Anti-electromagnetic interference and wire harness integrated spaceflight data bus cable structure

Abstract

The invention relates to the technical field of cables, and discloses an anti-electromagnetic interference and wire harness integrated spaceflight data bus cable structure which comprises a conductor, an insulating layer, a fireproof layer, a filling core, a shielding layer, a wrapping layer, a sheath layer and a shielding armor layer, the conductor is wrapped with the insulating layer and the fireproof layer, the insulating wire cores are stranded together through cabling, the filling core is added, and the shielding armor layer is wrapped with the fireproof layer. The shielding layer is woven outside the cabling, the protective layer is coated outside the shielding layer, the shielding armor layer is coated outside the sheath, the fireproof layer is formed by lapping mica tapes, the filling core is formed by weaving alkali-free glass fiber filaments, the mica tapes and the alkali-free glass fiber filament filling core are used for synergistically improving the fire resistance, and the flame temperature can be tolerated to be greater than 1000 DEG C. The spaceflight data bus cable structure integrating the anti-electromagnetic interference and the wire harness has the characteristics of excellent high and low temperature resistance and fire resistance, aging resistance, radiation resistance, bending resistance and the like, and is suitable for being used in an aviation aircraft environment for a long time.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cables, in particular to a space data bus cable structure integrated with electromagnetic interference resistance and wire harness. BACKGROUND

[0002] As the nerve system of an airplane, aviation cables bear the heavy responsibility of connecting key systems such as aircraft electrical equipment, avionics, fire control, and manipulation, and provide power supply, control signals, and data transmission channels for various components. The internal cable system of a modern airplane can be hundreds of kilometers long, and is densely distributed in small spaces such as wings under strict space constraints, forming a highly complex electrical environment. This special environment puts forward three core requirements for cables: high reliability to ensure flight safety, high integration to adapt to space constraints, and lightweight to reduce fuel consumption.

[0003] The working environment of aviation cables is extremely harsh: in the engine near field, it needs to withstand high temperatures above 400℃; in the cruising extreme, it needs to withstand high air temperatures of-55℃; in the event of a fire, it needs to maintain functional integrity for a certain period of time (such as 90 minutes) in flames above 950℃ or even 1000℃ to ensure emergency operation of key systems. In addition, cables also need to resist strong electromagnetic interference (EMI) / radio frequency interference (RFI), atomic oxygen erosion, ultraviolet radiation, ozone corrosion, and mechanical vibration, bending, and other stresses.

[0004] Currently, traditional aviation data bus cables often have the following technical deficiencies when dealing with the above extreme environments: 1. Limited high-temperature and fire resistance performance: Many existing aviation cables use conventional polytetrafluoroethylene (FEP) and other materials for insulation and sheath, and their long-term use temperature is usually limited to 200℃ to 260℃. This is far from enough for the engine compartment of the new generation of hypersonic aircraft, which needs to withstand high temperatures above 400℃. In terms of fire resistance, although some cables use certain fire-resistant structures, they may not be able to maintain structural integrity and insulation performance for a long time under higher temperature (such as 1000℃ and above) flame burning. The degradation of insulation performance of mica tape and other fire-resistant materials at high temperatures is also a challenge.

[0005] 2. Electromagnetic shielding ability needs to be strengthened: Traditional shielding structures (such as single aluminum foil shielding or braided shielding) may have incomplete shielding (such as braided layer gaps leading to electromagnetic leakage), poor low-frequency shielding effect, and shielding layer breakage or electrical connection interruption when bending. In a complex airborne electromagnetic environment, and in the face of possible high-power microwave threats, insufficient shielding effectiveness may lead to signal transmission quality degradation or system malfunction.

[0006] 3. Balance of lightweight, flexibility and durability: aircrafts are extremely sensitive to weight, requiring lightweight cables. However, some designs for high shielding or high strength can result in increased cable weight and diameter, which is not conducive to wiring installation and fuel efficiency. At the same time, the cable needs to have good flexibility and bending resistance to adapt to wiring in narrow space and resist vibration wear. Existing cables may have deficiencies in balancing lightweight, flexibility and mechanical protection (such as cut-through resistance and wear resistance).

