Composite cable for aerospace

Abstract

The utility model relates to a composite cable for aerospace. The composite cable is sequentially provided with a signal wire core, a control wire core, a power wire core, a filling layer, a shielding layer, an anti-radiation layer and an outer protective layer from inside to outside, each signal wire core comprises a signal wire core conductor, and a signal wire core inner insulating layer and a signal wire core outer insulating layer which are sequentially arranged on the outer side of the signal wire core conductor; the two signal wire cores are twisted and filled with a first filling layer; a first shielding layer and a second shielding layer are sequentially arranged on the outer side of the first filling layer to form a twisted pair wire core; a second filling layer is arranged on the outer sides of the two signal twisted pair wire cores; a control wire core is arranged outside the twisted pair cable core; the two signal twisted pair wire cores are arranged in the center, the control wire cores are arranged around the signal twisted pair wire cores, and one-time cabling is completed to form a control signal cable core; two layers of hot melting aluminum foil mylar tapes are arranged on the outer side of the control signal cable core. The composite cable for aerospace avoids the interference of electromagnetic waves, reduces the size of the cable, reduces the cost, improves the use stability of the cable, and prolongs the service life of the cable.

Description

Technical Field

[0001] The utility model relates to aviation electric wires and cables, in particular to a composite cable for aviation and aerospace use. Background Art

[0002] In recent years, with the exploration of space by human beings, the space station has become a stepping stone for human beings to explore space in depth, and the application of cables has also entered space. As the blood vessels and nerves of the aerospace industry, wires and cables connect various electrical, communication and control systems, and transmit power, control signals and data information. Aerospace cables are constantly developing towards high strength, softness, high and low temperature resistance, oxidation resistance, corrosion resistance and other high performance and high reliability. With the development of the aerospace industry, higher requirements are also put forward for the functionality, safety and service life of the cables used in the space station. The cables used in the existing aerospace industry cannot meet the needs of the current aerospace system due to their unreasonable structural design. Some multifunctional composite cables have the ability to transmit power, and the electromagnetic waves generated by themselves will also affect the internal signal transmission.

[0003] The cables used in the aerospace industry in the prior art have the following deficiencies during use:

[0004] 1. The cable has a single function, resulting in waste of materials and space.

[0005] 2. The cable has poor heat dissipation capacity, resulting in low current carrying capacity and reducing the safety of the cable.

[0006] 3. In order to pursue higher current-carrying capacity, some multifunctional composite cables have their own electromagnetic interference, which affects the signal transmission capacity of themselves and external signal lines.

[0007] 4. The cable's radiation resistance is insufficient and its service life is greatly reduced. Utility Model Content

[0008] In view of the above-mentioned deficiencies in the prior art, the utility model provides a composite cable for aerospace use, which avoids interference from electromagnetic waves, reduces the size of the cable, reduces the cost, and improves the stability of cable use and the service life.

[0009] The technical solution adopted by the utility model is:

[0010] A composite cable for aerospace use, which is provided with a signal core, a control core, a power core, a filling layer, a shielding layer, an anti-radiation layer, and an outer sheath in sequence from the inside to the outside.

[0011] The signal wire core comprises a signal wire core conductor and a signal wire core inner insulating layer and a signal wire core outer insulating layer which are sequentially arranged outside the signal wire core conductor;

[0012] The signal line core conductor is made of annealed Category 5 soft copper conductor bundles;

[0013] The signal line cores are 4 cores, twisted in pairs;

[0014] Two signal wire cores are twisted into pairs and filled with a first filling layer;

[0015] The first filling layer is an organic silicon material;

[0016] A first shielding layer and a second shielding layer are sequentially arranged outside the first filling layer to form a twisted pair wire core;

[0017] A second filling layer is arranged outside the two signal twisted pair wire cores;

[0018] A control core is arranged outside the twisted pair cable core;

[0019] The control core comprises a control core conductor and a control core inner insulating layer and a control core outer insulating layer which are sequentially arranged outside the control core conductor;

[0020] The control line core conductor is made of annealed Category 5 soft copper conductor bundles;

[0021] The inner insulation layer of the control line core is wrapped with a layer of polyimide film coated with PI adhesive;

[0022] The outer insulation layer of the control line core adopts radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation to form a composite insulation layer, with a total of 16 cores;

[0023] Two signal twisted pairs are placed in the center, and control cores are arranged around them. The cabling is completed at one time to form a control signal cable core.

