High-fidelity tensile wear-resistant flexible avionics wire

Abstract

The utility model provides a high-fidelity tensile wear-resistant flexible avionic wire, which enhances the signal fidelity and tensile wear-resistant characteristics on the basis of ensuring the characteristics of high temperature resistance, low temperature resistance, radiation resistance, chemical corrosion resistance and the like of a cable and ensuring that the cable can still work normally in various severe environments. The high-fidelity tensile wear-resistant flexible avionic wire comprises silver-plated flexible conductors (1) which are arranged in parallel as wire harnesses, a high-flame-retardant cotton fiber filler (4), polyimide wire cores (5) which are distributed in a central symmetry manner, a copolymer insulating layer (2) which wraps the silver-plated flexible conductors (1), and an independent shielding layer (3) which wraps the copolymer insulating layer (2), and a high-temperature-resistant belting isolation layer (6), a reinforced shielding layer (7), a polytetrafluoroethylene sheath layer (8) and an aramid fiber woven sheath (9) are sequentially arranged on the outer layer of the parallel arrangement from inside to outside.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and in particular to a high-fidelity, tensile-resistant, wear-resistant, flexible aviation electronic wire. Background Technology

[0002] Aerospace electronic wiring is the lifeblood of aircraft safety, often playing a crucial role. The aerospace environment is complex and highly variable, requiring electronic wiring to operate stably for extended periods in extreme conditions without open circuits or short circuits. High reliability is fundamental to the normal operation of avionics systems. During use, electronic wiring is subjected to various physical forces such as vibration and friction, necessitating excellent wear resistance to ensure long-term stable operation. Aerospace vehicles have extremely stringent weight requirements; lightweight design is key to reducing fuel consumption and improving flight efficiency. Therefore, electronic wiring also needs to be lightweight to reduce overall weight. With increasingly compact internal space layouts in aerospace vehicles, electronic wiring needs good flexibility to adapt to various complex wiring requirements. While existing electronic wiring meets the needs of the aerospace field to some extent, some limitations remain. Signal distortion is a significant challenge for existing avionics wiring. In complex flight environments, wiring is susceptible to electromagnetic interference, vibration, and other factors, leading to signal distortion or even loss, seriously threatening flight safety. Traditional wiring often uses a single metal conductor, offering limited shielding performance and failing to effectively resist external interference. In addition, impedance mismatch issues in the cable can also lead to signal reflection and attenuation, further exacerbating signal distortion.

[0003] Insufficient abrasion resistance is also a key factor limiting the performance of existing avionics wiring. During long-term aircraft operation, wiring undergoes frequent bending, friction, and vibration, easily causing wear and damage to the wire surface, leading to a decline in electrical performance and even safety hazards such as short circuits. Traditional wiring typically uses simple insulation and sheathing materials with limited abrasion resistance, making it difficult to cope with the harsh flight environment.

[0004] Besides signal distortion and insufficient wear resistance, existing avionics wires also have many shortcomings in terms of lightweighting, flexibility, and high-temperature resistance. In order to meet the requirements of next-generation aerospace vehicles for high-performance connection systems, it is imperative to develop high-fidelity, tensile-strength, wear-resistant, and flexible avionics wires.

[0005] High-fidelity, tensile-resistant, and wear-resistant flexible avionics wire is a high-performance electronic wire specifically designed for the aerospace field. It possesses excellent electrical, mechanical, and environmental adaptability. It will play a significant role in promoting the development of my country's aerospace industry and provide strong support for the safe and reliable operation of aircraft. Summary of the Invention