[0007] Therefore, it is of great importance to develop a space data bus cable that can simultaneously meet the requirements of extreme high and low temperature adaptability, excellent fire resistance, high-efficiency broad-spectrum electromagnetic shielding, lightweight, high reliability and long service life, which is also a key problem to be broken through in the current cable technology field. SUMMARY

[0008] The purpose of the present application is to solve the defects of existing high-temperature-resistant and fire-resistant composite shielding cables for aviation in structural design, material performance and environmental adaptability, and to provide a high-temperature-resistant and fire-resistant composite shielding cable for aviation and a manufacturing method thereof.

[0009] The technical solution of the present application to solve the above technical problems is as follows: An electromagnetic interference resistant and wire bundle integrated space data bus cable structure, comprising: characterized in that the conductor, the outer wrapping insulation layer of the conductor, the fire-resistant layer wrapped outside the insulation layer, the filler core, the shielding layer woven outside the cable core, the wrapping layer wrapped outside the shielding layer, the sheath layer wrapped in the wrapping layer, the shielding armor layer woven outside the sheath layer, the conductor adopts the stranded conductor in GJB1640-93 "Aerospace Wire and Cable Conductor Types and Section Series", the insulation layer is wrapped and sintered by polytetrafluoroethylene film, the filler core adopts alkali-free glass fiber, the shielding layer adopts silver-plated copper wire weaving, the wrapping layer adopts polytetrafluoroethylene raw material tape wrapping, and the sheath layer adopts tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer extrusion sheath.

[0010] Further, the conductor adopts the stranded conductor in GJB1640-93 "Aerospace Wire and Cable Conductor Types and Section Series", and the cross section of the conductor is 0.14mm 2 .

[0011] Further, the insulation layer is wrapped and sintered by polytetrafluoroethylene film, which has the advantages of high temperature resistance, aging resistance, softness, etc.

[0012] Further, the fireproof layer is wrapped outside the insulating layer by mica tape, the mica tape is wrapped by overlapping, the overlapping rate of each tape is 30%-40%, the mica tape has excellent fire resistance, acid and alkali resistance, and radiation resistance, so that the cable can be powered for more than 90 minutes at a flame temperature of 1000℃.

[0013] Further, the filling core is made of alkali-free glass fiber, the alkali-free glass fiber is woven to fill, the woven structure makes the cable more compact, and the alkali-free glass fiber is better covered on the surface of the fireproof layer, the alkali-free glass fiber can be used for a long time at 300-550℃, the alkali-free glass fiber has an ultimate oxygen index LOL≥95%, is completely non-flammable, and has chemical corrosion resistance and high tensile strength.

[0014] Further, the shielding layer is made of silver-plated copper wire braiding shielding, the braiding wire has a diameter of 0.1mm, and the braiding density is greater than or equal to 85%.

[0015] Further, the wrapping layer is wrapped by polytetrafluoroethylene raw material tape.

[0016] Further, the sheath layer is made of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer extruded sheath.

[0017] Further, the shielding armor layer is made of stainless steel wire braiding.

[0018] A manufacturing method of a space data bus cable structure integrated with electromagnetic interference resistance and wire harness, comprising the following steps: S10, an insulating layer made of polytetrafluoroethylene film is wrapped outside the conductor by a wrapping sintering process, so as to obtain an insulating core, and a mica tape is wrapped outside the single-core group, so as to obtain a single-core group (4); S20, the alkali-free glass fiber is woven to form a filling core; S30, the single-core group and the filling core are twisted to obtain a cable core; S40, a total braiding shielding layer is braided outside the cable core, then a polytetrafluoroethylene raw material tape is wrapped outside the outer layer, a sheath layer is covered outside the raw material tape by an extrusion process, finally, a shielding armor layer is braided outside the sheath by a braiding process, so as to obtain a complete cable product.

[0019] Further, in the step S10, the polytetrafluoroethylene film has a wrapping specification of 1*10*0.035, is wrapped in a right direction, and has a lap rate of 80%, and the mica tape is wrapped by overlapping, and the overlapping rate of each tape is 30%-40%.

[0020] Further, in the step S20, the filling core weaving process uses alkali-free glass fiber as the weaving material, and 8 strands of alkali-free glass fiber are used for weaving on a 16-spindle weaving machine.

