A lightweight aerospace cable

Abstract

The present application relates to the technical field of aerospace cable, in particular to a kind of light-weight cable for aerospace, two structures of conductive wire core unit and conductive gap unit are used for the internal electric core part of cable, and conductive metal frame is arranged in conductive wire core unit and conductive gap unit, the former is additionally provided with conductive wire core, and the latter is hollow structure with cavity, conductive metal frame and conductive wire core are used to conduct electricity together, hollow structure with cavity can reduce the overall weight of aerospace cable on the one hand, and on the other hand, heat can be better conducted under the condition that the total cross-sectional area of conductor is reduced, so that the weight of cable and heat conduction in use reach balance, the total cross-sectional area of conductor is reduced by 25%-40%, the overall weight is reduced by about 30% compared with solid cable structure, and is almost the same or slightly reduced compared with hollow cable structure in weight, but the heat distribution is more reasonable.

Description

Technical Field

[0001] This invention relates to the field of aerospace cable technology, specifically a lightweight aerospace cable. Background Technology

[0002] Aerospace cables and components are components used in aerospace and high-reliability equipment engineering, transmitting electrical power and control signals in spacecraft and other engineering equipment. Figure 1 As shown, mainstream cables adopt a solid metal conductor structure, which can be a single copper conductor or a solid structure made up of multiple metal single wire conductors twisted together.

[0003] However, with the rapid development of aerospace technology, aircraft such as airplanes, spacecraft, and drones have higher requirements for the lightweight, integration, and reliability of airborne equipment. The weight of an aircraft is directly related to fuel consumption and payload. Reducing the weight of an aircraft can greatly reduce the cost of launch and flight. Therefore, lightweighting is one of the design goals of aerospace cables.

[0004] Meanwhile, the thickness of the metal conductor in the cable primarily affects current transmission efficiency and resistance loss; the thickness of the metal conductor directly affects the resistance. According to Ohm's law, resistance is inversely proportional to the cross-sectional area of ​​the metal conductor; the larger the cross-sectional area, i.e., the thicker the metal conductor, the lower the resistance. Under the same current, lower resistance means lower energy loss and higher transmission efficiency.

[0005] Furthermore, thinner metal conductors have higher resistance, causing more energy to be lost as heat during power transmission, which may also lead to cable overheating. Thicker metal conductors, on the other hand, can significantly reduce resistance loss, especially in long-distance or high-power transmission scenarios.

[0006] In the aerospace field, this presents a contradiction: to reduce cable resistance, the metal conductors in the cable need to be made thicker, i.e., the cross-sectional area needs to be larger, but the weight increases significantly. On the other hand, to reduce weight, the metal conductors in the cable need to be made thinner, i.e. the cross-sectional area needs to be smaller, but the resistance will increase significantly. Heat will be concentrated on the surface of the conductor, while the surface insulation layer, such as polyimide, has a thermal conductivity of only 0.2-0.5 W / (m·K), which exacerbates the temperature rise and accelerates the aging of the cable insulation layer.

[0007] like Figure 2 As shown, this is a hollow metal cable structure with a metal skeleton at its center. Multiple metal monofilament conductors are then twisted together along the metal skeleton. This scheme can reduce the cross-sectional area and maximum resistance of the copper conductor after twisting in the conductor of the cable to a certain extent while meeting the requirements of GB / T3956-2008.

[0008] But in the specific application, although the heat generated by the smaller metal conductor cross section can be conducted out through the hollow area of the hollow metal framework structure, the peripheral conductor is tightly twisted without gap, the heat needs to be slowly diffused through the insulating layer, the metal framework is heat-conducting but covered by the conductor, the heat dissipation path is blocked, forming a sandwich heat distribution with low intermediate temperature and high peripheral temperature, and in order to achieve the effect, high filler plugging is necessary, which leads to high filling rate and large cable outer diameter, which will occupy the equipment installation space in the space limited scene such as spacecraft and unmanned aerial vehicle. SUMMARY

[0009] The purpose of the present application is to provide a lightweight aerospace cable to solve the above problems.

[0010] The technical scheme adopted by the present application is as follows: a lightweight aerospace cable, comprising an outer protective sleeve and an internal core, the outer protective sleeve wrapping the outer periphery of the internal core, wherein the internal core comprises a conductive wire core unit and a conductive gap unit, and the conductive wire core unit and the conductive gap unit are connected and uniformly arranged.