[0006] To overcome the shortcomings of existing technologies, this utility model patent provides a high-fidelity, tensile-resistant, and wear-resistant flexible aerospace electronic cable. While ensuring the cable's resistance to high and low temperatures, radiation, and chemical corrosion, guaranteeing its normal operation in various harsh environments, it also enhances signal fidelity and tensile and wear-resistant properties. In particular, it employs an ultra-soft conductor, using the sixth type of silver-plated conductor in GB / T 3956-2008. Compared to the first, second, and fifth types of conductors in ordinary cables, it has significantly greater flexibility, greatly increasing the cable's bending resistance and service life. Simultaneously, the silver plating greatly enhances the conductor's conductivity and corrosion resistance, ensuring efficient and stable signal transmission. The cross-linked ethylene-tetrafluoroethylene copolymer insulation material not only guarantees long-term use within a wide temperature range of -80℃ to 220℃ but also possesses superior tensile strength, impact resistance, and corrosion resistance. Independent and reinforced shielding structures effectively isolate signal interference, preventing noise that could affect information transmission and listening experience. The use of high flame-retardant cotton fiber filling further protects information transmission while reducing weight and improving the flame-retardant performance of the cable. The centrally symmetrically distributed polyimide cores (at least 6) ensure even load distribution, enhancing cross-sectional stability and preventing cable breakage due to excessive elongation. The PTFE sheath has extremely high insulation resistance, effectively isolating current and heat. Its extremely high surface tension and low coefficient of friction make it resistant to stains and other debris, preventing adhesion and facilitating cleaning. It also withstands various corrosive media, including strong acids, strong alkalis, and organic solvents, extending the service life of equipment. Furthermore, the cable maintains stable performance under high-temperature conditions (continuous operating temperature up to 260℃), is not easily combustible, and will not produce toxic gases even if ignited. The aramid fiber braided sheath can withstand significant tensile and compressive forces, is not easily deformed or broken, and has excellent wear resistance and tear resistance. Meanwhile, the woven sheath layer is also resistant to high temperatures and corrosion, and has excellent flame retardant and electrical insulation properties. Even when burning at high temperatures, the surface will carbonize, without producing molten droplets or supporting combustion, thus effectively preventing the spread of fire.

[0007] The technical solution of this utility model is: a high-fidelity tensile and wear-resistant flexible aviation electronic wire, characterized in that it includes: a silver-plated soft conductor (1) arranged in parallel with the wire bundle, a high flame-retardant cotton fiber filler (4), and a polyimide wire core (5) distributed in a centrally symmetrical manner, wherein it also includes a copolymer insulation layer (2) covering the silver-plated soft conductor (1) and an independent shielding layer (3) covering the copolymer insulation layer (2), and a high-temperature resistant wrapping isolation layer (6), a reinforced shielding layer (7), a polytetrafluoroethylene sheath layer (8), and an aramid fiber braided sheath (9) arranged sequentially from the inside to the outside of the parallel arrangement.

[0008] By adopting the above technical solution, this utility model has the following advantages:

[0009] (1) The cable of this utility model, under the premise of ensuring that it meets the requirements of aerospace wear resistance, corrosion resistance, high and low temperature resistance and stable performance, uses highly conductive materials (such as silver-plated copper) for its internal conductor, which can effectively reduce the loss and interference in the signal transmission process, thereby ensuring the high fidelity of the signal.

[0010] (2) Independently braided and reinforced shielding layers ensure the accuracy and stability of signal transmission between avionics devices.

[0011] (3) High flame retardant cotton fiber filling can reduce external interference to signal transmission and reduce weight. The centrally symmetrically distributed polyimide core can ensure that the cable can withstand various complex mechanical stresses and ensure the stable operation of the equipment.

[0012] (4) The high tensile strength insulation layer, sheath layer, and aramid braided sheath can effectively prevent damage to the cable caused by friction and wear during long-term use. This not only extends the service life of the cable but also improves the reliability and safety of avionics equipment.

[0013] (5) Its flexible design allows it to easily handle various complex wiring scenarios. This not only facilitates cable installation and wiring but also improves the adaptability and flexibility of the cables.

[0014] Furthermore, the silver-plated soft conductor (1) is a wire harness formed using Class 6 silver-plated conductors in GB / T3956-2008. Its beneficial effects are: (1) It increases the bending performance of the cable, making it less prone to damage and effectively extending the cable's service life. (2) The silver plating structure greatly enhances the cable's conductivity and corrosion resistance, ensuring undistorted information transmission.

[0015] Furthermore, the copolymer insulation layer (2) is a sheet extruded from cross-linked ethylene-tetrafluoroethylene copolymer insulation material. Specifically, the copolymer insulation layer (2) is extruded from cross-linked ethylene-tetrafluoroethylene copolymer insulation material (XETFE) (insulation concentricity not less than 75%). After cross-linking by electron beam irradiation, its mechanical strength and aging resistance can be significantly improved, while maintaining the original characteristics of ETFE, such as lightweight, chemical resistance and good flame retardancy. It can ensure long-term use of the cable in a wide temperature range of -80℃ to 220℃, and also has super tensile strength, impact resistance and corrosion resistance.