[0021] Further, in the step S40, the weaving process uses silver-plated copper wire as the weaving material, the diameter of the weaving wire is 0.1 mm, 6 copper wires are used for weaving per spindle, and a 16-spindle weaving machine is used for weaving operation, the weaving pitch is set to 13 mm, and the weaving density needs to be greater than or equal to 85%, the polytetrafluoroethylene raw material band wrapping specification is 1*8.5*0.051, the right wrapping method is used, and the overlap rate is controlled between 50.5% and 54.0%, in addition, the armor uses a weaving wire with a diameter of 0.15 mm, 3 stainless steel wires are used for weaving per spindle, and a 16-spindle weaving machine is used for weaving operation, the weaving pitch is set to 8.9 mm, and the weaving density needs to be greater than or equal to 70%.

[0022] Compared with the prior art, the technical scheme of the present application has the following beneficial technical effects: 1. Fire resistance and extreme temperature adaptability Excellent extreme high-temperature fire resistance: Through the synergistic design of "mica tape fire-resistant layer + alkali-free glass fiber filling core", a gradient fire-resistant barrier is constructed. The mica tape used in the fire-resistant layer can form a stable ceramic protective layer at high temperatures, while the alkali-free glass fiber used in the filling core has a limiting oxygen index (LOI) ≥95%, which is a completely non-flammable material and can be used at 300-550°C for a long time. This synergistic effect ensures that the cable can maintain its structure and continue to be powered for at least 90 minutes in a 1000°C flame, far exceeding the fire resistance standards of conventional aviation cables, providing valuable time for emergency operations of critical systems in fire situations; Excellent wide temperature range stability and durability: The insulation layer is wrapped with polytetrafluoroethylene (PTFE) film and sintered, and the sheath layer is made of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer (PFA). These materials themselves have excellent high and low temperature resistance (for example, PFA has a long-term use temperature range of about -60°C to +200°C or above), combined with the oxidation resistance of silver-plated conductors, ensuring that the cable remains highly stable in electrical and mechanical properties during the extreme high and low temperature cycles of -55°C to 200°C or above experienced by aerospace vehicles, and is resistant to aging and radiation; 2. Electromagnetic compatibility and signal integrity Highly efficient multi-layer electromagnetic shielding structure: It employs a double-layer shielding system consisting of a silver-plated copper wire braided shielding layer and a stainless steel wire braided shielding armor layer. The inner shielding layer (silver-plated copper wire braid, density ≥85%) primarily provides excellent high-frequency electromagnetic interference protection; the outer shielding armor layer (stainless steel wire braid) not only enhances mechanical protection but also effectively shields against low-frequency magnetic field interference. The two shielding layers work together to ensure high stability and reliability of data bus signal transmission in complex and severe airborne electromagnetic environments, significantly reducing the bit error rate. Structural design and material selection contribute to signal fidelity: The conductor strictly follows the stranded conductor specifications in GJB1640-93 standard (such as cross-section 0.14mm²), and the insulation layer uses PTFE with excellent dielectric properties. These measures work together to give the cable the advantages of stable characteristic impedance, low attenuation, and small capacitance, making it particularly suitable for high-quality signal transmission of high-speed data buses (such as ARINC 429, 1553B bus, etc.). 3. Mechanical and environmental durability Enhanced mechanical protection and durability: The outermost shielding armor layer is made of braided stainless steel wire, providing the cable with mechanical protection against compression, impact, abrasion, and bending fatigue. During cabling, alkali-free glass fiber filaments with a braided structure are used as the filler core, which not only improves the overall roundness and tightness of the cable, but also enhances its tensile strength due to its high tensile strength. This design enables the cable to withstand mechanical stresses such as vibration and impact in aerospace environments. Comprehensive environmental resistance: The key materials selected, such as the PFA sheath, PTFE insulation and wrapping layer, and mica tape, all possess excellent resistance to chemical corrosion, oil, and radiation. The stainless steel wire armor layer also exhibits good corrosion resistance. This enables the cable to withstand corrosive media such as ozone, fuel, and hydraulic oil that may be present in aerospace environments, as well as the effects of atomic oxygen and radiation in space environments, significantly extending the cable's service life. 4. Lightweight design and manufacturing reliability Lightweight design: By using low-density materials such as thin-walled PTFE wrapping insulation, PFA sheath, and braided filler core, and optimizing the structure while meeting performance requirements, the unit weight of the cable is effectively reduced, which helps to reduce the overall weight of the aircraft and meets the aerospace industry's continuous pursuit of weight reduction. Process adaptability and connection reliability: The patent clearly defines key process parameters (such as wrapping overlap, braiding density, and pitch), and these finely controlled processes ensure the consistency and reliability of product performance. The overall structural design of the cable also considers bending radius, flexibility, and ease of installation, enabling it to adapt to the complex wiring spaces and installation requirements inside aerospace vehicles. Attached Figure Description

[0023] Fig. 1This is a schematic diagram of the planar structure of the present invention; Fig. 2 This is a schematic cross-sectional view of the present invention; Fig. 3 This is a three-dimensional structural diagram of the present invention.