[0011] The conductive wire core unit and the conductive gap unit each comprise a conductive metal frame, the conductive metal frame is a closed structure, and a cavity is arranged in the conductive metal frame.

[0012] The conductive wire core unit further comprises a conductive wire core, and the conductive wire core is arranged in the cavity and abuts against the conductive metal frame.

[0013] Optionally, the cross section of the conductive metal frame is a regular polygon structure.

[0014] Optionally, the cross section of the conductive metal frame is a regular hexagon structure.

[0015] Optionally, the internal core is a honeycomb structure, the center is a conductive metal frame, and the six edges of the conductive metal frame are connected with six other conductive metal frames respectively.

[0016] Optionally, the internal core is a three-layer structure, the center is a conductive gap unit, and six conductive wire core units are connected outside the periphery of the conductive gap unit in the center.

[0017] Optionally, the internal core is a five-layer structure, the middle layer comprises four conductive wire core units and one conductive gap unit, and the four conductive wire core units are arranged on both sides of the conductive gap unit.

[0018] The top layer comprises two conductive wire core units and one conductive gap unit, and the two conductive wire core units are arranged on both sides of the conductive gap unit.

[0019] The bottom layer comprises two conductive core units and one conductive gap unit, and the two conductive core units are arranged on the two sides of the conductive gap unit;

[0020] The sub-top layer is located between the top layer and the middle layer, comprises two conductive core units and two conductive gap units, and the two conductive gap units are arranged at the two ends of the sub-top layer, respectively;

[0021] The sub-bottom layer is located between the bottom layer and the middle layer, comprises two conductive core units and two conductive gap units, and the two conductive gap units are arranged at the two ends of the sub-bottom layer, respectively.

[0022] Optionally, the internal core has a seven-layer structure, the middle layer comprises four conductive core units and three conductive gap units, two of the three conductive gap units are arranged at the two ends of the middle layer, respectively, and one of the three conductive gap units is arranged at the center of the middle layer, and the four conductive core units are arranged on the two sides of the conductive gap unit at the center;

[0023] The top layer comprises two conductive core units and two conductive gap units, and the two conductive gap units are arranged at the two ends of the top layer, respectively;

[0024] The first sub-top layer is located below the top layer, the sub-top layer comprises four conductive core units and one conductive gap unit, and the four conductive core units are arranged on the two sides of the conductive gap unit;

[0025] The second sub-top layer is located between the first sub-top layer and the middle layer, the second sub-top layer comprises four conductive core units and two conductive gap units, two of the four conductive core units are arranged at the two ends of the second sub-top layer, respectively, and the other two conductive core units are located in the middle of the second sub-top layer, and the conductive gap unit is arranged between the conductive core unit at the end of the second sub-top layer and the conductive core unit in the middle of the second sub-top layer;

[0026] The bottom layer comprises two conductive core units and two conductive gap units, and the two conductive gap units are arranged at the two ends of the bottom layer, respectively;

[0027] The first sub-bottom layer is located below the bottom layer, the sub-bottom layer comprises four conductive core units and one conductive gap unit, and the four conductive core units are arranged on the two sides of the conductive gap unit;

[0028] The second sub-bottom layer is located between the first sub-bottom layer and the middle layer, the second sub-bottom layer comprises four conductive core units and two conductive gap units, two of the four conductive core units are arranged at the two ends of the second sub-bottom layer, respectively, and the other two conductive core units are located in the middle of the second sub-bottom layer, and the conductive gap unit is arranged between the conductive core unit at the end of the second sub-bottom layer and the conductive core unit in the middle of the second sub-bottom layer.

[0029] Optionally, the center of the internal core is a conductive wire core unit, and the outer periphery of the center conductive wire core unit is further connected with three conductive wire core units and three conductive gap units, and the conductive wire core units and the conductive gap units are arranged alternately.

[0030] Optionally, the internal core is connected with at most three conductive wire core units in addition to the center conductive gap unit or the conductive wire core unit, and the conductive wire core units are arranged alternately.

[0031] The remaining conductive wire core units are connected with at most three conductive gap units, and the conductive gap units are arranged alternately.

[0032] Optionally, the outer edge protective sleeve comprises a wire core filling layer, a shielding layer and a protective layer.