[0024] Two layers of hot-melt aluminum foil Mylar tape are set on the outside of the control signal cable core;

[0025] Two layers of hot melt aluminum foil Mylar tape aluminum foil Mylar can remove electromagnetic interference.

[0026] A braided shielding layer is set on the outside of the hot-melt aluminum foil Mylar tape;

[0027] Wrap two layers of hot-melt aluminum foil Mylar tape around the control signal cable core;

[0028] The overlap rate of two layers of hot-melt aluminum foil Mylar tape is 20% when wound in opposite directions;

[0029] A power line core is arranged around the outside of the control signal cable core;

[0030] The power line core includes: a power line core conductor and a power line core insulation layer;

[0031] The power line core conductor is composed of annealed round compacted soft copper conductors twisted together and then braided with a copper wire braided shielding layer;

[0032] The power line core conductor is composed of an annealed round compacted soft copper conductor and a copper wire braided shielding layer outside the compacted conductor;

[0033] A power line core conductor insulation layer is arranged on the outside of the power line core conductor; the insulation layer is a wrapped polyimide film; and there are 9 power line cores in total.

[0034] The power line core conductor is first bundled and then re-twisted, and each layer of the re-twisted layer is pressed through a nano-diamond composite coating mold;

[0035] The control signal cable core and the power cable core are twisted into a composite cable core;

[0036] An anti-radiation layer and an outer sheath are sequentially arranged on the outside of the composite cable core;

[0037] A third filling layer is arranged in the gap between the shielding layer and the composite cable core and between the composite cable core and the anti-radiation layer.

[0038] The third filling layer is filled with silicon.

[0039] The cable conductors of the two insulated wire cores are twisted in opposite directions; the twist directions of adjacent twisted pairs are opposite, the twisted pair pitch of one insulated wire core is 60-80mm, and the twisted pair pitch of the other insulated wire core is 80-100mm.

[0040] The signal line core conductor pitch ratio is 14-16;

[0041] The inner insulation layer of the signal wire core and the outer insulation layer of the signal wire core;

[0042] The inner insulation layer of the signal line core is wrapped with a layer of polyimide film coated with PI adhesive;

[0043] The outer insulation layer of the signal line core adopts radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation to form a composite insulation layer;

[0044] The thickness of the polyimide film coated with PI adhesive was 0.05 mm, single layer, and the overlap ratio was 5%;

[0045] Radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation, thickness 0.13mm, irradiation dose preferably 8-13M;

[0046] The signal wire core is twisted and longitudinally wrapped with a layer of aluminum-plastic composite tape, with the aluminum side facing outwards, and the thickness is 0.05mm;

[0047] A layer of magnesium-aluminum alloy wire braided shielding is arranged outside the aluminum-plastic composite belt, and the braiding density is 80%.

[0048] The control line core conductor pitch ratio is 14-16;

[0049] Inner insulation layer of control wire core, outer insulation layer of control wire core;

[0050] The inner insulation layer of the control line core is wrapped with a layer of polyimide film coated with PI adhesive;

[0051] The outer insulation layer of the control line core adopts radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation to form a composite insulation layer;

[0052] The thickness of the polyimide film coated with PI adhesive was 0.05 mm, single layer, and the overlap ratio was 5%;

[0053] The thickness of the radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation layer is 0.13 mm, and the radiation dose is preferably 8-13 M.

[0054] The power line core conductor bundle has a pitch-diameter ratio of 16-18, a pitch-diameter ratio of the outermost layer of the double-twisted strand is 10-12, and the direction is all left-handed;

[0055] The braiding density of the copper wire braided shield of the power line core conductor is 90%;

[0056] The power line core conductor pressing mold is a nano-diamond composite coating pressing mold, and the pressing coefficient is 0.9.

[0057] The power line core insulation layer is a wrapped polyimide film with a thickness of 0.05 mm, two layers, and an overlap rate of 20%.

[0058] The shielding layer is a braided shielding layer formed by cross-weaving flat magnesium-aluminum alloy wires, the thickness of the flat magnesium-aluminum alloy wires is 0.05 mm, the width of the flat wires is 0.3 mm, and the braiding density is 80%.

[0059] The anti-radiation layer is an MLI film (a composite film material formed by combining polyimide and aluminum foil), with a thickness of 0.1 mm, one layer, an overlap rate of 30%, and an aluminum surface facing outwards.

