High-temperature-resistant flexible twisted-pair communication cable for complete machine system

Abstract

The utility model relates to a cable, in particular to a high-temperature-resistant flexible twisted-pair communication cable for a complete machine system. The utility model aims to provide a high-temperature-resistant flexible twisted-pair communication cable for a complete machine system. The cable has the characteristics of low attenuation, external electromagnetic interference resistance, light weight and high flexibility. According to the technical scheme, the high-temperature-resistant flexible twisted-pair communication cable for the complete machine system comprises a cable core, and a belting layer, an inner shielding layer, an outer shielding layer, a middle layer and an outer protection layer which sequentially wrap the cable core from inside to outside; the cable is characterized in that the cable core comprises a plurality of leads and a plurality of filling wires which are arranged in parallel along the length direction of the cable; each wire comprises a conductor, an insulating layer and a high-temperature colored tape layer, wherein the insulating layer and the high-temperature colored tape layer sequentially wrap the conductor.

Description

Technical Field

[0001] This utility model relates to a cable, and more particularly to a high-temperature resistant flexible twisted-pair communication cable for use in a complete system. Background Technology

[0002] With the rapid development of overall communication control systems (such as early warning, guidance, information communication, and electronic warfare systems), the requirements for communication cables are becoming increasingly stringent. In addition to meeting basic electrical performance requirements, they also need to meet requirements such as low attenuation, light weight, flexibility, high reliability, high temperature resistance, resistance to various aerospace oils, and suitability for use in various extreme, complex, and harsh environments. These cables are frequently used in the aerospace field, such as in early warning, guidance, information communication, and electronic warfare systems.

[0003] CN213583190U discloses a high-temperature resistant aviation cable, including a protective sheath, an insulation layer bonded inside the protective sheath, a filler layer bonded inside the insulation layer, a drain wire wrapped in the middle of the filler layer, an insulation layer bonded inside the filler layer, a shielding layer bonded inside the insulation layer, and a conductor bonded inside the shielding layer. The protective sheath is made of polyurethane, the insulation layer is made of insulation cotton, the conductor is made of multiple strands of tinned copper wire twisted together, the shielding layer has a braided structure, the insulation layer is a polytetrafluoroethylene layer, and the protective sheath provides overall protection. The shortcomings of this cable are that its resistance to external electromagnetic interference, weight, and flexibility need further improvement. Utility Model Content

[0004] The purpose of this utility model is to overcome the shortcomings in the above-mentioned background technology and provide a high-temperature resistant flexible twisted-pair communication cable for whole system. The cable should have the characteristics of low attenuation, resistance to external electromagnetic interference, light weight, and high flexibility.

[0005] The technical solution provided by this utility model is:

[0006] A high-temperature resistant flexible twisted-pair communication cable for a complete system: comprising a cable core and a wrapping layer, an inner shielding layer, an outer shielding layer, an intermediate layer, and an outer sheath that are sequentially wrapped around the cable core from the inside out; characterized in that: the cable core comprises a plurality of conductors and a plurality of filler wires arranged parallel to each other along the length of the cable; the conductors comprise conductors and an insulation layer and a high-temperature colored tape layer sequentially wrapped around the conductors.

[0007] The conductor is a multi-stranded copper wire with a plating layer;

[0008] The insulating layer is a three-layer composite wrapping structure of low-density microporous tape (LDPTFE) and PTFE raw material tape.

[0009] The inner shielding layer is a silver-plated copper strip armor layer.

[0010] The outer shielding layer is a silver-plated copper wire braided layer.

[0011] The intermediate layer is a polyimide film wrapping layer.

[0012] The sheath layer is a highly flexible, high-strength, flame-retardant thermoplastic elastomer material layer;

[0013] The thickness of the insulating layer is 0.50. ～ 0.55mm; the outer protective layer thickness is 0.70mm. ～ 0.80mm.

[0014] The diameter of the plated copper wire is 0.08 mm. ～ The thickness of the silver-plated copper strip in the silver-plated copper strip armor layer is 0.04 mm (0.10 mm). ～ 0.06mm.

[0015] The wrapping layer is a polytetrafluoroethylene raw material tape wrapping layer.

[0016] The high-temperature color ribbon layer is a polytetrafluoroethylene high-temperature resistant color ribbon wrapping layer.

[0017] The filler line is a solid polytetrafluoroethylene filler line.