[0024] In the diagram, 1 is the conductor; 2 is the insulation layer; 3 is the fire-resistant layer; 4 is the single-core assembly; 5 is the filler core; 6 is the shielding layer; 7 is the wrapping layer; 8 is the sheath layer; and 9 is the shielding armor layer. Detailed Implementation

[0025] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0026] Combination Figs. 1-3 As shown, the present invention discloses an aerospace data bus cable structure integrating anti-electromagnetic interference and wire harness, comprising: conductor, insulation layer, fire-resistant layer, filler core, shielding layer, wrapping layer, sheath layer, and shielding armor layer.

[0027] First, the manufacturing process begins with single-core group 4, which is the basic unit of the cable, and there are two of them. The conductor 1 of each single-core group 4 is covered with a layer of insulation material 2, and mica tape 3 is wrapped around the insulation. Then, the filler core 5 is braided, and the cable core structure is constructed. A total braided shielding layer 6 is wrapped around the cable core. The total braided shielding layer 6 further enhances the cable's anti-interference ability and provides additional mechanical strength. Finally, a wrapping layer 7 is wrapped around the total braided shielding layer 6. The wrapping layer 7 provides additional protection and support, enhancing the stability and durability of the cable core structure. A total sheath layer 8 is wrapped around the wrapping layer 7. The total sheath layer 8 is usually made of wear-resistant and chemical corrosion-resistant materials to protect the cable from damage from the external environment. Finally, a shielding armor layer is braided around the sheath layer to improve the cable's strength, wear resistance, and fire resistance.

[0028] In a preferred embodiment, the present invention can be further configured such that: the conductor is a silver-plated copper conductor, and the cross-section of the conductor is 0.14 mm. 2In the aerospace data bus cable structure integrating electromagnetic interference resistance and wiring harness integration, the conductor, as the core component for current transmission, utilizes silver-plated copper conductors. The plating process employs electroplating silver, with a silver layer thickness ≥1.0μm to ensure that conductor oxidation does not cause a decrease in DC resistance during high-temperature operation. Silver-plated copper conductors are high-performance materials, combining the excellent conductivity of copper with the low resistivity, high corrosion resistance, and good oxidation resistance of silver. This material selection results in lower energy loss, higher efficiency, and stronger corrosion resistance during power transmission, thereby extending the cable's service life. Furthermore, the conductor's cross-sectional dimensions are specified within a range of 0.14mm². 2 The setting of this size range is based on a comprehensive consideration of cable transmission requirements, ease of installation, and cost-effectiveness. A smaller cross-section allows for installation in confined spaces, while still meeting transmission requirements, and helps reduce material usage and lower costs.

[0029] In a preferred embodiment, the present invention can be further configured such that: the insulation layer is formed by wrapping and sintering a polytetrafluoroethylene (PTFE) film. In the design of the aerospace data bus cable structure integrating anti-electromagnetic interference and wire harness integration, in order to improve the temperature resistance, chemical stability, flexibility, and extreme environment resistance of the cable core assembly, PTFE film material is specially selected as the insulation material. PTFE film material is a high-performance fluoroplastic. 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 effects in extreme environments, thereby significantly extending the service life of the cable. At the same time, it also has good flexibility, and the wrapping insulation has a relatively small thickness, which greatly reduces the weight of the cable.

[0030] In a preferred embodiment of the present invention, the fire-resistant layer is made of mica tape. In the design of the aerospace data bus cable structure that integrates anti-electromagnetic interference and wire harness, the mica tape is wrapped in an overlapping manner, with an overlap rate of 30% to 40% for each layer of tape. The mica tape has excellent fire resistance, acid and alkali resistance, and radiation resistance, which enables the cable to maintain power supply for more than 90 minutes at a flame temperature of 1000°C.

