Aerospace-level fixed-amplitude and fixed-phase radio frequency coaxial cable

Abstract

The utility model discloses an astronavigation-level amplitude-stable phase-stable radio frequency coaxial cable, which comprises an inner conductor wire, an insulating layer, an outer conductor, a protective layer, an outer shielding layer and a sheath layer which are sequentially and coaxially arranged from inside to outside, the insulating layer adopts an insulating layer film, the insulating layer film covers the outer side of the inner conductor wire core, and the outer shielding layer covers the outer side of the outer shielding layer. The outer conductor is wrapped on the outer side of the insulating layer by adopting a strip material, the protective layer is wrapped on the outer side of the outer conductor by adopting a strip material, the outer shielding layer is covered on the outer side of the protective layer by adopting a wire material, and the sheath layer is wrapped on the outer side of the outer shielding layer by adopting a cross-linked ethylene-tetrafluoroethylene copolymer. The cable can be used for a long time in a temperature range of-65 to 200 DEG C, and can reach a high temperature of 300 DEG C in a short time. The radiation resistance is excellent, and the strength is still kept at 70% after the radiation with the dose of 25Mrad.

Description

Technical Field

[0001] This utility model belongs to the field of cable technology, specifically relating to an aerospace-grade amplitude-stable and phase-stable radio frequency coaxial cable. Background Technology

[0002] Aerospace-grade RF coaxial cables primarily stem from the aerospace industry's demand for high-performance, high-reliability wireless communication. With the rapid development of aerospace technology, especially the widespread application of drones and satellite communications, the demand for aerospace-grade RF coaxial cables has increased significantly. Modern aerospace systems have increasingly demanding requirements for wireless communication, requiring cables to operate stably in extreme environments, such as high altitudes, low temperatures, and strong radiation. Therefore, developing RF coaxial cables that can maintain high performance and stability in these environments has become an urgent need. Aerospace-grade RF coaxial cables are widely used in satellite communications, radar systems, drones, airborne command and control systems, and pagers. With the continuous advancement of aerospace technology, the demand for high-performance RF coaxial cables will continue to grow. With the development of 5G technology and quantum communication, the technical standards and market demands for aerospace-grade RF coaxial cables will further change, and the industry's demand for high-performance aerospace-grade RF cables will continue to increase.

[0003] Benefiting from rapid macroeconomic development and related policy support, my country's mobile communications, microwave communications, communication terminals, military electronics, and aerospace industries will experience rapid growth in the future, leading to sustained rapid growth in demand for radio frequency coaxial cables. Simultaneously, as downstream industries continue to demand higher signal transmission quality, the demand for high-end products such as semi-flexible, low-loss, micro-fine, phase-stable, and aerospace-grade cables will see even more significant growth.

[0004] Radio frequency (RF) cables are crucial interconnecting components for spacecraft signal communication. During their operation in orbit, the performance of RF cables is significantly affected by the space environment. To provide a basis for the selection, use, and protection of aerospace-grade RF cables, simulation experiments were conducted to study the effects of high and low temperature environments, alternating temperature environments, radiation environments, and high vacuum environments on RF cables. By conducting preliminary research on RF cable performance during the ground phase, effective design improvements and protective measures can be proposed to enhance the lifespan and reliability of spacecraft. Special attention was paid to tackling key technical challenges in areas such as high temperature resistance, high frequency, and long-distance transmission. The development of high-performance, radiation-resistant, aerospace-grade coaxial cables with environmental adaptability was also undertaken. Utility Model Content

[0005] To address the problems in the existing technology, this utility model provides an aerospace-grade amplitude and phase stable radio frequency coaxial cable, which has good radiation resistance, excellent high and low temperature resistance, superior mechanical properties, and excellent amplitude and phase stabilization performance, and can be applied in the harsh environment of aerospace.