[0018] The beneficial effects of this utility model are:

[0019] This invention boasts outstanding advantages such as low attenuation, high shielding, high flexibility, good stability, light weight, high flame retardancy, high temperature resistance, chemical corrosion resistance, excellent mechanical properties, resistance to salt spray, mold, and moisture, and superior resistance to outer space radiation. It withstands temperatures ranging from -60℃ to 150℃ and can be used long-term at 150℃. It can be applied to systems such as early warning, guidance, information communication, and electronic warfare. It can operate in environments with both high and low ambient temperatures and poor heat dissipation. Compared to other conventional extruded insulated communication cables, it is suitable for areas requiring lower attenuation, higher electromagnetic interference resistance, higher flexibility, and lighter weight. Attached Figure Description

[0020] Figure 1 This is a cross-sectional structural diagram of an embodiment of the present invention.

[0021] Figure reference numerals: 1. Filler line; 2. Conductor; 3. Insulation layer; 4. High-temperature colored tape layer; 5. Wrapping tape layer; 6. Inner shielding layer; 7. Outer shielding layer; 8. Intermediate layer; 9. Outer sheath layer. Detailed Implementation

[0022] The embodiments shown in the accompanying drawings will be described in further detail below.

[0023] Figure 1The high-temperature resistant flexible twisted-pair communication cable shown in the diagram includes a cable core and a wrapping layer, an inner shielding layer, an outer shielding layer, an intermediate layer, and an outer sheath that are sequentially wrapped around the cable core from the inside out. The cable core is characterized by having several conductors and filler wires arranged parallel to each other along the length of the cable (shown as two conductors + two filler wires in the diagram). The conductors include a conductor and an insulation layer and a high-temperature colored tape layer covering the conductor.

[0024] The conductor comprises a multi-strand copper wire stranded structure; the copper wire is silver-plated copper wire, wherein the outer diameter of a single copper wire is 0.08 mm. ～ The conductor has a diameter of 0.12 mm and a coating thickness of >1 μm, conforming to GJB1640A. Through a multi-strand stranded structure, compared to conventional concentric stranded conductors, the single filaments are thinner and the number of strands is greater. Furthermore, the multi-strand stranding and compression method results in a conductor with roundness similar to a single conductor, significantly improving its flexibility and allowing for a smaller bending radius. The physical arrangement provides better roundness, which is beneficial for achieving better attenuation uniformity and also reduces weight.

[0025] The insulation layer adopts a three-layer composite wrapping structure of low-density microporous tape and PTFE raw material tape: since PTFE material cannot be foamed, low-density microporous tape (LDPTFE, density 0.7 g / cm³) is used. 3 ) and polytetrafluoroethylene raw material tape (PTFE, density 1.5~1.6g / cm³) 3 The insulation structure consists of three layers: an inner layer of PTFE tape, an intermediate layer of LDPTFE tape, and an outer layer of PTFE tape. This three-layer wrapping process is completed in a single operation, controlling the tension of each layer between 300g and 400g and the overlap rate between 50% and 67%. This achieves the required outer diameter and basic transmission performance, with a transmission rate exceeding 83%. Finally, a high-temperature colored tape layer 4 (colored PTFE semi-oriented film) is wrapped around the insulation to distinguish the core wire colors.

[0026] After the insulation layer is processed, the core wire needs to undergo high-temperature curing at 125°C for 4 to 6 hours. This relatively uniform curing of the insulation layer allows for control of the stranding tension during subsequent cabling, ensuring uniformity and stability in the stranding process and ultimately achieving stable cable transmission performance.

[0027] Compared to solid PTFE pushed insulation, the insulation layer has a smaller insulation outer diameter, lower attenuation, higher transmission rate, and greater flexibility, with no risk of conductor layer breakage after bending.

[0028] The wrapping layer is made of polytetrafluoroethylene raw material tape with a material density of 1.5. ～ 1.6g / cm 3The wrapping tape is relatively soft, has low mechanical strength, and fits the cable core well, resulting in a smooth wrapping appearance.

[0029] The inner shielding layer is a silver-plated copper strip armor layer, using 0.04mm copper strip. ～ The coating thickness is 0.06mm, with a thickness of 2µm. The silver-plated copper strip armor uses a wrap-around structure, achieving 40% coverage. ～ A 50% overlap rate completely covers and controls the cable core, protecting the insulation layer from external mechanical damage, reducing cable loss, and achieving a better shielding effect.