[0031] In a preferred embodiment, the present invention can be further configured such that: the filling core is made of alkali-free glass fiber filaments. In the design of the aerospace data bus cable structure integrating anti-electromagnetic interference and wire harness integration, the alkali-free glass fiber filaments of the filling core are braided to serve as filling. This braided structure has three unique advantages compared to solid filling: forming a three-dimensional network to enhance mechanical isotropy, retaining pores to buffer thermal expansion, and optimizing the cross-sectional combination by directional arrangement of surface fibers. This not only makes the cable more compact after cabling, but also allows the alkali-free glass fiber filaments to better cover the surface of the fire-resistant layer. The alkali-free glass fiber filaments can be used for a long time at 300-550℃. The limiting oxygen index (LOL) of the alkali-free glass fiber filaments is ≥95%, which makes them completely non-flammable. They also have chemical corrosion resistance and high tensile strength. This is not only an innovation in material application, but also pushes the performance of inorganic fibers to the extreme through microstructure design, providing irreplaceable technical support for aviation.

[0032] In a preferred embodiment, the present invention can be further configured as follows: the shielding layer is made of silver-plated copper wire braid. In the design of the aerospace data bus cable structure integrating anti-electromagnetic interference and wire harness, the shielding layer is made of silver-plated copper stranded wire braid with a wire diameter of 0.1 mm and a braiding density greater than or equal to 85%. In the aerospace data bus cable structure integrating anti-electromagnetic interference and wire harness, in order to improve the electromagnetic shielding effect and enhance the mechanical strength and corrosion resistance of the cable, silver-plated copper stranded wire braiding technology is specially used to manufacture the shielding layer. The silver plating layer thickness of the silver-plated copper stranded wire is ≥1.0 μm. This technology not only utilizes the excellent conductivity and corrosion resistance of silver-plated copper wire, but also forms a tight and uniform shielding layer through stranded wire braiding, effectively blocking the transmission path of electromagnetic waves and improving the anti-interference capability of the cable. The choice of a braiding wire diameter of 0.1 mm is a... A carefully calculated range of braided wires allows for a tighter, more uniform braided structure, thus improving the shielding effectiveness of the shielding layer. This range of wires also ensures cable flexibility and processability while maintaining effective shielding, making installation and use easier. A braiding density of 85% or higher further guarantees the shielding effect and mechanical strength of the shielding layer. Higher braiding density means smaller gaps between the braided wires, making it harder for electromagnetic waves to penetrate, thus improving the cable's electromagnetic shielding performance. Furthermore, higher braiding density enhances the mechanical strength and abrasion resistance of the shielding layer, allowing the cable to maintain good performance even in harsh environments. In practical applications, the braided shielding layer tightly wraps around the cable core, providing additional protection for the core wires and enhancing the cable's anti-interference capability and mechanical strength.

[0033] In a preferred embodiment, the present invention can be further configured such that: the sheath layer is made of polytetrafluoroethylene raw material tape. In the design of the aerospace data bus cable structure that integrates anti-electromagnetic interference and wire harness, the polytetrafluoroethylene raw material tape fills the micron-level unevenness of the braided shielding outer surface. The low coefficient of friction allows the sheath layer to slide, which not only effectively prevents the shielding layer from oxidizing, but also releases the stress generated when bending.

[0034] In a preferred embodiment, the present invention can be further configured such that: the sheath layer is made of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer. In the design of the aerospace data bus cable structure integrating anti-electromagnetic interference and wire harness integration, 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 PFA) is specially selected. 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 enables the cable sheath layer to maintain stable electrical performance in a wide temperature range of -60°C to +200°C, effectively preventing current leakage and short circuits, ensuring the clarity and accuracy of signal transmission. At the same time, its good flexibility and wear resistance enable the cable to maintain good performance when bent and stretched.

[0035] In a preferred embodiment, the present invention can be further configured such that: the shielding armor layer 4 is made of stainless steel wire. In the design of the aerospace data bus cable structure that integrates anti-electromagnetic interference and wire harness, the stainless steel wire, as the outermost shielding armor layer of the cable, plays the role of ultimate protection in the cable of the present invention. Its function is far from the traditional mechanical protection, but through the integration of multiple sciences such as materials science, electromagnetics and structural mechanics, it has the characteristics of impact resistance, fatigue resistance, pressure resistance and high temperature resistance.