[0033] The shielding layer is wrapped around the outer periphery of the internal core.

[0034] The wire core filling layer is filled between the internal core and the shielding layer.

[0035] The protective layer is wrapped around the outer periphery of the shielding layer.

[0036] The conductive wire core is an oxygen-free copper conductor.

[0037] The beneficial effects of the present application at least include one of the following;

[0038] 1. The conductive wire core unit and the conductive gap unit are adopted for the internal core part of the cable, and the conductive metal frame is arranged in the conductive wire core unit and the conductive gap unit, the former is additionally provided with a conductive wire core, and the latter is a hollow structure with a cavity, the conductive metal frame and the conductive wire core are used for common conduction, the hollow structure with a cavity can reduce the overall weight of the aerospace cable on one hand, and can facilitate better heat conduction under the condition that the total cross-sectional area of the conductor is reduced, so that the weight of the cable and the heat conduction in use are balanced.

[0039] 2. The conductive metal frame in the form of a regular hexagon is adopted to construct the internal core in the form of a honeycomb structure, the total cross-sectional area of the conductor is reduced by 25%-40%, the overall weight is reduced by about 30% compared with the solid cable structure, and is almost the same or slightly reduced compared with the hollow cable structure, but the heat distribution is more reasonable.

[0040] 3. The conductive metal frame in the form of a regular hexagon is adopted to construct the internal core in the form of a honeycomb structure, the regular hexagonal pores form a natural convection channel, the heat is quickly diffused through air flow, the temperature rise is reduced compared with the solid cable, and the conductive metal frame, the cavity and the conductive wire core cooperate with each other, the conductive wire core and the conductive metal frame conduct electricity, and the conductive metal frame and the cavity are used for auxiliary heat dissipation. BRIEF DESCRIPTION OF DRAWINGS

[0041] Figure 1 Figure 1 is a schematic diagram of a solid cable;

[0042] Figure 2 Figure 2 is a schematic diagram of a hollow cable;

[0043] Figure 3 Figure 3 is a schematic diagram of a flat cable structure;

[0044] Figure 4 Figure 4 is a schematic diagram of a flat cable connection structure;

[0045] Figure 5 Figure 5 is a schematic diagram of a lightweight aerospace cable structure;

[0046] Figure 6 Figure 6 is a schematic diagram of another lightweight aerospace cable structure;

[0047] Figure 7 Figure 7 is a schematic diagram of a third lightweight aerospace cable structure;

[0048] Figure 8 Figure 8 is a schematic diagram of a three-layer internal core structure;

[0049] Figure 9 Figure 9 is a schematic diagram of a five-layer internal core structure;

[0050] Figure 10 Figure 10 is a schematic diagram of another three-layer internal core structure;

[0051] Figure 11 Figure 11 is a schematic diagram of another five-layer internal core structure.

[0052] In the figures:

[0053] 1 is a protective layer, 2 is a shielding layer, 3 is a core filling layer, 4 is a conductive metal frame, 5 is a cavity, 6 is a conductive core, 7 is an internal core, 8 is a flat outer skin, 9 is a flat parallel section, 10 is a first flat connection seat, 11 is a flat connection head, and 12 is a second flat connection seat. DETAILED DESCRIPTION

[0054] In order to make the objects, technical solutions, and advantages of the embodiments of the present application clearer, the technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the accompanying drawings in the embodiments of the present application. Obviously, the described embodiments are some but not all of the embodiments of the present application. Generally, the components of the embodiments of the present application described in the accompanying drawings can be arranged and designed in various different configurations.

[0055] Therefore, the following detailed description of the embodiments of the application provided in the drawings is not intended to limit the scope of the application claimed, but merely represents selected embodiments of the application. Based on the embodiments in the application, all other embodiments obtained by those of ordinary skill in the art without creative labor fall within the scope of the application.

[0056] It should be noted that the embodiments in the application and the features in the embodiments can be combined with each other without conflict.

[0057] It should be noted that: similar reference numerals and letters represent similar items in the following drawings, so once an item is defined in one drawing, it does not need to be further defined and explained in subsequent drawings.

[0058] In the description of the application, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, or the orientation or positional relationship commonly placed when the product of the application is used, or the orientation or positional relationship commonly understood by those skilled in the art, and are only for the convenience of describing the application and simplifying the description, and are not intended to indicate or imply that the indicated device or element must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the application. In addition, the terms "first", "second" and the like are only used to distinguish the description and cannot be understood as indicating or implying relative importance.