[0030] The outer shielding layer is made of silver-plated copper wire braid: the silver-plated copper wire size is 0.08 mm. ～ 0.10mm, braiding density greater than 95%. The inner shielding layer is bonded with silver-plated copper strip, achieving a good shielding effect. The combined inner and outer shielding structure can effectively resist external electromagnetic interference, and the shielding attenuation value can be greater than 95dB.

[0031] The intermediate layer is a polyimide film wrapping layer to enhance the cable's torsional resistance.

[0032] The outer protective layer is extruded from a high-flexibility, high-strength, flame-retardant thermoplastic elastomer material: the material has excellent softness (Shore A 65-70) and low density (1.03 g / cm³). 3 High strength, excellent high and low temperature performance (long-term use at -50℃) ～ It possesses properties such as high temperature (up to 150℃). Furthermore, the material can be extruded into thin-walled layers, with a minimum thickness of 0.2mm. Stable wire diameter control is achieved by adjusting the temperature control and wire winding / unwinding of the extrusion equipment. The use and control of this type of material have reduced the weight of cables, making them more flexible and easier to install. Its applications in the military and aerospace fields have been perfectly demonstrated.

[0033] The filler wire is a solid PTFE wire, used to ensure the structural roundness of the cable and thus the stability of the product's transmission performance.

[0034] All materials described in this invention can be purchased externally.

[0035] The above is a detailed description of a high-temperature resistant flexible twisted-pair communication cable for a complete system provided by this utility model. For general manufacturers in this field, there will be changes in the specific implementation methods and application scope based on the ideas and principles of the embodiments of this utility model. Therefore, the content of this specification should not be construed as a limitation of this utility model.

Claims

1. A high-temperature resistant flexible twisted-pair communication cable for a complete system, comprising a cable core and, from the inside out, a wrapping layer (5), an inner shielding layer (6), an outer shielding layer (7), an intermediate layer (8), and an outer sheath (9) sequentially covering the cable core; characterized in that: The cable core includes several conductors and several filler wires (1) arranged parallel to each other along the length of the cable; the conductors include conductors (2) and an insulation layer (3) and a high-temperature ribbon layer (4) sequentially covering the outside of the conductors; The conductor is a multi-stranded copper wire with a plating layer; The insulating layer is a three-layer composite wrapping structure consisting of low-density microporous tape and PTFE raw material tape.

2. The high-temperature resistant flexible twisted-pair communication cable for the whole system according to claim 1, characterized in that: The inner shielding layer is a silver-plated copper strip armor layer.

3. The high-temperature resistant flexible twisted-pair communication cable for the whole system according to claim 2, characterized in that: The outer shielding layer is a silver-plated copper wire braided layer.

4. The high-temperature resistant flexible twisted-pair communication cable for the whole system according to claim 3, characterized in that: The intermediate layer is a polyimide film wrapping layer.

5. The high-temperature resistant flexible twisted-pair communication cable for the complete system according to claim 4, characterized in that: The outer protective layer is a layer of highly flexible, high-strength, flame-retardant thermoplastic elastomer material.

6. The high-temperature resistant flexible twisted-pair communication cable for the whole system according to claim 5, characterized in that: The thickness of the insulating layer is 0.

50. ～ 0.55mm; the outer protective layer thickness is 0.70mm. ～ 0.80mm.

7. The high-temperature resistant flexible twisted-pair communication cable for the complete system according to claim 6, characterized in that: The diameter of the plated copper wire is 0.08 mm. ～ The thickness of the silver-plated copper strip in the silver-plated copper strip armor layer is 0.04 mm (0.10 mm). ～ 0.06mm.

8. The high-temperature resistant flexible twisted-pair communication cable for the complete system according to claim 7, characterized in that: The wrapping layer is a colored polytetrafluoroethylene raw material tape wrapping layer.

9. The high-temperature resistant flexible twisted-pair communication cable for a complete system according to claim 8, characterized in that: The high-temperature ribbon layer is a polytetrafluoroethylene (PTFE) high-temperature resistant ribbon wrapping layer.

10. The high-temperature resistant flexible twisted-pair communication cable for a complete system according to claim 9, characterized in that: The filler line is a solid polytetrafluoroethylene filler line.

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