[0060] The outer sheath is radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE), the sheath thickness is 2.0 mm, and the radiation dose is preferably in the range of 8-13M.

[0061] The beneficial effects of the utility model compared with the prior art are as follows:

[0062] The utility model is a composite cable for aerospace, and the power line core conductor is composed of an annealed round compacted soft copper conductor and a layer of copper wire braided shielding layer outside the compacted conductor. Compared with traditional solid conductors and Class II compacted conductors, it is softer, has good bendability and long service life. The conductor wire bundle and double twisting are both left-handed, which further increases the softness of the conductor; each layer of the double twisting is compacted by a nano mold, which can reduce the gap inside the conductor, reduce the conductor diameter and cross-sectional area, reduce the conductor resistance, save subsequent processing materials, and improve the conductor filling factor. The surface of the conductor after compaction is smooth, round and free of burrs, and the electric field on the conductor surface is uniform; by setting a layer of copper wire braided shielding layer, the heat dissipation capacity of the conductor can be increased, and the current carrying capacity of the conductor can be improved; by setting a layer of copper wire braided shielding layer, the electromagnetic waves generated by the power line core itself in the process of transmitting electric energy can be reduced, which will have an electromagnetic impact on surrounding electronic equipment, thereby causing signal quality, data loss, equipment damage, safety hazards, etc. The advantages of a conductor composed of annealed round compressed soft copper conductors that are twisted and compressed and then woven with a copper wire braided shielding layer over traditional solid conductors and Class II compressed conductors are: good flexibility and long service life; good heat dissipation and high current carrying capacity; small dielectric loss, more stable transmission capacity, and the ability to avoid electromagnetic wave interference generated by itself; by setting a polyimide film as the insulating layer of the power line core, the polyimide film has the following characteristics: excellent mechanical properties, excellent dielectric properties, high and low temperature resistance, wear resistance, creep resistance, radiation resistance, combustion resistance, and low outgassing, and is widely used in the aerospace field; using polyimide film as the insulating layer of the power line core can meet the requirements of the aerospace field while reducing its volume and reducing costs.

[0063] The utility model composite cable for aerospace use has a control core and a signal core insulation inner layer wrapped with a layer of polyimide film coated with PI adhesive, and an outer layer is made of radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation to form a composite insulation layer. Radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) has high high and low temperature resistance, strong crack resistance and radiation resistance; polyimide film has high high temperature resistance and strong radiation resistance. The composite insulation composed of polyimide film and radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) combines the advantages of the two materials, further improves the cable's high temperature resistance, moisture resistance, hydrolysis resistance, wear resistance, and radiation resistance, and also has flame retardancy, overcoming the performance of simple polyimide film that is not resistant to arcing and oxygen atoms, and can reduce the thickness of radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE), reduce the volume of the cable, and reduce costs.

[0064] The utility model composite cable for aerospace reduces distributed inductance and improves electromagnetic interference capability by setting the twisting pitch and twisting direction of the wire pairs. It adopts the longitudinal wrapping method, has good overall shielding performance and moisture-proof performance. At the same time, the aluminum-plastic composite tape longitudinally wrapped outside the signal wire core can further improve the anti-electromagnetic interference capability.

[0065] The utility model composite cable for aerospace uses an MLI film (composite film material formed by combining polyimide and aluminum foil) with a thickness of 0.1 mm, one layer, an overlap rate of 30%, and an aluminum surface facing outwards; the MLI film combines the advantages of the two materials, has the advantages of a wide temperature range, excellent mechanical properties, high stability, excellent radiation resistance, etc., and has a reflectivity of more than 78% for radiation with a wavelength from 0.2 microns to 1.2 microns, has good radiation resistance, and is stable;

[0066] The utility model aerospace composite cable is provided with a braided shielding layer formed by cross-weaving of flat magnesium-aluminum alloy wires. The magnesium-aluminum alloy wires have a small specific gravity, light weight, strong braidability, and low price. At the same time, the braided shielding layer adopts a flat magnesium-aluminum alloy wire weaving design, and the flat wire thickness is 0.05mm and the flat wire width is: 0.3mm. Compared with the round braided wire, the total size and weight of the wire can be reduced, which is more in line with the requirements of aerospace products. The cross-weaving design can make the braided shielding layer anti-bending and anti-vibration, greatly improving the stability and service life of the cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Figure 1 This is a schematic diagram of the structure of the composite cable for aerospace use of the utility model;