[0059] In the description of the application, it should also be noted that, unless otherwise explicitly specified and limited, the terms "arrangement", "installation", "connection", "connection" should be broadly understood, for example, it can be fixedly connected, or it can be detachably connected, or integrally connected; it can be mechanically connected, or it can be electrically connected; it can be directly connected, or it can be indirectly connected through an intermediate medium, or it can be the communication inside two elements. For those of ordinary skill in the art, the specific meaning of the above terms in the application can be understood according to the specific circumstances.

[0060] As shown in Figure 5 A light-weight aerospace cable includes an outer protective sleeve and an inner core 7, the outer protective sleeve is wrapped around the outer periphery of the inner core 7, wherein the inner core 7 includes a conductive wire core unit and a conductive gap unit, and the conductive wire core unit and the conductive gap unit are connected and uniformly arranged;

[0061] The conductive wire core unit and the conductive gap unit each include a conductive metal frame 4, the conductive metal frame 4 is a closed structure, and a cavity 5 is arranged in the conductive metal frame 4;

[0062] The conductive wire core unit further comprises a conductive wire core 6, and the conductive wire core 6 is arranged in the cavity 5 and abuts against the conductive metal frame 4.

[0063] The purpose of such design is that the conductive wire core unit and the conductive gap unit are adopted for the inner core part of the cable, and the conductive metal frame is arranged in the conductive wire core unit and the conductive gap unit, the former is additionally provided with the conductive wire core, and the latter is a hollow structure with a cavity, the conductive metal frame and the conductive wire core are used for common conduction, the hollow structure with the cavity can reduce the overall weight of the aerospace cable on one hand, and facilitate better heat conduction under the condition that the total cross-sectional area of the conductor is small, so that the weight and heat conduction of the cable in use are balanced.

[0064] Meanwhile, in the embodiment, the cross section of the conductive metal frame 4 is a regular hexagonal structure.

[0065] It should be noted that the specific shape of the conductive wire core can be a round bar type, which can be tangent to the inner wall of the regular hexagonal structure of the electric metal frame when inserted, or a regular hexagonal conductive wire core, which can directly fit the inner wall of the regular hexagonal structure of the electric metal frame, but considering that it will expand under heat in actual use, the round bar type conductive wire core is more preferable.

[0066] The structure of the conductive metal frame can provide certain mechanical strength for the entire inner core, so that the area of the cavity part will not change greatly with the extrusion of the conductive wire core in actual use, ensuring sufficient heat dissipation space.

[0067] In the embodiment, the inner core 7 is in a honeycomb structure, the center is a conductive metal frame 4, and the six edges of the conductive metal frame 4 are respectively connected with other six conductive metal frames 4.

[0068] For such a honeycomb structure, there are various setting methods, such as Figure 10 As shown, the inner core 7 is a three-layer structure, the center is a conductive gap unit, and the outer periphery of the conductive gap unit at the center is further connected with six conductive wire core units.

[0069] In actual use, taking the metal surface ratio of the conductive metal frame 4 as 20%, the cavity ratio as 80%, and the cross-sectional ratio of the conductive wire core as 75% as an example, the metal conductive part of the inner core of the three-layer structure accounts for 84%, and the heat dissipation cavity accounts for 16%.

[0070] On the basis of Figure 10 , the structure of Figure 11 can be obtained, in the structure of Figure 11 , the inner core 7 is a five-layer structure, the middle layer comprises four conductive wire core units and one conductive gap unit, and the four conductive wire core units are arranged on both sides of the conductive gap unit.

[0071] The top layer comprises two conductive wire core units and one conductive gap unit, and the two conductive wire core units are arranged on the two sides of the conductive gap unit;

[0072] The bottom layer comprises two conductive wire core units and one conductive gap unit, and the two conductive wire core units are arranged on the two sides of the conductive gap unit;

[0073] The sub-top layer is located between the top layer and the middle layer, comprises two conductive wire core units and two conductive gap units, and the two conductive gap units are respectively arranged at the two ends of the sub-top layer;

[0074] The sub-bottom layer is located between the bottom layer and the middle layer, comprises two conductive wire core units and two conductive gap units, and the two conductive gap units are respectively arranged at the two ends of the sub-bottom layer.