[0016] Furthermore, the independent shielding layer (3) is formed by continuous braiding of silver-plated copper monofilaments with a diameter of not less than 0.1 mm, a braiding density of not less than 90%, and a braiding angle between [50, 72] degrees. The independent shielding layer (3) and the reinforced shielding layer (7) use silver-plated copper monofilaments with a diameter of more than 0.1 mm and a braiding density of not less than 90%. (Except for cable core outer diameter greater than 7.9 mm, the braiding angle should be not less than 50 degrees and not more than 72 degrees. The braiding should be continuous and without damage.) The highly conductive silver-plated copper wire can transmit current more effectively, reduce energy loss, and improve the efficiency and stability of signal transmission. In the aviation environment, due to the presence of various corrosive substances and high temperature conditions, ordinary copper wires are easily damaged, while silver-plated copper wires can better adapt to these harsh environments. Silver-plated copper wires can also enhance the corrosion resistance and oxidation resistance of aviation electronic wires, extending their service life. Silver-plated copper wires are easy to weld, and the welded connection points have high strength and good stability, improving the reliability and safety of the entire line. Furthermore, the silver-plated copper wire braiding can significantly reduce the contact resistance of the metal surface, ensuring accurate signal transmission and normal operation of the equipment (increased contact resistance leads to energy loss and signal attenuation, thus affecting the performance of electronic devices).

[0017] Furthermore, the polyimide core (5) adopts a centrally symmetrical distribution of polyimide cores, with a number of not less than 6.

[0018] Furthermore, the high flame-retardant cotton fiber filler (4) is made by filling the entire inner wall space of the high-temperature resistant packaging tape isolation layer (6) with high flame-retardant cotton fiber. Specifically, the high flame-retardant cotton fiber filler (4) is filled with high flame-retardant cotton fiber with an oxygen index ≥30. The optimized high flame-retardant cotton fiber is much lighter than ordinary filler materials. At the same time, the cotton fiber material can ensure the stability of signal transmission, and the flame retardant is evenly dispersed in the cotton fiber, which improves the flame-retardant performance of the cotton fiber.

[0019] Furthermore, the centrally symmetrically distributed polyimide cores (5) are ≥6 in number, ensuring uniform load distribution, enhancing cross-sectional stability, and preventing wire breakage due to excessive elongation. This significantly enhances the cable's resistance to torsion and tension. The material also possesses permanent antistatic properties, effectively reducing mutual interference between signals. When cabling with two or more cores, to ensure stability, the cabling pitch should be no less than 6 times the cable's outer diameter and no more than 16 times the cabling pitch.

[0020] Furthermore, after the high-temperature resistant wrapping isolation layer (6) is cabled, two layers of polytetrafluoroethylene (PTFE) machined film tape or other tapes with suitable temperature resistance are wrapped around the outside of the cable core, and the wrapping overlap rate is not less than 30%.

[0021] The reinforced shielding layer (7) is formed by continuous weaving and extension of silver-plated copper monofilaments with a wire diameter of not less than 0.1 mm, a weaving density of not less than 90%, and a weaving angle between [50, 72] degrees.

[0022] Furthermore, the PTFE sheath layer (8) is a sheet extruded from PTFE. Specifically, the PTFE sheath layer (8) is extruded from PTFE (with a sheath concentricity of not less than 75%). PTFE maintains excellent physical and mechanical properties over a very wide temperature range (-80℃ to 220℃), ensuring the stability and reliability of signal transmission. Moreover, the material is almost unaffected by any substance, resisting various corrosions and extending the cable's service life. PTFE also has excellent electrical insulation properties, further ensuring the purity and stability of signal transmission and preventing electromagnetic interference and signal leakage. It also improves the transmission efficiency of microwave signals and reduces signal distortion. In addition, PTFE has high strength, light weight, and extremely low surface energy, which not only meets the requirements of lightweight design but also has extremely strong non-stick and self-lubricating properties. This reduces friction and wear between the cable and connector, improving the cable's insertion and extraction force and durability.