[0068] Figure 2 This is a schematic diagram of the twisted pair core structure of the composite cable for aerospace use of the utility model;

[0069] Figure 3 This is a schematic diagram of the control signal cable core of the composite cable for aerospace use of the utility model;

[0070] Figure 4 This is a schematic diagram of the control wire core structure of the composite cable for aerospace use of the utility model;

[0071] Figure 5 This is a schematic diagram of the power core structure of the composite cable for aerospace use of the utility model. Explanation of the main component symbols in the attached figure:

[0072] In the figure:

[0073] 1. Power core 2. Control core

[0074] 3. Signal cable core 4. Control signal cable core

[0075] 5. The third filling layer 6. Shielding layer

[0076] 7. Anti-radiation layer 8. Outer sheath

[0077] 101. Round compressed soft copper conductor

[0078] 102. Copper wire braided shield

[0079] 103. Power line core insulation layer

[0080] 201. Control line core conductor

[0081] 202. Inner insulation layer of control line core

[0082] 203. Outer insulation layer of control wire core

[0083] 301. Signal line core conductor

[0084] 302, signal line core inner insulation layer

[0085] 303, signal line core outer insulation layer

[0086] 304. First filling layer

[0087] 305. First shielding layer

[0088] 306. Second shielding layer

[0089] 307, Signal twisted pair core

[0090] 308. Second filling layer

[0091] 401, Hot-melt aluminum foil Mylar tape. DETAILED DESCRIPTION

[0092] The present invention is described in detail below with reference to the accompanying drawings and embodiments:

[0093] Attached Figure 1-5 It can be seen that a composite cable for aerospace use is provided with a signal core 3, a control core 2, a power core 1, a filling layer, a shielding layer, an anti-radiation layer 7, and an outer sheath 8 in sequence from the inside to the outside;

[0094] The signal core 3 comprises a signal core conductor 301 and a signal core inner insulating layer 302 and a signal core outer insulating layer 303 which are sequentially arranged outside the signal core conductor 301;

[0095] The signal line core conductor 301 is formed by twisting annealed Category 5 soft copper conductor bundles;

[0096] The signal line cores are 4 cores, twisted in pairs;

[0097] Two signal wire cores are twisted into a pair and filled with a first filling layer 304;

[0098] The first filling layer 304 is an organic silicon material;

[0099] A first shielding layer 305 and a second shielding layer 306 are sequentially arranged outside the first filling layer 304 to form a twisted pair core 307;

[0100] A second filling layer 308 is disposed outside the two signal twisted pair wire cores 307;

[0101] The second filling layer 308 is glass fiber rope;

[0102] The first shielding layer 305 is an aluminum-plastic composite tape, which is longitudinally wrapped and has good overall shielding performance and moisture-proof performance. A second shielding layer is arranged outside the aluminum-plastic composite tape, and the second shielding layer is a magnesium-aluminum alloy wire braided shield 306 .

[0103] The signal twisted pair core 307 and the second filling layer 308 constitute a twisted pair cable core;

[0104] Two signal twisted pair wire cores 307 constitute a signal cable core;

[0105] A control core 2 is arranged outside the twisted pair cable core;

[0106] The control core 2 includes a control core conductor 201 and a control core inner insulating layer 202 and a control core outer insulating layer 203 which are sequentially arranged outside the control core conductor 201;

[0107] The control line core conductor is made of annealed Category 5 soft copper conductor bundles;

[0108] The inner insulation layer of the control line core is wrapped with a layer of polyimide film coated with PI adhesive;

[0109] The outer insulation layer of the control line core adopts radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation to form a composite insulation layer; a total of 16 cores;

[0110] Two signal twisted pair cores 307 are placed in the center, and the control cores 2 are arranged around them, and the cabling is completed at one time to form a control signal cable core 4;

[0111] Two layers of hot-melt aluminum foil Mylar tape 401 are arranged on the outside of the control signal cable core 4;

[0112] Two layers of hot melt aluminum foil Mylar tape 401 aluminum foil Mylar can remove electromagnetic interference.

