High-flexibility lightweight cable

Abstract

The utility model discloses a high-flexibility lightweight cable, and belongs to the technical field of wire and cable manufacturing. Comprising a conductor, an insulating layer is arranged outside the conductor, the conductor is composed of a plurality of rectangular copper flat wires which are arranged side by side at certain intervals, the insulating layer is arranged outside the conductor and is a polyimide / silver-plated (or nickel-plated) copper composite film, glue is arranged between the conductor and the insulating layer, and silver-plated / nickel-copper composited on the surface of polyimide serves as a shielding layer. The device has the characteristics of small size and light weight, and can effectively meet the use requirements of aerospace environments.

Description

Technical Field

[0001] This invention relates to a highly flexible and lightweight cable, specifically a highly flexible and lightweight multi-core conductor flat cable, belonging to the field of wire and cable manufacturing technology, and can be applied to aerospace, flying car and other fields. Background Technology

[0002] Currently, multi-core round cables are widely used in the domestic aerospace and flying car fields for transmitting low-frequency signals and 28V (DC) current. The aerospace and flying car fields have increasingly stringent requirements for weight reduction, leading to higher demands for smaller cable sizes. In some missile and rocket-borne applications, due to space constraints, the need for smaller cable sizes is even more urgent. Using flat cables can address these user pain points. This invention's product uses silver-plated or nickel-plated flat copper conductors and employs a thin, adhesive-coated polyimide / silver-plated (or nickel-plated) copper composite film and high-temperature pressing technology, effectively reducing the weight and volume of the system cable. The product features small size, light weight, and excellent insulation performance, as well as superior resistance to high and low temperatures, scratches, and cuts. Utility Model Content

[0003] The purpose of this invention is to overcome the shortcomings of existing aerospace wires and cables: the outer diameter and weight of wires and cables cannot be made smaller and lighter, which cannot meet the requirements of weight reduction and installation in narrow spaces.

[0004] The present invention proposes a highly flexible and lightweight cable, comprising a conductor, an insulating layer outside the conductor, the conductor being a plurality of rectangular copper flat wires arranged side by side at a certain interval, the insulating layer being a polyimide composite film, and an adhesive between the conductor and the insulating layer.

[0005] Furthermore, the insulating layer and the silver / nickel-copper shielding layer are composited into a single unit, wherein the inner layer is polyimide and the outer layer is a silver / nickel-copper plating layer.

[0006] Furthermore, the insulating polyimide surface is laminated with silver (or nickel) copper as a shielding layer.

[0007] Furthermore, the width of the copper flat wire is 0.25–1.0 mm and the thickness is 0.028–0.04 mm.

[0008] Furthermore, the outer surface of the copper flat wire is plated with silver or nickel.

[0009] Furthermore, the thickness of the polyimide composite film is 0.018–0.050 mm.

[0010] Furthermore, the insulating layer consists of two layers, upper and lower, with adhesive applied to the inner side, and is bonded together into a single integral layer using high temperature pressing.

[0011] (1) Unlike existing cable products that generally use round conductors, the conductors of this product are flat conductors, and the minimum conductor cross-sectional area can reach 0.007mm2 (0.25mm×0.028mm), which is much smaller than the smallest round cable currently used in aerospace (7 / 0.08mm, cross-section 0.035mm2). The reduction in conductor cross-sectional area makes the product lighter and smaller; (2) Unlike existing round cables that use separate insulation layers for each conductor and require multiple insulation molding and cable stranding, the conductors of this product are arranged side by side at a certain interval. In one insulation layer, and can be formed in one step, the product realization method is simplified and the production efficiency is higher; (3) Adhesive polyimide pressing technology is used, the insulation thickness is thin, about (0.018~0.05) mm, and the combination of copper flat wire and thin insulation makes the cable have the characteristics of small size; (4) Unlike the existing polyimide high temperature tape with a low temperature resistance of -70℃, the adhesive polyimide composite film used in this solution can withstand a low temperature of -150℃, and the temperature resistance range is (-150~+200)℃. The wide range of operating temperatures can effectively meet the requirements of aerospace environment. (5) Unlike the existing cable products where the shielding layer and insulation layer are formed separately, this solution can realize the one-time forming of the insulation layer and shielding layer. The insulation material uses polyimide material, which has excellent scratch resistance and cut resistance; Attached Figure Description

[0012] Appendix Figure 1 This is a flowchart of the production process for highly flexible and lightweight cables.

