m·K), covering different heat flux density requirements. Through the synergy of high-proportion composite fillers and special silicone oil, the thermal resistance of the thermal paste 10 is reduced and it has high thermal conductivity. It can fill the tiny gaps in the heat dissipation contact surface, improve the heat conduction efficiency, and prevent cable performance degradation, damage or even failure due to high temperature. The long-term stability is improved, and the full component insulation can effectively prevent oxidation corrosion on the metal surface, avoid the risk of short circuit, and extend the service life of the cable. This formula is suitable for harsh environments such as high-speed rail communication equipment and meets the reliability requirements of the cable for the heat dissipation medium. Preferably, the anti-interference layer 7 is a copper wire braided shielding layer, which is woven with copper wires or tinned copper wires with a diameter of ≥0.1 mm, and a braiding density of ≥90%; The anti-interference layer 7 is preferably a copper wire braided shielding layer, which is preferably woven from copper wire or tinned copper wire with a diameter of not less than 0.1 mm, and its braiding density is ≥90%. The anti-interference layer 7 is light and soft, has good shielding effect, high tensile strength and good bending performance. Preferably, the inner insulating layer 12 is an inner foam insulating layer, the outer insulating layer 14 is an outer foam insulating layer, and an "eight"-shaped slot is provided on the outer conductor 13; The inner insulating layer 12 is preferably an inner foam insulating layer, and the outer insulating layer 14 is preferably an outer foam insulating layer. Both the inner foam insulating layer and the outer foam insulating layer have properties such as low dielectric constant and high insulation resistance, which can reduce the transmission loss of the cable, effectively prevent electromagnetic leakage, and ensure stable signal transmission; The outer conductor 13 is provided with an "eight"-shaped slot. The special "eight"-shaped structure helps to achieve efficient coupling between the cable and the electromagnetic field in the surrounding space. This slot shape can better couple the radio frequency signal transmitted in the cable to the surrounding environment, and couple the surrounding electromagnetic signals into the cable, thereby enhancing the signal transmission efficiency and receiving sensitivity, thereby improving the communication performance; compared with some irregularly shaped slots, the "eight"-shaped slot has a certain inhibitory effect on external interference signals. When there is an interfering electromagnetic field in the outside world, the "eight"-shaped slot structure can change the propagation path and intensity distribution of the interference signal to a certain extent, reduce the impact of the interference signal on the normal signal transmission in the cable, improve the cable's anti-interference ability, and make the signal transmission more stable and reliable. Preferably, it includes: a protective layer, which is coated on the outside of the cable core, and the protective layer includes: a cable core tape layer 17, and the outside of the cable core tape layer 17 is provided with a thermal insulation layer 18, a metal shielding layer 19, an inner lining layer 20, a pressure-resistant shielding layer 21, an isolation layer 22 and an outer sheath 23 from the inside to the outside to form a protective layer; this structure reduces the signal transmission loss of the cable in extreme environments of humidity, heat and electromagnetic interference, improves the mechanical strength and reduces the failure rate. Preferably, the metal shielding layer 19 is a corrugated aluminum sheath with a thickness of ≥1.2 mm; The compressive shielding layer 21 is a double steel belt armor layer, which includes a galvanized steel belt, which is wound in a left-hand spiral gap through a double steel belt wrapping process to form a double steel belt armor layer. The left-hand spiral gap of the double steel belt wrapping process is controlled to be 40% to 50% of the belt width. The thickness of the galvanized steel belt is 0.2 to 0.8 mm. The metal shielding layer 19 is preferably a corrugated aluminum sheath, preferably made of aluminum plate with a thickness of not less than 1.2 mm through a welding and corrugation process. The corrugated structure gives the cable excellent buffering and absorption capabilities, which can effectively reduce vibration and noise in the system. In addition, aluminum itself has good electrical conductivity and corrosion resistance, and can resist erosion in harsh environments such as chemical corrosion, high temperature and high pressure, thereby reducing the impact of external electromagnetic interference on internal cable signal transmission. The compressive shielding layer 21 is preferably a double steel belt armor layer, and the thickness of the galvanized steel belt is preferably 0.2mm, 0.5mm and 0.8mm. Due to space limitations and for the sake of simplicity, the present invention no longer exhaustively lists the specific point values ​​included in the range. It is preferred to use a galvanized steel belt with a thickness of 0.5mm and an armor layer wrapped in a left-hand spiral gap through a double steel belt wrapping process. In order to ensure the compressive shielding performance of the cable, the wrapping gap of the steel belt must be controlled at about 45% of the bandwidth, so that it has the advantages of high structural strength and good bending performance, so that the cable can effectively protect the internal cable core from