[0113] A braided shielding layer 6 is provided outside the hot-melt aluminum foil Mylar tape 401;

[0114] Wrap two layers of hot-melt aluminum foil Mylar tape around the control signal cable core;

[0115] The overlap rate of two layers of hot-melt aluminum foil Mylar tape is 20% when wound in opposite directions;

[0116] A power line core 1 is arranged around the outside of the control signal cable core;

[0117] The power line core 1 comprises: a power line core conductor and a power line core insulation layer 103;

[0118] The power line core conductor is composed of an annealed round compacted soft copper conductor 101 which is twisted and then braided with a copper wire braided shielding layer 102;

[0119] The power line core conductor 101 is composed of an annealed round compacted soft copper conductor and a copper wire braided shielding layer outside the compacted conductor;

[0120] A power line core conductor insulation layer 103 is arranged outside the power line core conductor; the insulation layer is a wrapped polyimide film; and there are 9 power line cores in total.

[0121] The power line core conductor is first bundled and then re-twisted, and each layer of the re-twisted layer is pressed through a nano-diamond composite coating mold;

[0122] The control signal cable core and the power cable core are twisted into a composite cable core;

[0123] An anti-radiation layer 7 and an outer sheath 8 are sequentially arranged on the outside of the composite cable core;

[0124] A third filling layer 5 is provided in the gap between the shielding layer 6 and the composite cable core and between the composite cable core and the anti-radiation layer 7 .

[0125] The third filling layer 5 is filled with silicon.

[0126] The cable conductors of the two insulated wire cores are twisted in opposite directions; the twist directions of adjacent twisted pairs are opposite, the twisted pair pitch of one insulated wire core is 60-80mm, and the twisted pair pitch of the other insulated wire core is 80-100mm.

[0127] The signal line core conductor pitch ratio is 14-16;

[0128] The signal line core inner insulating layer 302 and the signal line core outer insulating layer 303;

[0129] The inner insulation layer of the signal line core is wrapped with a layer of polyimide film coated with PI adhesive;

[0130] The outer insulation layer of the signal line core adopts radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation to form a composite insulation layer;

[0131] The thickness of the polyimide film coated with PI adhesive was 0.05 mm, single layer, and the overlap ratio was 5%;

[0132] Radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation, thickness 0.13mm, irradiation dose preferably 8-13M;

[0133] The signal wire core is twisted and longitudinally wrapped with a layer of aluminum-plastic composite tape, with the aluminum side facing outwards, and the thickness is 0.05mm;

[0134] A layer of magnesium-aluminum alloy wire braided shielding is arranged outside the aluminum-plastic composite belt, and the braiding density is 80%.

[0135] The control line core conductor pitch ratio is 14-16;

[0136] Control line core inner insulation layer 202, control line core outer insulation layer 203;

[0137] The inner insulation layer of the control line core is wrapped with a layer of polyimide film coated with PI adhesive;

[0138] The outer insulation layer of the control line core adopts radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation to form a composite insulation layer;

[0139] The thickness of the polyimide film coated with PI adhesive was 0.05 mm, single layer, and the overlap ratio was 5%;

[0140] The thickness of the radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation layer is 0.13 mm, and the radiation dose is preferably 8-13 M.

[0141] The power line core conductor bundle has a pitch-diameter ratio of 16-18, a pitch-diameter ratio of the outermost layer of the double-twisted strand is 10-12, and the direction is all left-handed;

[0142] The braiding density of the copper wire braided shield of the power line core conductor is 90%;

[0143] The power line core conductor pressing mold is a nano-diamond composite coating pressing mold, and the pressing coefficient is 0.9.

[0144] The nano-diamond composite coating pressing mold has a high surface finish, high hardness, and high heat dissipation efficiency, which reduces the friction of the conductor entering the mold and reduces the heat generation phenomenon. The nano-diamond composite coating pressing mold can minimize the outer diameter of the soft conductor and make the conductor surface round without affecting the resistance of the soft conductor.

[0145] The power line core insulation layer is a wrapped polyimide film with a thickness of 0.05 mm, two layers, and an overlap rate of 20%.

[0146] The filling material is silicone filler, which is a new type of filling material, mostly used in aerospace industry systems, and has good thermal conductivity and high temperature resistance. They can effectively reduce the heat generated by the power line core during power transmission and further improve the current carrying capacity of the power line core.

[0147] The shielding layer is a braided shielding layer formed by cross-weaving flat magnesium-aluminum alloy wires, the thickness of the flat magnesium-aluminum alloy wires is 0.05 mm, the width of the flat wires is 0.3 mm, and the braiding density is 80%.