[0036] An aerospace data bus cable structure integrating electromagnetic interference resistance and wiring harness, comprising the following steps: S10. By using the wrapping and sintering process, an insulating layer made of polytetrafluoroethylene film is wrapped around the outer layer of the conductor to obtain an insulated core wire. A mica tape is wrapped around the outside of the single core group to obtain a single core group (4). S20. Alkali-free glass fiber filaments are woven to form a filling core; S30. The single-core group and the filler core are twisted together to finally obtain the cable core; S40. A braided shielding layer is woven on the outer surface of the cable core, and then a layer of polytetrafluoroethylene raw material tape is wrapped around the outer layer. A sheath layer is covered on the outside of the raw material tape by extrusion process. Finally, a shielding armor layer is woven on the outer layer of the sheath by braiding process to obtain a complete cable product.

[0037] In a preferred embodiment, the present invention can be further configured as follows: in step S10, the polytetrafluoroethylene film is wrapped with a specification of 1*10*0.035, using a right-hand wrapping method, and the overlap rate is controlled at 80%. The mica tape is wrapped in an overlapping manner, with the overlap rate of each layer of tape being 30% to 40%. After processing, the size of the product is greatly reduced, and the product's flexibility, resistance to high and low temperatures, and electrical properties are improved.

[0038] In a preferred embodiment of the present invention, the invention can be further configured as follows: In step S20, the filling core weaving process uses alkali-free glass fiber as the weaving material, and 8 strands of alkali-free glass fiber are used for weaving on a 16-spindle weaving machine. The alkali-free glass fiber can be used for a long time at 300-550°C. The alkali-free glass fiber has a limiting oxygen index (LOL) ≥ 95%, which makes it completely non-flammable. It also has chemical corrosion resistance and high tensile strength.

[0039] In a preferred embodiment, the present invention can be further configured as follows: In step S40, the braiding process uses silver-plated copper wire as the braiding material, the diameter of the braiding wire is 0.1 mm, and 6 copper wires are used for braiding per spindle. Simultaneously, a 16-spindle braiding machine is used for the braiding operation, the braiding pitch is set to 13 mm, and the braiding density must be greater than or equal to 85%. The braiding process is carefully designed and executed to ensure that the cable's shielding performance reaches its optimal state. First, silver-plated copper wire is selected as the braiding material. This material not only has good conductivity but also effectively resists corrosion from the external environment, thereby improving the cable's durability. The diameter of the braiding wire is precisely set to 0.1 mm. This size selection ensures braiding density and shielding effect while also taking into account the cable's flexibility and processability. During the braiding process, 6 copper wires are used for braiding per spindle. This design enhances the strength and stability of the braided layer. Simultaneously, a 16-spindle braiding machine is used for the braiding operation, which means that a total of 96 silver-plated copper wires participate in the braiding process simultaneously, thus forming a tight and uniform structure. The braided layer effectively improves the cable's shielding performance. The braiding pitch, i.e., the distance between two adjacent turns of braided wire, is set at 13mm. This parameter is crucial for ensuring the uniformity and stability of the braided layer. Furthermore, the braiding density, i.e., the proportion of braided wire in the braided layer, is required to be greater than or equal to 85%. A high braiding density means smaller gaps between the braided wires, making it more difficult for electromagnetic waves to penetrate, thus further improving the cable's shielding effect. After completing the braiding layer, a layer of PTFE raw material tape is wrapped around the outer layer to provide protection for the shielding. The PTFE raw material tape specifications are 1*8.5*0.051, using a right-hand wrapping method, and the overlap rate is controlled between 50.5% and 54.0%. In addition, the armor uses braided wire with a diameter of 0.15mm, with 3 stainless steel wires per spindle for braiding. A 16-spindle braiding machine is used for the braiding operation, with a braiding pitch set at 8.9mm and a braiding density greater than or equal to 70%.

[0040] In the initial stage of the manufacturing process, namely step S10, an insulating layer made of polytetrafluoroethylene film is wrapped around the outer layer of the conductor through a wrapping and sintering process to form a strong and insulating barrier. A mica tape is then wrapped around the insulating layer to obtain a single core assembly. Next, in step S20, the filler core is braided. In step S30, the filler core and the single core assembly are twisted together to finally obtain the cable core. Finally, a layer is braided, another layer is wrapped around, and a sheath layer is extruded. Finally, a last layer is braided to obtain a complete cable product.