[0013] Appendix Figure 2 This is a schematic diagram of the cable structure.

[0014] In the attached diagram, 1 is the conductor, and 2 is the adhesive-coated polyimide composite insulation layer and the silver / nickel-copper plated shielding layer. Detailed Implementation

[0015] Referring to the attached diagram, the highly flexible and lightweight cable comprises a conductor 1 and an insulation layer 2. The conductor 1 consists of several rectangular flat copper wires arranged side-by-side at a certain spacing. The insulation layer 2 is a polyimide composite film, and there is adhesive between the conductor and the insulation layer. A silver / nickel-copper plating layer is laminated onto the surface of the insulation layer as a shielding layer.

[0016] The method for preparing a highly flexible and lightweight cable includes the following steps:

[0017] 1) Select silver-plated or nickel-plated copper flat wire conductors with a width of (0.2~1.0) mm and a thickness of (0.02~0.04) mm;

[0018] 2) Select a high thermal conductivity polyimide / silver-plated (or nickel-plated) copper composite film with an appropriate width and a thickness of (0.018~0.050) mm;

[0019] 3) A high-precision multi-axis active cable feeding machine is used to pull out multiple silver-plated or nickel-plated copper flat wires and two-axis adhesive polyimide / silver-plated (or nickel-plated) copper composite films under traction. Under the action of the groove mold, multiple conductors are arranged between the adhesive polyimide films with a conductor spacing of (1~3) mm. The adhesive side of the polyimide composite film faces the conductors, and the silver-plated (or nickel-plated) copper layer faces outwards. A high-temperature pressing machine is used to apply a high-temperature pressing process of (200~230)℃ to bond the upper and lower polyimide adhesive surfaces, forming an insulation layer with a single-sided thickness of (0.018~0.050) mm, thus forming the finished cable.

[0020] Example 1 (4-core cable with a cross-sectional area of ​​0.012 mm²):

[0021] 1) Select a 0.4mm × 0.03mm silver-plated copper flat wire conductor;

[0022] 2) Select a 10mm × 0.025mm adhesive-coated high thermal conductivity polyimide composite film;

[0023] 3) A high-precision 6-axis active cable feeding machine is used to pull out 4 silver-plated copper flat wires and 2 axes of adhesive polyimide / silver-plated copper composite film under traction. Under the action of the groove mold, the 4 conductors are arranged between the adhesive polyimide with a conductor spacing of 1.5mm. The adhesive side of the polyimide composite film faces the conductors, and the silver-plated copper side faces outward. A high-temperature pressing machine is used to bond the upper and lower polyimide adhesive sides together using a (200~230)℃ high-temperature pressing process to form an insulation layer with a single-sided thickness of 0.025mm, forming a 4-core cable with a cross-sectional area of ​​0.012mm2. The cable is 10mm wide and 0.08mm thick.

Claims

1. A high-flexibility lightweight cable comprising a conductor, outside of which there is an insulating layer, characterized in that, The conductor is several rectangular copper flat wires in parallel with a certain interval, and the conductor is surrounded by an insulation layer, which is a polyimide composite film, and there is glue between the conductor and the insulation layer, and the surface of the polyimide is coated with a silver / nickel copper layer.

2. The high-flexible lightweight cable according to claim 1, wherein, The insulation layer and the silver / nickel copper shielding layer are combined into one whole, in which the inner layer is polyimide and the outer layer is a silver / nickel copper layer.

3. The high-flex lightweight cable of claim 1, wherein, The width of the copper flat wire is 0.25-1.0 mm and the thickness is 0.028-0.04 mm.

4. The high-flex lightweight cable of claim 1, wherein, The outer surface of the copper flat wire is plated with silver or nickel.

5. The high-flex lightweight cable of claim 1, wherein, The thickness of the polyimide composite film is 0.018-0.050 mm, and the thickness of the combined silver / nickel copper layer is greater than or equal to 6 μm.

6. The high-flex lightweight cable of claim 1, wherein, The insulation layer is divided into two layers, the inner side is coated with glue, and high-temperature pressing is used to combine them into one whole layer.

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