[0148] The anti-radiation layer is an MLI film (a composite film material formed by combining polyimide and aluminum foil), with a thickness of 0.1 mm, one layer, an overlap rate of 30%, and an aluminum surface facing outwards.

[0149] MLI film combines the advantages of both materials and has the advantages of a wide temperature range, excellent mechanical properties, high stability, and excellent radiation resistance. It has a reflectivity of more than 78% for radiation with a wavelength ranging from 0.2 microns to 1.2 microns and performs relatively stably.

[0150] The outer protective layer is radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE), the thickness of the outer protective layer is 2.0 mm, and the radiation dose is preferably in the range of 8-13M.

[0151] A composite cable for aerospace use comprises a signal core, a control core, a power core, a filling, a shielding layer, an anti-radiation layer and an outer sheath which are arranged in sequence from the inside to the outside.

[0152] A layer of polyimide film 302 coated with PI adhesive is arranged outside the annealed Category 5 soft copper conductor of the signal core 3 as the inner insulation of the signal core. A layer of radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation layer is extruded outside the inner insulation layer 302 of the signal core. The composite insulation layer is composed of a layer of polyimide film coated with PI adhesive and an extruded layer of radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation. This composite structure combines the advantages of the two materials, further improves the high temperature resistance, moisture resistance, hydrolysis resistance, wear resistance, and radiation resistance of the cable, and at the same time can reduce the thickness of the radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE), reduce the volume of the cable, and reduce the cost. By designing the signal core 3, two signal cores 3 are twisted into pairs and filled with silicone material to form a twisted pair core. By setting the twisting pitch and twisting direction of the wire pairs, the distributed inductance is reduced and the electromagnetic interference capability is improved. A layer of aluminum-plastic composite tape is arranged outside the twisted pair core. The aluminum-plastic composite tape is longitudinally wrapped and has good overall shielding performance and moisture-proof performance. A layer of magnesium-aluminum alloy wire braided shielding is arranged outside the aluminum-plastic composite tape. The braiding density is 80%. Together with the longitudinally wrapped aluminum-plastic composite tape, the electromagnetic interference resistance capability can be further improved.

[0153] A layer of polyimide film coated with PI adhesive is arranged outside the annealed Category 5 soft copper conductor of the control line core 2 as the inner insulation of the signal line core. A layer of radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation is extruded outside the inner insulation of the signal line core. A composite insulation layer is formed by a layer of polyimide film coated with PI adhesive and an extruded layer of radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) insulation.

[0154] Two signal twisted pairs of cores are placed in the center, and control cores are arranged around them. The cabling is completed at one time to form a control signal cable core 4, which is also filled with glass fiber rope. As an inorganic non-metallic material with excellent performance, glass fiber rope has good insulation, strong heat resistance and good corrosion resistance, and can further improve the shielding ability of the cable signal core.

[0155] After the cable is formed, two layers of hot-melt aluminum foil Mylar tape are arranged outside the control signal cable core 4. The aluminum foil Mylar can remove electromagnetic interference and prevent the electromagnetic waves generated by the power core 1 when transmitting electric energy from affecting the functions of the control core 2 and the signal core 3, which can make the shielding effect more superior. In addition, it has a good effect on the static discharge after grounding, and has a good hot-melt bonding effect at a lower preheating temperature, and maintains long-term stability; a braided shielding layer 6 made of flat magnesium-aluminum alloy wire cross-woven is arranged outside the hot-melt aluminum foil Mylar tape. The magnesium-aluminum alloy wire has a small specific gravity, light weight, strong braidability, and low price. At the same time, the braided shielding layer adopts a flat magnesium-aluminum alloy wire weaving design, which can reduce the total size and weight of the wire compared to the round braided wire, and is more in line with the requirements of aerospace products. The cross-weaving design can make the braided shielding layer 6 anti-bending and anti-vibration, greatly improving the stability and service life of the cable.