[0006] To achieve the above objectives, the technical solution adopted by this utility model is as follows: it includes an inner conductor core, an insulation layer, an outer conductor, a protective layer, an outer shielding layer, and a sheath layer arranged coaxially from the inside to the outside. The insulation layer is covered with a microporous polytetrafluoroethylene film on the outside of the inner conductor core. The outer conductor is wrapped with tape on the outside of the insulation layer. The protective layer is wrapped with tape on the outside of the outer conductor. The outer shielding layer is covered with filaments on the outside of the protective layer. The outer shielding layer is wrapped with cross-linked ethylene-tetrafluoroethylene copolymer on the outside of the outer shielding layer.

[0007] Preferably, the inner conductor core is a single-core silver-plated copper metal core.

[0008] Preferably, the insulating layer is a microporous polytetrafluoroethylene film.

[0009] Preferably, the insulating layer is made of microporous polytetrafluoroethylene film with a thickness of 0.050 and 0.076 mm.

[0010] Preferably, the microporous polytetrafluoroethylene film of the insulating layer has a 2 / 3 overlap.

[0011] Preferably, the microporous polytetrafluoroethylene film of the insulating layer is wrapped in three layers.

[0012] Preferably, the outer conductor is formed by wrapping silver-plated copper strip to form a tubular structure.

[0013] Preferably, the outer conductor is formed by spirally wrapping silver-plated copper strip to form a spiral tubular structure.

[0014] Preferably, the silver-plated copper strip is wrapped with a 1 / 2 overlap.

[0015] Preferably, the protective film of the protective layer is a microporous polytetrafluoroethylene film, which wraps around and covers the outside of the outer conductor.

[0016] Preferably, the protective film has a thickness of 0.050 mm.

[0017] Preferably, the microporous polytetrafluoroethylene film of the protective layer is wrapped with a 1 / 2 overlap.

[0018] Preferably, the outer shielding layer is made of silver-plated copper wires interwoven and covers the outside of the protective layer.

[0019] Preferably, the outer shielding layer covers the protective layer by a coverage rate of 93% or more.

[0020] Preferably, the sheath layer is a tubular structure extruded from a cross-linked ethylene-tetrafluoroethylene copolymer.

[0021] Preferably, the sheath layer is a tubular structure extruded from cross-linked ethylene-tetrafluoroethylene copolymer with a single-side wall thickness greater than or equal to 0.1 mm.

[0022] Preferably, the sheath layer is a tubular structure extruded from a cross-linked ethylene-tetrafluoroethylene copolymer, and the irradiation catalyst dosage is 25 Mrad.

[0023] Compared with existing technologies, this invention uses a microporous PTFE film-wrapped core wire as the insulation layer to replace the solid PTFE, foamed PTFE, and extruded sintered fusible PTFE core wires available on the market. The microporous PTFE film-wrapped core wire offers superior high and low temperature resistance, excellent mechanical properties, and excellent amplitude and phase stability compared to solid PTFE, foamed PTFE, and extruded sintered fusible PTFE core wires, making it suitable for the demanding environments of aerospace applications. The sheath is made of cross-linked ethylene-tetrafluoroethylene copolymer, which exhibits excellent high and low temperature resistance, allowing for long-term use within a temperature range of -65℃ to 200℃, and short-term high temperatures up to 300℃. It also demonstrates excellent radiation resistance, retaining 70% of its strength after 25 Mrad radiation, and possesses excellent mechanical properties with a tensile strength exceeding 50 MPa.

[0024] Furthermore, the inner conductor core uses a single-core silver-plated copper metal core, which can greatly improve the stability and signal transmission of the cable.

[0025] Furthermore, the insulation layer uses a microporous polytetrafluoroethylene film wrapped around the core wire insulation layer, and adopts a spiral wrapping structure, which effectively improves attenuation and transmission efficiency. It exhibits stable amplitude and phase, with a temperature phase stability within 850 PPM within a temperature range of -45~85℃, and a mechanical phase stability within ±15°. Its mechanical amplitude stability is within ±0.2dB.