damage even when it is squeezed or impacted by a large external force. As a preferred technical solution, the isolation layer 22 is a carbon fiber reinforced composite material layer, and the carbon fiber reinforced composite material layer includes the following components in percentage by mass: Matrix material: synthetic resin, accounting for 30% to 70% of the total mass of the composite material; Reinforcement: carbon fiber, accounting for 30% to 70% of the total mass of the composite material; The isolation layer 22 is preferably a carbon fiber reinforced composite material layer. The carbon fiber reinforced composite material layer is made by adding carbon fiber as reinforcement to a synthetic resin matrix. Its specific gravity is less than 1 / 4 of that of steel, and its tensile strength is above 3500MPa, which is 7 to 9 times that of steel. Its tensile elastic modulus is 23000 to 43000MPa, and its thermal expansion coefficient is close to zero. When subjected to repeated loading, fatigue cracks are not easy to occur. Even if cracks occur, the expansion speed is relatively slow. Therefore, the carbon fiber reinforced composite material layer has the advantages of high strength, high specific modulus, low thermal expansion coefficient, and good fatigue resistance, which improves the safety and reliability of the cable. On the other hand, the present invention also provides a method for manufacturing a multi-domain adaptive integrated cable, which manufactures the multi-domain adaptive integrated cable as described in any one of the above items, comprising the following steps: The inner skin layer 3, the reinforcing layer 4 and the outer skin layer 5 are extruded onto the surface of the copper conductor 2 at one time by a skin-foam-skin physical foaming three-layer co-extrusion process, and then a coating layer 6 is sprayed on the outside of the outer skin layer 5 by a spraying process to obtain an insulated single wire 1; A plurality of insulated single wires 1 are twisted into an insulated wire group by a twisting process, an anti-interference layer 7 is coated on the outside of the insulated wire group by a braiding process, and a sleeve 8 is extruded on the outside of the anti-interference layer 7 by an extrusion process to obtain a signal unit 9; A hollow inner conductor 11 is coated on the outside of the multiple signal units 9 by a continuous argon arc welding process, and a heat dissipation paste 10 is simultaneously filled into the gap between the hollow inner conductor 11 and the sleeve 8 by a filling process. An inner insulating layer 12 is extruded on the outside of the hollow inner conductor 11 by a foaming extrusion process. An outer conductor 13 is coated on the outside of the inner insulating layer 12 by a copper strip welding corrugation process and a slotting process. An outer insulating layer 14 is coated on the outside of the outer conductor 13. A protective cover 15 is coated on the outer insulating layer 14 by an extrusion process, thereby obtaining a radio frequency unit 16 containing the signal unit 9; Twisting multiple radio frequency units 16 containing signal units 9 through a cabling process to obtain a cable core; The outer side of the cable core is coated with a cable core tape layer 17, a thermal insulation layer 18, a metal shielding layer 19, an inner lining layer 20, a pressure-resistant shielding layer 21, an isolation layer 22 and an outer sheath 23 in sequence from the inside to the outside to obtain a multi-domain adaptive integrated cable. The present invention provides a method for manufacturing a multi-domain adaptive integrated cable, which realizes the integrated integration of the radio frequency unit and the signal unit, not only improving space utilization and system integration, but also reducing interface compatibility risk issues, while forming an electrically interconnected composite shielding system and improving anti-interference capabilities; the integrated design also reduces repeated construction, facilitates subsequent maintenance and management, and achieves effective cost control from the perspective of the entire life cycle. Example 1 The invention provides a multi-domain adaptive integrated cable, comprising: a signal unit 9 and a radio frequency unit 16, wherein the radio frequency unit 16 is coated on the outside of two corresponding signal units to form a radio frequency unit 16 containing the signal unit 9, and the three radio frequency units 16 containing the signal unit 9 are arranged in an equilateral triangle and twisted into a cable to form a cable core, and the outside of the cable core is coated with a sheath, and the sheath comprises: a cable core tape layer 17, and the outside of the cable core tape layer 17 is provided with an insulation layer 18, a corrugated aluminum sheath 19, an inner lining layer 20, a double steel tape armor layer 21, a carbon fiber reinforced composite material layer 22 and an outer sheath 23 in sequence from the inside to the outside to form a sheath, The thickness of the corrugated tube aluminum sheath 19 is 1.3mm. The double steel belt armor layer 21 includes: galvanized steel belt, which is wound with a left-hand spiral gap through a double steel belt wrapping process to form a double steel belt armor layer 21. The left-hand spiral gap of the double steel belt wrapping process is controlled at about 45% of the bandwidth. The thickness of the galvanized steel belt is 0.5mm. The carbon fiber reinforced composite material layer 22 includes the following components in mass percentage: 50% matrix material and 50% reinforcement. The matrix material is synthetic resin and the reinforcement is carbon fiber. The signal unit 9 includes: an insulated