[0156] A power core 1 is arranged outside the braided shielding layer 6, and the conductor of the power core 1 is composed of an annealed round compacted soft copper conductor, which is twisted and then braided with a copper wire braided shielding layer. Compared with traditional solid conductors and Class II compacted conductors, the annealed round compacted soft copper conductor is softer, has good bendability, and has a long service life. The conductor wire bundle and the double twist are both left-handed, which further increases the softness of the conductor; the double twisted layers are compacted by a nano-diamond composite coating compacting mold, which can reduce the gap inside the conductor, reduce the conductor diameter and cross-sectional area, reduce the conductor resistance, save subsequent processing materials, and increase the conductor filling factor. The surface of the conductor after compaction is smooth, round and burr-free, and the electric field on the conductor surface is uniform; by setting a layer of copper wire braided shielding layer, the heat dissipation capacity of the conductor can be improved, thereby increasing the current carrying capacity of the conductor; and the copper wire braided shielding layer can reduce the electromagnetic waves generated by the power core itself in the process of transmitting electric energy, which will have an electromagnetic impact on the surrounding electronic equipment, thereby causing signal quality, data loss, equipment damage, safety hazards, etc. The conductor structure composed of annealed round compact soft copper conductors twisted together and then braided with a copper wire braided shielding layer has the advantages of good bending and long service life; good heat dissipation and high current carrying capacity; small dielectric loss, more stable transmission capacity, and can avoid electromagnetic wave interference generated by itself. The insulation layer 103 of the power line core is a polyimide film. The characteristics of polyimide materials are: excellent mechanical properties, excellent dielectric properties, high and low temperature resistance, wear resistance, creep resistance, radiation resistance, combustion resistance, low outgassing, and are widely used in the aerospace field; using polyimide thin material as the insulation layer of the power line core 1 can meet the requirements of the aerospace field while reducing its volume and reducing costs. The power line core 1 and the control signal cable core 4 are cabled again, and the gap is filled with organic silicon filler 5 to make it round. Silicone filler 5 is a new type of filling material, which is mostly used in aerospace industrial systems and has good thermal conductivity and high temperature resistance. They can effectively reduce the heat generated by the power line core during power transmission and further improve the current carrying capacity of the power line core. A layer of MLI film 7 (a composite film material formed by combining polyimide and aluminum foil) is arranged outside the power line core 1. The MLI film 7 combines the advantages of two materials and has the advantages of a wide temperature range, excellent mechanical properties, high stability, and excellent radiation resistance. It has a reflectivity of more than 78% for radiation with a wavelength from 0.2 microns to 1.2 microns, has good radiation resistance, and performs stably.A layer of radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) outer sheath 8 is extruded outside the MLI film 7. Under the conditions of large temperature difference and high radiation intensity in outer space, the mechanical properties of the radiation cross-linked modified ethylene-tetrafluoroethylene (X-ETFE) outer sheath 8 can still meet the use requirements of the space environment. It has good high and low temperature resistance and excellent radiation resistance. Its internal macromolecular linear structure is changed to a macromolecular network structure. At the same time, the MLI film 7 is used to further improve the mechanical protection performance of the cable, reduce the safety accidents such as short circuit caused by mechanical or chemical environment factors, and greatly improve the service life and safety level of the cable.

[0157] The above is only a preferred embodiment of the utility model, and does not limit the structure of the utility model in any form. Any simple modification, equivalent change and modification made to the above embodiment based on the technical essence of the utility model are within the scope of the technical solution of the utility model.

Claims

1. A composite cable for aerospace use, which is provided with a signal core (3), a control core (2), a power core (1), a filling layer, a shielding layer, an anti-radiation layer (7), and an outer sheath (8) in sequence from the inside to the outside, characterized in that: The signal wire core (3) comprises a signal wire core conductor (301) and a signal wire core inner insulating layer (302) and a signal wire core outer insulating layer (303) which are sequentially arranged outside the signal wire core conductor (301); The signal line core conductor (301) is formed by twisting annealed Category 5 soft copper conductor bundles; The signal line cores are 4 cores, twisted in pairs; Two signal wire cores are twisted into a pair and filled with a first filling layer (304); A first shielding layer (305) and a second shielding layer (306) are sequentially arranged outside the first filling layer (304) to form a twisted pair wire core (307); A second filling layer (308) is arranged outside the two signal twisted pair wire cores (307); A control core (2) is arranged outside the twisted pair cable core; The control core (2) comprises a control core conductor (201) and a control core inner insulating layer (202) and a control core outer insulating layer (203) which are sequentially arranged outside the control core conductor (201); The control line core conductor is made of annealed Category 5 soft copper conductor bundles; Two signal twisted pair wire cores (307) are placed in the center, and control wire cores (2) are arranged around them, and the cabling is completed at one time to form a control signal cable core (4); Two layers of hot-melt aluminum foil Mylar tape (401) are arranged on the outside of the control signal cable core (4); A braided shielding layer (6) is arranged outside the hot-melt aluminum foil Mylar tape (401); A power line core (1) is arranged around the outer side of the control signal cable core; The power line core (1) comprises: a power line core conductor and a power line core insulation layer (103); The power line core conductor is composed of annealed round compacted soft copper conductor (101) which is twisted and then braided with a copper wire braided shielding layer (102); The power line core conductor is first bundled and then re-twisted, and each layer of the re-twisted layer is pressed through a nano-diamond composite coating mold; The control signal cable core and the power line core are twisted into a composite cable core; An anti-radiation layer (7) and an outer sheath (8) are sequentially arranged on the outer side of the composite cable core; A third filling layer (5) is provided in the gap between the shielding layer (6) and the composite cable core and between the composite cable core and the anti-radiation layer (7).