[0023] Furthermore, the aramid fiber braided sheath (9) is woven from high-strength, low-density aramid fibers with a braiding density of not less than 85%. Its beneficial effects include: aramid fibers possess excellent high-temperature resistance, allowing them to be used for extended periods in high-temperature environments without melting or deformation (withstanding 400℃); they remain stable in strong acid and alkali environments and are not easily damaged by insects, fungi, or molds. Aramid fibers themselves also have good flame-retardant properties; they not only do not burn but can also quickly extinguish fires, preventing the fire from spreading. In addition, aramid fibers can make the electric field distribution between the insulating and cooling media more uniform, ensuring stable and reliable signals. Even with an electromagnetic radiation dose of 8 MGy, its performance is essentially unaffected. Attached Figure Description

[0024] The present invention will be further described below with reference to the accompanying drawings:

[0025] Figure 1 This is a schematic cross-sectional view of a high-fidelity, tensile-resistant, and wear-resistant flexible avionics wire according to this utility model. The reference numerals are:

[0026] Silver-plated soft conductor (1), copolymer insulation layer (2), independent shielding layer (3), high flame-retardant cotton fiber filling (4), centrally symmetrically distributed polyimide core (5), high temperature resistant wrapping isolation layer (6), reinforced shielding layer (7), polytetrafluoroethylene sheath layer (8), aramid fiber braided sheath (9). Detailed Implementation

[0027] The embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0028] In the description of this utility model, it should be understood that the terms "center", "longitudinal", "lateral", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", and "outer" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0029] Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0030] Or it may implicitly indicate the number of indicated technical features. Thus, features defined as "first" or "second" may explicitly or implicitly include at least one of those features. In the description of this utility model, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified.

[0031] In this utility model, unless otherwise expressly specified and limited, the terms "installation," "connection," "linking," and "fixing" are used interchangeably.

[0032] The terms "connection" and "interconnection" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between the components; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal connection of two components or the interaction between two components, unless otherwise explicitly defined. Those skilled in the art can understand the specific meaning of the above terms in this utility model according to the specific circumstances.

[0033] See Figure 1 Taking the implementation of this utility model of a high-fidelity, tensile-resistant, wear-resistant, flexible avionics wire as an example, the soft conductor 1 adopts the silver-plated conductor of Class 6 in GB / T 3956-2008, which is thinner than the monofilaments of Class 1 and Class 2, has better flexibility, longer bending life, is easier to lay, and also increases conductor strength. The service life of the cable is effectively extended. The silver plating structure greatly enhances the cable's conductivity and corrosion resistance, ensuring undistorted information transmission.

[0034] The copolymer insulation layer 2 is formed by electron irradiation after extrusion of cross-linked ethylene-tetrafluoroethylene copolymer insulation material. Its insulation thickness, color recognition, etc. meet the requirements of GJB 773B-2015 standard (insulation concentricity not less than 75%).

[0035] The independent shielding layer 3 uses silver-plated copper monofilaments with a diameter of 0.1mm or more, and the braiding density is not less than 90%. (Except for cable cores with an outer diameter greater than 7.9mm, the braiding angle should be not less than 50 degrees and not more than 72 degrees.) The braiding is continuous and without damage.

[0036] 4. High flame-retardant cotton fiber filling: The filling material is high flame-retardant cotton fiber with an oxygen index ≥30.

[0037] The polyimide cores 5 are centrally symmetrically distributed, with a quantity of ≥6 cores. When cabling two or more cores, to ensure stability, the cabling pitch shall not be less than 6 times the outer diameter of the cabling and not more than 16 times the cabling pitch.

[0038] After the high-temperature resistant insulation layer is 60% complete, a layer of polytetrafluoroethylene (PTFE) machined film tape or other suitable tape can be wrapped around it, with a wrapping overlap rate of not less than 30%.

[0039] The reinforced shielding layer 7 uses silver-plated copper monofilaments with a diameter of 0.1mm or more, and a braiding density of not less than 90%. (Except for cable cores with an outer diameter greater than 7.9mm, the braiding angle should be not less than 50 degrees and not more than 72 degrees.) The braiding should be continuous and without damage.

[0040] The PTFE sheath layer 8 is made of PTFE through extrusion. Its sheath thickness and other specifications meet the requirements of GJB 773B-2015 standard, and the concentricity of the sheath is not less than 75%.