[0075] In actual use, taking the conductive metal frame 4 metal surface ratio of 20%, the cavity ratio of 80%, and the conductive wire core section ratio of 75% as an example, the internal core metal conductive part of the five-layer structure accounts for 67%, and the heat dissipation cavity accounts for 33%.

[0076] At the same time, on the basis of Figure 10 , the structure of Figure 6 can be obtained, in the structure of Figure 6 , the internal core 7 is a seven-layer structure, the middle layer comprises four conductive wire core units and three conductive gap units, and among the three conductive gap units, two conductive gap units are respectively arranged at the two ends of the middle layer, and one conductive gap unit is arranged at the center of the middle layer, and the four conductive wire core units are arranged on the two sides of the conductive gap unit at the center;

[0077] The top layer comprises two conductive wire core units and two conductive gap units, and the two conductive gap units are respectively arranged at the two ends of the top layer;

[0078] The first top layer is located below the top layer, the sub-top layer comprises four conductive wire core units and one conductive gap unit, and the four conductive wire core units are arranged on the two sides of the conductive gap unit;

[0079] The second top layer is located between the first top layer and the middle layer, the second top layer comprises four conductive wire core units and two conductive gap units, and among the four conductive wire core units, two conductive wire core units are respectively arranged at the two ends of the second top layer, and the other two conductive wire core units are located in the middle of the second top layer, and the conductive gap unit is arranged between the conductive wire core units at the end of the second top layer and the conductive wire core units in the middle of the second top layer;

[0080] The bottom layer comprises two conductive wire core units and two conductive gap units, and the two conductive gap units are respectively arranged at the two ends of the bottom layer;

[0081] The first bottom layer is located below the bottom layer, the second bottom layer comprises four conductive wire core units and one conductive gap unit, and the four conductive wire core units are arranged on both sides of the conductive gap unit;

[0082] The second bottom layer is located between the first bottom layer and the intermediate layer, the second bottom layer comprises four conductive wire core units and two conductive gap units, and two of the four conductive wire core units are arranged at both ends of the second bottom layer, and the other two conductive wire core units are arranged in the middle of the second bottom layer, and the conductive gap units are arranged between the conductive wire core units arranged at the ends of the second bottom layer and the conductive wire core units arranged in the middle of the second bottom layer.

[0083] In actual use, for example, the metal surface of the conductive metal frame 4 accounts for 20%, the cavity accounts for 80%, and the cross section of the conductive wire core accounts for 75%, the internal core metal conductive part of the seven-layer structure accounts for 69%, and the heat dissipation cavity accounts for 31%.

[0084] On the contrary, as shown in Figure 8 The center of the internal core 7 is a conductive wire core unit, and the periphery of the conductive wire core unit in the center is also connected with three conductive wire core units and three conductive gap units, and the conductive wire core units and the conductive gap units are arranged alternately.

[0085] In actual use, for example, the metal surface of the conductive metal frame 4 accounts for 20%, the cavity accounts for 80%, and the cross section of the conductive wire core accounts for 75%, the internal core metal conductive part of the three-layer structure accounts for 63%, and the heat dissipation cavity accounts for 37%.

[0086] On the basis of Figure 8 Further expansion, Figure 5 As shown in the figure, a seven-layer structure is obtained, Figure 9 A five-layer structure is obtained, and the specific arrangement mode can be obtained from the figure, which will not be described here.

[0087] In actual use, for example, the metal surface of the conductive metal frame 4 accounts for 20%, the cavity accounts for 80%, and the cross section of the conductive wire core accounts for 75%, the internal core metal conductive part of the five-layer structure accounts for 71%, and the heat dissipation cavity accounts for 29%.

[0088] At the same time, based on the above design, in addition to the central conductive gap unit or conductive wire core unit, the remaining conductive gap units are connected with at most three conductive wire core units, and the conductive wire core units are arranged alternately;

[0089] The remaining conductive wire core units are connected with at most three conductive gap units, and the conductive gap units are arranged alternately.

[0090] It should be pointed out that in some use scenarios, a gradual density arrangement mode can be adopted, for example,Figure 7 As shown, the density of the conductive core in the central region of the aerospace cable is increased to meet the demand for high current, and the five-layer, seven-layer or multi-layer structure is arranged in the periphery.