2. The composite cable for aerospace use according to claim 1, characterized in that: The cable conductors of the signal cores are twisted in opposite directions; adjacent twisted pairs are twisted in opposite directions, with one insulated core twisted pair pitch being 60-80mm and the other insulated core twisted pair pitch being 80-100mm.

3. The composite cable for aerospace use according to claim 1, characterized in that: The signal line core conductor pitch ratio is 14-16; The inner insulation layer of the signal line core is wrapped with a layer of polyimide film coated with PI adhesive; The outer insulation layer of the signal line core adopts radiation cross-linked modified ethylene-tetrafluoroethylene insulation to form a composite insulation layer; The thickness of the polyimide film coated with PI adhesive was 0.05 mm, single layer, and the overlap ratio was 5%; Radiation cross-linked modified ethylene-tetrafluoroethylene insulation, thickness 0.13mm, radiation dose 8-13M; The signal wire core is twisted and longitudinally wrapped with a layer of aluminum-plastic composite tape, with the aluminum side facing outwards, and the thickness is 0.05mm; A layer of magnesium-aluminum alloy wire braided shielding is arranged outside the aluminum-plastic composite belt, and the braiding density is 80%.

4. The composite cable for aerospace use according to claim 1, characterized in that: The control line core conductor pitch ratio is 14-16; The inner insulation layer of the control line core is wrapped with a layer of polyimide film coated with PI adhesive; The outer insulation layer of the control line core adopts radiation cross-linked modified ethylene-tetrafluoroethylene insulation to form a composite insulation layer; The thickness of the polyimide film coated with PI adhesive was 0.05 mm, single layer, and the overlap ratio was 5%; The thickness of the radiation cross-linked modified ethylene-tetrafluoroethylene insulation layer is 0.13 mm, and the radiation dose is 8-13 M.

5. The composite cable for aerospace use according to claim 1, characterized in that: The power line core conductor bundle has a pitch-diameter ratio of 16-18, a pitch-diameter ratio of the outermost layer of the double-twisted strand is 10-12, and the direction is all left-handed; The braiding density of the copper wire braided shield of the power line core conductor is 90%; The power line core conductor pressing mold is a nano-diamond composite coating pressing mold, and the pressing coefficient is 0.

9.

6. The composite cable for aerospace use according to claim 1, characterized in that: The power line core insulation layer is a wrapped polyimide film with a thickness of 0.05 mm, two layers, and an overlap rate of 20%.

7. The composite cable for aerospace use according to claim 1, characterized in that: The shielding layer is a braided shielding layer formed by cross-weaving flat magnesium-aluminum alloy wires, the thickness of the flat magnesium-aluminum alloy wires is 0.05 mm, the width of the flat wires is 0.3 mm, and the braiding density is 80%; The anti-radiation layer is an MLI film with a thickness of 0.1 mm, one layer, and an overlap rate of 30%; the aluminum surface faces outwards; The outer sheath is radiation cross-linked modified ethylene-tetrafluoroethylene, the sheath thickness is 2.0mm, and the radiation dose is in the range of 8-13M.

8. The composite cable for aerospace use according to claim 1, characterized in that: The first filling layer (304) is an organic silicon material; The second filling layer (308) is glass fiber rope; The third filling layer (5) is an organic silicon material; The first shielding layer (305) is an aluminum-plastic composite tape, which is longitudinally wrapped; The second shielding layer is a magnesium-aluminum alloy wire braided layer.

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