wire group, and the outer side of the insulated wire group is provided with copper wire braids from the inside to the outside. The signal unit 9 is formed by weaving a shielding layer 7 and a sleeve 8. The copper wire braided shielding layer 7 is woven with copper wire or tinned copper wire with a diameter of 0.15 mm and a weaving density of 95%. The insulated wire group is twisted by four insulated single wires 1 of different colors. The insulated single wire 1 includes: a silver-plated copper conductor 2, and the outer side of the silver-plated copper conductor 2 is provided with an inner skin layer 3, a physical foaming insulation reinforcement layer 4, an outer skin layer 5 and a polyimide coating layer 6 from the inside to the outside to form the insulated single wire 1; the radio frequency unit 16 includes: a hollow inner conductor 11, and the outer side of the hollow inner conductor 11 is provided with an inner foaming insulation layer 12, an outer conductor 13 from the inside to the outside. , an outer foam insulation layer 14 and a protective cover 15, the outer conductor 13 is provided with an "eight"-shaped slot; the hollow inner conductor 11 is arranged on the outside of the sleeve 8, and the gap between the sleeve 8 and the hollow inner conductor 11 is filled with a heat dissipation paste 10; the heat dissipation paste 10 includes: special silicone oil, filler and additives, wherein the mass ratio of the filler to the base oil is 4:1, and the filler includes: a mixture of zinc oxide, aluminum nitride and silicon carbide, wherein the mass ratio of zinc oxide, aluminum nitride and silicon carbide is 3:2:1; the additives include: 1.3% structural stabilizer, 0.9% anti-corrosion agent, and 1.7% viscosity regulator. The present invention also provides a method for manufacturing a multi-domain adaptive integrated cable, which comprises the following steps: An inner skin layer 3, a physical foaming insulation reinforcement layer 4, and an outer skin layer 5 are extruded onto the surface of a silver-plated copper conductor 2 at one time by a skin-foam-skin physical foaming three-layer co-extrusion process, and then a layer of polyimide is sprayed on the outer side of the outer skin layer 5 by a spraying process to form a polyimide coating layer 6, thereby obtaining an insulated single wire 1; The four insulated single wires 1 of different colors are twisted into an insulated wire group using a high-speed star-shaped twisting machine by a twisting process, a copper wire braided shielding layer 7 is coated on the outside of the insulated wire group by a braiding process, and a sleeve 8 is extruded on the outside of the copper wire braided shielding layer 7 by an extrusion process to obtain a signal unit 9; According to the requirements, a hollow inner conductor 11 is coated on the outside of multiple signal units 9 by a continuous argon arc welding process, and a heat dissipation paste 10 is simultaneously filled into the gap between the hollow inner conductor 11 and the sleeve 8 by a filling process. An inner foamed insulation layer 12 is extruded on the outside of the hollow inner conductor 11 by a foaming extrusion technology. An outer conductor 13 is coated on the outside of the inner foamed insulation layer 12 by a copper strip welding corrugation process and a slotting process. An outer foamed insulation layer 14 is coated on the outside of the outer conductor 13. A protective cover 15 is coated on the outer foamed insulation layer 14 by an extrusion process, thereby obtaining a radio frequency unit 16 containing the signal unit 9; Then, according to the requirements, three radio frequency units 16 containing signal units 9 are twisted together through a cabling process to obtain a cable core; Finally, the outer side of the cable core is covered with a cable core tape layer 17, a thermal insulation layer 18, a corrugated tube aluminum sheath 19, an inner lining layer 20, a double steel belt armor layer 21, a carbon fiber reinforced composite material layer 22 and an outer sheath 23 from the inside to the outside to obtain a multi-domain adaptive integrated cable. This embodiment proposes a multi-domain adaptive integrated cable and a manufacturing method thereof, which realizes the integrated integration of the radio frequency unit and the signal unit, which not only improves space utilization and system integration, but also reduces interface compatibility risk issues, and at the same time forms an electrically interconnected composite shielding system, thereby improving anti-interference capabilities; the integrated design also reduces repeated construction, facilitates subsequent maintenance and management, and realizes effective cost control from the perspective of the entire life cycle. It will be appreciated that the present invention is described through some embodiments, and it will be appreciated by those skilled in the art that various changes or equivalent substitutions may be made to these features and embodiments without departing from the spirit and scope of the present invention. In addition, under the teachings of the present invention, these features and embodiments may be modified to adapt to specific circumstances and materials without departing from the spirit and scope of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are subject to various changes or equivalent substitutions. In addition, under the teachings of the present invention, these features and embodiments may be modified to adapt to specific circumstances and materials without departing from the spirit and scope of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of this application are within the scope protected by the present invention.