[0091] It should be noted that due to different specific use scenarios, the problem of increasing resistance caused by reducing the total conductive cross section needs to be selected according to the actual situation. Three-layer, seven-layer or multi-layer structure.

[0092] The embodiment also provides a lightweight aerospace cable preparation method, including the following steps:

[0093] The preparation of the conductive core selects a high-conductivity metal material, draws a single wire of a specified diameter through a wire drawing process, and then twists multiple single wires into a target specification of the conductive core through a twisting process to ensure uniform twisting pitch and smooth surface without oxidation.

[0094] Conductive metal frame forming and installation, according to the current carrying requirement of aerospace cable, design the metal frame structure and specific cross section size, select the metal conductive sheet to extrude into tubular shape, then stamp the conductive metal frame on the regular hexagon mold. The formed metal frame is sleeved outside the conductive core and connected with the conductive core through pressure welding, welding and other methods to ensure the mechanical support strength and the continuity of the conductive path.

[0095] Preparation of honeycomb-shaped internal core, welding the conductive metal frame with installed conductive core and the conductive metal frame with unfilled conductive core in the cavity to obtain a honeycomb-shaped internal core of a specified size.

[0096] Filling of the core filling layer, selecting high-temperature-resistant and flame-retardant insulating materials, filling the internal core as a whole through extrusion or molding process, and excluding bubbles during the filling process to ensure that the filling layer is dense, uniform and cylindrical, achieving mechanical protection and electrical insulation of the internal structure.

[0097] Shielding layer coating, using metal shielding material to wrap or longitudinally wrap the cylindrical core filling layer, fixing the edge of the shielding layer by adhesion or mechanical compression, forming a continuous conductive shielding body.

[0098] Protection layer forming, selecting outer layer materials according to the specific use environment of aerospace, uniformly coating the molten material outside the shielding layer through extrusion process, and controlling the thickness and outer diameter precision of the protection layer through mold. For special scenarios, anti-ultraviolet, weather-resistant or flame-retardant additives can be added to the protection layer, and the material performance can be improved through vulcanization, irradiation crosslinking and other processes.

[0099] During the preparation process, the volume resistivity is tested by four-probe method, the tensile strength is tested by universal testing machine, and the temperature rise is tested by thermal vacuum test chamber to meet the use standards.

[0100] It should be noted that the conductive metal frame and the shielding layer have a synergistic effect on the shielding performance. The conductive metal frame acts as a secondary shield, and the shielding layer acts as a primary shield, especially for low-frequency magnetic fields such as power frequency interference.

[0101] As shown in Figure 3 and Figure 4 Based on the obtained lightweight aerospace cable, an aerospace flat cable is prepared according to the actual scene, that is, a flat outer skin 8 is further arranged outside the protective layer 1, a plurality of flat outer skins 8 are connected side by side through flat parallel sections 9, and a first flat connecting seat 10 is arranged at the end of the composed aerospace flat cable, and the first flat connecting seat 10 is electrically connected to a second flat connecting seat 12 of another section of the aerospace flat cable through a flat connecting head 11.

[0102] In this embodiment, solid conductor cables, hollow conductor cables with the same pipe diameter, and lightweight aerospace cables prepared in this embodiment are selected for comparison. In the comparison, the metal framework used in the hollow conductor cable is an aluminum alloy framework, and the conductive metal framework in this embodiment is also an aluminum alloy framework. Of course, according to the actual use scene, other metals or alloys with a lower density than copper can be selected, such as copper-silver alloy materials or titanium alloy materials.

[0103] The solid conductor cable uses a copper conductor, and its weight is 1.8 kg / m. The hollow conductor cable has a weight of 1.5 kg / m. The lightweight aerospace cable provided in this embodiment has a weight of 1.3 kg / m.

[0104] Under a load of 100 W / m, the solid conductor cable has a ΔT of 50 K, the hollow conductor cable has a ΔT of 45 K, and the lightweight aerospace cable provided in this embodiment has a ΔT of 35 K.