[0026] Furthermore, the outer conductor adopts a spiral tubular structure formed by spirally wrapping silver-plated copper strip, wherein the silver-plated copper strip is wrapped with 1 / 2 overlapping edge; the spiral tubular structure is the most stable structure among low-loss and stable phase structures internationally, effectively improving the transmission performance of the cable.

[0027] Furthermore, the protective layer is made of microporous polytetrafluoroethylene film wrapped around the outer conductor, and the protective layer adopts a 1 / 2 overlap, which forms a protection on the outer conductor. The thickness of the film is 0.05mm, which reduces the obstruction between conductors. The protective layer mainly serves to limit the movement of the outer conductor and forms a buffer wear-resistant layer between the outer conductor and the outer shield. It also plays a certain role in isolation and protection during irradiation catalysis.

[0028] Furthermore, the outer shielding layer is made of silver-plated copper wires interwoven and covered on the protective layer, and the coverage of the outer shielding layer is not less than 93%, forming a tight shielding layer on the protective layer. This woven outer shielding mainly plays the role of shielding against electromagnetic interference and improving the mechanical strength of the product.

[0029] Furthermore, the sheath layer adopts a tubular structure extruded from cross-linked ethylene-tetrafluoroethylene copolymer, which surrounds the outer layer of the braided outer shield, serving to protect the cable. The sheath layer material uses cross-linked ethylene-tetrafluoroethylene copolymer, a thermoplastic radiation-resistant material, giving it excellent resistance to abrasion and mechanical properties, chemical and moisture resistance, and resistance to various environments. It exhibits high and low temperature resistance, capable of long-term use within a temperature range of -65℃ to 200℃, and can withstand short-term high temperatures up to 300℃. It also possesses excellent radiation resistance, retaining 70% of its strength after a 25Mrad dose of radiation. Excellent mechanical properties are also present, with a tensile strength exceeding 50MPa. This effectively protects the inner conductor core of the cable, ensuring its inherent mechanical properties and durability, and guaranteeing its use in aerospace environments. Attached Figure Description

[0030] Figure 1 This is a structural schematic diagram of an embodiment of the present utility model;

[0031] Figure 2 This is a cross-sectional schematic diagram of an embodiment of the present invention.

[0032] Among them, 1-inner conductor core, 2-insulation layer, 21-insulation layer film, 3-outer conductor, 4-protective layer, 41-protective layer film, 5-outer shielding layer, 6-sheath layer, 61-crosslinked ethylene-tetrafluoroethylene copolymer. Detailed Implementation

[0033] The present invention will be further explained and described below with reference to the accompanying drawings and specific embodiments. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0034] This utility model provides an aerospace-grade amplitude- and phase-stable radio frequency coaxial cable, which is particularly suitable for environments with harsh temperature and radiation requirements. See [link to relevant documentation]. Figure 1 and Figure 2It includes an inner conductor core 1, an insulation layer 2, an outer conductor 3, a protective layer 4, an outer shielding layer 5, and a sheath layer 6 arranged coaxially from the inside to the outside. The insulation layer 2 is made of an insulating film 21 wrapped around the core wire and covering the outside of the inner conductor core 1. The outer conductor 3 is made of a strip wrapped around the outside of the insulation layer 2. The protective layer 4 is made of a strip wrapped around the outside of the outer conductor 3. The outer shielding layer 5 is made of a wire covering the outside of the protective layer 4. The sheath layer 6 is made of cross-linked ethylene-tetrafluoroethylene copolymer 61 wrapped around the outside of the outer shielding layer 5.

[0035] The protective layer 4 uses a protective film 41, which is a strip made of microporous polytetrafluoroethylene film. The protective layer 4 is formed by wrapping the protective film 41 to form a tubular structure, which is wrapped around the outer conductor. The protective layer adopts a 1 / 2 overlap, forming a protection on the outer conductor. The thickness of the film is 0.05mm, which reduces the obstruction between conductors. The protective layer mainly serves to limit the movement of the outer conductor and forms a buffer and wear-resistant layer between the outer conductor and the outer shield. It also plays a certain role in isolation and protection during irradiation catalysis.