Claims

1. A multi-domain adaptive integrated cable, characterized in that: include: A cable core, the cable core comprising: a signal unit and a radio frequency unit coated on the outside of the signal unit, the signal unit comprising: an insulated wire group, the outside of the insulated wire group being provided with an anti-interference layer and a sleeve in sequence from the inside to the outside to form a signal unit, the insulated wire group being twisted together by a plurality of insulated single wires, the insulated single wire comprising: a copper conductor, the outside of the copper conductor being provided with an inner skin layer, a reinforcement layer, an outer skin layer and a coating layer in sequence from the inside to the outside to form an insulated single wire; the radio frequency unit comprising: a hollow inner conductor, the outside of the hollow inner conductor being provided with an inner insulating layer, an outer conductor, an outer insulating layer and a protective sleeve in sequence from the inside to the outside.

2. The multi-domain adaptive integrated cable according to claim 1, characterized in that: The copper conductor is a silver-plated copper conductor, the reinforcement layer is a physical foaming insulation reinforcement layer, and the coating layer is a polyimide coating layer.

3. The multi-domain adaptive integrated cable according to claim 1 or 2, characterized in that: The hollow inner conductor is arranged outside the sleeve, and the gap between the sleeve and the hollow inner conductor is filled with heat dissipation paste.