[0041] The aramid fiber braided sheath 9 is made of high-strength aramid fiber for wires and cables, with a braiding density of not less than 85%.

[0042] This invention relates to a high-fidelity, tensile-resistant, and wear-resistant flexible avionics cable. While ensuring compliance with aerospace requirements for wear resistance, corrosion resistance, high and low temperature resistance, and stable performance, it effectively reduces signal loss and interference during transmission, thereby ensuring high signal fidelity and the accuracy and stability of signal transmission between avionics devices. The cable can also withstand various complex mechanical stresses, ensuring stable equipment operation. It effectively prevents damage caused by friction and wear during long-term use. This not only extends the cable's service life but also improves the reliability and safety of avionics equipment.

[0043] This cable is particularly suitable for electrical system connections in aircraft and helicopters, signal transmission and power connections in satellites and spacecraft, and internal connections and signal transmission in avionics equipment. It is also suitable for high-end applications in armored vehicles, weaponry, ships, electronics, and communications.

[0044] The above description is only a specific embodiment of the present utility model, but the technical features of the present utility model are not limited thereto. Any changes or modifications made by those skilled in the art within the scope of the present utility model are covered by the patent scope of the present utility model.

Claims

1. A high-fidelity, pull-resistant, wear-resistant, flexible avionics wire, characterized in that The parallel arrangement of the silver-plated soft conductor (1), the high-flame-retardant cotton fiber filler (4), the polyimide wire core (5) arranged in a central symmetry, wherein the silver-plated soft conductor (1) is covered with a copolymer insulation layer (2), and the copolymer insulation layer (2) is covered with an independent shielding layer (3), and the high-temperature-resistant tape isolation layer (6), the reinforced shielding layer (7), the polytetrafluoroethylene sheath layer (8), and the aramid fiber woven sheath (9) are arranged in the outer layer from inside to outside in sequence. The silver-plated soft conductor (1) is formed by using the silver-plated conductor of the 6th type in GB / T3956-2008.

2. The high-fidelity, tensile-strength, wear-resistant, flexible avionics wire of claim 1, wherein: The copolymer insulation layer (2) is a sheet layer formed by extruding cross-linked ethylene-tetrafluoroethylene copolymer insulation material.

3. The high-fidelity, tensile-strength, wear-resistant, flexible avionics wire of claim 1, wherein: The independent shielding layer (3) is a silver-plated copper monofilament continuous weaving extension formed by weaving a silver-plated copper monofilament with a wire diameter not less than 0.1 mm, and the weaving density is not less than 90%, and the weaving angle is between [50, 72] degrees.

4. The high-fidelity, tensile-strength, wear-resistant, flexible avionics wire of claim 1, wherein: The polyimide wire core (5) is arranged in a central symmetry, and the number of the polyimide wire core is not less than 6.

5. The high-fidelity, tensile-strength, wear-resistant, flexible avionics wire of claim 1, wherein: The high-flame-retardant cotton fiber filler (4) is used to fill the entire inner wall space of the high-temperature-resistant tape isolation layer (6) with high-flame-retardant cotton fiber.

6. The high-fidelity, pull-resistant, wear-resistant, flexible avionics wire of any of the preceding claims, wherein: The high-temperature-resistant tape isolation layer (6) is formed by winding two layers of polytetrafluoroethylene turning film tapes after cabling, and the winding overlap rate is not less than 30%.

7. The high-fidelity, tensile-strength, abrasion-resistant, flexible avionics wire of claim 6, wherein: The reinforced shielding layer (7) is formed by continuously weaving and extending a silver-plated copper monofilament with a wire diameter not less than 0.1 mm, and the weaving density is not less than 90%, and the weaving angle is between [50, 72] degrees.

8. The high-fidelity, tensile-strength, abrasion-resistant, flexible avionics wire of claim 1, wherein: The polytetrafluoroethylene sheath layer (8) is a sheet layer formed by extruding polytetrafluoroethylene.

9. The high-fidelity, tensile-strength, abrasion-resistant, flexible avionics wire of claim 1, wherein: The aramid fiber woven sheath (9) is a high-strength aramid fiber woven sheet layer for electric wires and cables, and the weaving density is not less than 85%.

10. The high-fidelity, tensile-strength, abrasion-resistant, flexible avionics wire of claim 1, wherein: ​

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