[0041] It should be noted that, in this document, relational terms such as "first" and "second" are used merely to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0042] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A space data bus cable structure integrating electromagnetic interference resistance and wiring harness, characterized in that, Including the following settings from the inside out: Conductor (1) adopts stranded conductor in GJB1640-93 "Series of Conductor Types and Cross Sections for Aerospace Wires and Cables"; The insulating layer (2) covering the outside of the conductor (1) is formed by wrapping and sintering a polytetrafluoroethylene film; The fire-resistant layer (3) covering the outside of the insulation layer (2) is made by wrapping with mica tape; The filler core (5), which is cabled together with the single core assembly (4) consisting of the conductor (1), the insulation layer (2) and the fire-resistant layer (3), is made of alkali-free glass fiber. The shielding layer (6) woven on the outside of the cable core after cabling is made of silver-plated copper wire. The wrapping layer (7) wrapped around the outside of the shielding layer (6) is made of polytetrafluoroethylene raw material tape; The sheath layer (8) covering the outside of the wrapping layer (7) is made of tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer extruded sheath; The shielding armor layer (9) woven outside the sheath layer (8) is made of stainless steel wire.

2. The aerospace data bus cable structure according to claim 1, characterized in that, The cross-section of the conductor (1) is 0.14 mm².

3. The aerospace data bus cable structure according to claim 1, characterized in that, The mica tape of the refractory layer (3) is wrapped in an overlapping manner, with an overlap rate of 30% to 40% for each layer of tape.

4. The aerospace data bus cable structure according to claim 1, characterized in that, The alkali-free glass fiber filaments of the filling core (5) are woven.

5. The aerospace data bus cable structure according to claim 1, characterized in that, The silver-plated copper wire of the shielding layer (6) has a diameter of 0.1 mm and a weaving density greater than or equal to 85%.

6. The aerospace data bus cable structure according to claim 1, characterized in that, The mica tape enables the cable to maintain its electrical conductivity for more than 90 minutes at a flame temperature of 1000°C.

7. The aerospace data bus cable structure according to claim 1, characterized in that, The alkali-free glass fiber can be used for a long time at temperatures of 300–550°C, and its limiting oxygen index (LOI) is ≥95%.

8. The aerospace data bus cable structure according to claim 1, characterized in that, The cable structure is suitable for aircraft environments and features resistance to high and low temperatures, fire resistance, aging resistance, radiation resistance, and bending resistance.

9. A method for manufacturing an aerospace data bus cable structure as described in any one of claims 1 to 8, characterized in that, Includes the following steps: S10: A polytetrafluoroethylene thin film insulation layer (2) is formed on the outer layer of the conductor (1) by a wrapping sintering process to obtain an insulated core wire. Then, a mica tape is wrapped around the insulated core wire to form a fire-resistant layer (3), thereby obtaining a single core assembly (4). S20: The alkali-free glass fiber filaments are woven to form a filling core (5). S30: Twisting at least one single core group (4) with a filler core (5) to obtain a cable core; S40: A silver-plated copper wire shielding layer (6) is woven on the outer surface of the cable core. Then, polytetrafluoroethylene raw material tape is wrapped around the shielding layer (6) to form a wrapping layer (7). Next, a tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer sheathing layer (8) is coated on the wrapping layer (7) by an extrusion process. Finally, a stainless steel wire shielding armor layer (9) is woven on the sheathing layer (8) to obtain a complete cable product.

10. The method according to claim 9, characterized in that: In step S10, the polytetrafluoroethylene film is wrapped with a specification of 1*10*0.035, using a right-hand wrapping method, with an overlap rate controlled at 80%; the mica tape is wrapped with overlapping layers, with an overlap rate of 30% to 40% for each layer. In step S40, the shielding layer (6) is woven with silver-plated copper wire with a diameter of 0.1 mm, with 6 copper wires per spindle, and is woven on a 16-spindle braiding machine with a braiding pitch of 13 mm, and the braiding density is greater than or equal to 85%; the shielding armor layer (9) is woven with stainless steel wire with a diameter of 0.15 mm, with 3 stainless steel wires per spindle, and is woven on a 16-spindle braiding machine with a braiding pitch of 8.9 mm, and the braiding density is greater than or equal to 70%.

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