4. The multi-domain adaptive integrated cable according to claim 3, characterized in that: The thermal paste comprises the following components in percentage by mass: Base oil, 16.7% to 20%, the base oil comprising: special silicone oil; Filler, 66.8% to 80%, wherein the mass ratio of the filler to the base oil is 4:1, and the filler comprises: a mixture of zinc oxide, aluminum nitride and silicon carbide, wherein the mass ratio of zinc oxide, aluminum nitride and silicon carbide is (3-5):(2-4):(1-3); The additives include: 0.5% to 2% of a structural stabilizer, 0.3% to 1.5% of an anti-corrosion agent, and 0.5% to 3% of a viscosity regulator.

5. The multi-domain adaptive integrated cable according to claim 1, characterized in that: The anti-interference layer is a copper wire braided shielding layer, which is braided with copper wires or tinned copper wires with a diameter of ≥0.1 mm, and has a braiding density of ≥90%.

6. The multi-domain adaptive integrated cable according to claim 1, characterized in that: The inner insulating layer is an inner foam insulating layer, the outer insulating layer is an outer foam insulating layer, and an "eight"-shaped slot is provided on the outer conductor.

7. The multi-domain adaptive integrated cable according to claim 1, characterized in that: include: The protective layer is coated on the outside of the cable core, and the protective layer includes: a cable core tape layer, and the outside of the cable core tape layer is provided with a thermal insulation layer, a metal shielding layer, an inner lining layer, a pressure-resistant shielding layer, an isolation layer and an outer sheath from the inside to the outside to form a protective layer.

8. The multi-domain adaptive integrated cable according to claim 7, characterized in that: The metal shielding layer is a corrugated aluminum sheath with a thickness of ≥1.2mm; The compressive shielding layer is a double steel belt armor layer, which includes: galvanized steel belt, which is wrapped with a left-hand spiral gap through a double steel belt wrapping process to form a double steel belt armor layer. The left-hand spiral gap of the double steel belt wrapping process is controlled at 40% to 50% of the bandwidth, and the thickness of the galvanized steel belt is 0.2 to 0.8 mm.

9. The multi-domain adaptive integrated cable according to claim 7, characterized in that: The isolation layer is a carbon fiber reinforced composite material layer, and the carbon fiber reinforced composite material layer includes the following components in percentage by mass: Matrix material: synthetic resin, accounting for 30% to 70% of the total mass of the composite material; Reinforcement: carbon fiber, accounting for 30% to 70% of the total mass of the composite material.

10. A method for manufacturing a multi-domain adaptive integrated cable, characterized in that: Manufacturing the multi-domain adaptive integrated cable according to any one of claims 1 to 9 comprises the following steps: The inner layer, reinforcement layer and outer layer are extruded onto the surface of the copper conductor at one time by using the skin-foam-skin physical foaming three-layer co-extrusion process, and then the outer surface of the outer layer is sprayed to form a coating layer to obtain an insulated single wire. The multiple insulated single wires produced are twisted into an insulated wire group using a twisting process, an anti-interference layer is coated on the outside of the insulated wire group using a braiding process, and a sleeve is extruded outside the anti-interference layer using an extrusion process to obtain a signal unit; A hollow inner conductor is coated on the outside of the multiple signal units by a continuous argon arc welding process, and a heat dissipation paste is simultaneously filled into the gap between the hollow inner conductor and the sleeve by a filling process. An inner insulating layer is extruded on the outside of the hollow inner conductor by a foaming extrusion process. An outer conductor is coated on the outside of the inner insulating layer by a copper strip welding corrugation process and a slotting process. An outer insulating layer is coated on the outside of the outer conductor. A protective sleeve is coated on the outer insulating layer by an extrusion process to obtain a radio frequency unit containing a signal unit; Twisting multiple radio frequency units containing signal units through a cabling process to obtain a cable core; The cable core is coated with a cable core tape layer, a thermal insulation layer, a metal shielding layer, an inner lining layer, a pressure-resistant shielding layer, an isolation layer and an outer sheath in sequence from the inside to the outside of the cable core to obtain a multi-domain adaptive integrated cable.

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