[0105] Although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent replacements to part of the technical features, and any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A lightweight aerospace cable comprising an outer protective sheath and an inner core (7), the outer protective sheath being wrapped around the outer periphery of the inner core (7), characterised in that, The internal core (7) comprises a conductive wire core unit and a conductive gap unit, and the conductive wire core unit and the conductive gap unit are connected and uniformly arranged; The conductive wire core unit and the conductive gap unit each comprise a conductive metal frame (4), the conductive metal frame (4) is a closed structure, and a cavity (5) is arranged in the conductive metal frame (4); The conductive wire core unit further comprises a conductive wire core (6), and the conductive wire core (6) is arranged in the cavity (5) and abuts against the conductive metal frame (4); The cross section of the conductive metal frame (4) is a regular hexagonal structure; The internal core (7) is in a honeycomb structure, the center is a conductive metal frame (4), and six edges of the conductive metal frame (4) are connected with six other conductive metal frames (4) respectively.

2. The lightweight aerospace cable of claim 1, wherein, The internal core (7) is a three-layer structure, the center is a conductive gap unit, and six conductive wire core units are further connected to the outer periphery of the conductive gap unit located at the center.

3. The lightweight aerospace cable of claim 1, wherein, The internal core (7) is a five-layer structure, the middle layer comprises four conductive wire core units and one conductive gap unit, and the four conductive wire core units are arranged on both sides of the conductive gap unit; The top layer comprises two conductive wire core units and one conductive gap unit, and the two conductive wire core units are arranged on both sides of the conductive gap unit; The bottom layer comprises two conductive wire core units and one conductive gap unit, and the two conductive wire core units are arranged on both sides of the conductive gap unit; The sub-top layer is located between the top layer and the middle layer, comprises two conductive wire core units and two conductive gap units, and the two conductive gap units are respectively arranged at both ends of the sub-top layer; The sub-bottom layer is located between the bottom layer and the middle layer, comprises two conductive wire core units and two conductive gap units, and the two conductive gap units are respectively arranged at both ends of the sub-bottom layer.

4. The lightweight aerospace cable of claim 1, wherein, The internal core (7) is a seven-layer structure, the middle layer comprises four conductive wire core units and three conductive gap units, two of the three conductive gap units are respectively arranged at both ends of the middle layer, one of the three conductive gap units is arranged at the center of the middle layer, and the four conductive wire core units are arranged on both sides of the conductive gap unit at the center; The top layer comprises two conductive wire core units and two conductive gap units, and the two conductive gap units are respectively arranged at both ends of the top layer; The first sub-top layer is located below the top layer, the sub-top layer comprises four conductive wire core units and one conductive gap unit, and the four conductive wire core units are arranged on both sides of the conductive gap unit; The second sub-top layer is located between the first sub-top layer and the middle layer, the second sub-top layer comprises four conductive wire core units and two conductive gap units, two of the four conductive wire core units are respectively arranged at both ends of the second sub-top layer, the other two conductive wire core units are located in the middle of the second sub-top layer, and the conductive gap unit is arranged between the conductive wire core units at the ends of the second sub-top layer and the conductive wire core units in the middle of the second sub-top layer; The bottom layer comprises two conductive wire core units and two conductive gap units, and the two conductive gap units are respectively arranged at both ends of the bottom layer; The first sub-bottom layer is located below the bottom layer, the sub-bottom layer comprises four conductive wire core units and one conductive gap unit, and the four conductive wire core units are arranged on both sides of the conductive gap unit. The second bottom layer is located between the first bottom layer and the intermediate layer, the second bottom layer comprises four conductive core units and two conductive gap units, two of the four conductive core units are respectively arranged at two ends of the second bottom layer, and the other two conductive core units are located in the middle of the second bottom layer, and the conductive gap units are arranged between the conductive core units at the ends of the second bottom layer and the conductive core units in the middle of the second bottom layer.

5. The lightweight aerospace cable of claim 1, wherein, The central conductive core unit is surrounded by three conductive core units and three conductive gap units.

6. A lightweight aerospace cable according to any one of claims 2 to 5, wherein, The remaining conductive gap units are connected with at most three conductive core units, and the conductive core units are arranged alternately. The remaining conductive core units are connected with at most three conductive gap units, and the conductive gap units are arranged alternately.

7. The lightweight aerospace cable of claim 6, wherein, The outer protective sleeve comprises a core filling layer (3), a shielding layer (2) and a protective layer (1); The shielding layer (2) is wrapped around the outer periphery of the inner core (7); The core filling layer (3) is filled between the inner core (7) and the shielding layer (2); The protective layer (1) is wrapped around the outer periphery of the shielding layer (2); The conductive core (6) is an oxygen-free copper conductor.

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