[0036] This embodiment uses a 21-layer insulating film-wound cored wire as the insulation layer to replace commercially available solid PTFE, foamed PTFE, and extruded sintered fusible PTFE cored wires. Compared to solid PTFE, foamed PTFE, and extruded sintered fusible PTFE cored wires, the microporous PTFE film-wound cored wire offers superior high and low temperature resistance, excellent mechanical properties, and excellent amplitude and phase stability, making it suitable for the demanding environments of aerospace applications. The sheath is made of cross-linked ethylene-tetrafluoroethylene copolymer, which has excellent high and low temperature resistance, can be used long-term in a temperature range of -65℃ to 200℃, and can withstand short-term high temperatures up to 300℃. It also exhibits excellent radiation resistance, retaining 70% of its strength after 25 Mrad of radiation. Furthermore, it possesses excellent mechanical properties, with a tensile strength exceeding 50 MPa. This effectively protects the inner conductor core of the cable, ensuring its inherent mechanical properties and durability, and guaranteeing its use in aerospace environments.

[0037] Preferably, the inner conductor core 1 is a single-core silver-plated copper metal core, which can greatly improve the stability and signal transmission of the cable.

[0038] Preferably, the insulating film 21 is made of microporous polytetrafluoroethylene film. The insulating film 21 forms the insulating layer 2 by wrapping the core wire, and the film thickness of 0.050 and 0.076 mm is used for 2 / 3 overlap wrapping, which can effectively increase the strength of the film itself, facilitate processing, reduce stress during processing, effectively enhance the signal transmission of the cable, improve attenuation, and effectively reduce the influence of external temperature changes on phase. The spiral wrapping structure effectively improves attenuation and transmission efficiency. It has stable amplitude and phase. In the temperature range of -45~85℃, the temperature phase can reach within 850PPM, its mechanical phase stability can reach within ±15°, and its mechanical amplitude stability can reach within ±0.2dB.

[0039] Preferably, the outer conductor 3 is made of silver-plated copper strip, and the outer conductor 3 is formed by wrapping the silver-plated copper strip to form a tubular structure. More preferably, the silver-plated copper strip is spirally wrapped to form a spiral tubular structure, wherein the silver-plated copper strip is wrapped with 1 / 2 overlapping edge. The spiral tubular structure is the most stable structure among low-loss and stable phase structures internationally, which effectively improves the transmission performance of the cable.

[0040] Preferably, the protective layer 4 is made of microporous polytetrafluoroethylene film. The protective layer 4 is formed by wrapping the microporous polytetrafluoroethylene film to form a tubular structure, which is wrapped around the outer conductor. The protective layer adopts a 1 / 2 overlap, which forms a protection on the outer conductor. The thickness of the film is 0.05mm, which reduces the obstruction between conductors. The protective layer mainly serves to limit the movement of the outer conductor and forms a buffer and wear-resistant layer between the outer conductor and the outer shield. It also plays a certain role in isolation and protection during irradiation catalysis.

[0041] Preferably, the outer shielding layer 5 uses silver-plated copper wire. The outer shielding layer 5 is made of silver-plated copper wire interlaced and woven and covers the outside of the protective layer 4. The coverage of the outer shielding layer 5 is not less than 93%, forming a tight shielding layer on the protective layer 4. This woven outer shielding mainly plays the role of shielding against electromagnetic interference and improving the mechanical strength of the product.

[0042] Preferably, the sheath layer 6 is a tubular structure extruded from cross-linked ethylene-tetrafluoroethylene copolymer 61, which surrounds the outer layer of the braided outer shield, serving to protect the cable. The sheath layer is made of cross-linked ethylene-tetrafluoroethylene copolymer 61, a thermoplastic radiation-resistant material, giving it excellent resistance to abrasion and mechanical properties, chemical and moisture resistance, and resistance to various environments. It exhibits high and low temperature resistance, capable of long-term use within a temperature range of -65℃ to 200℃, and can withstand short-term high temperatures up to 300℃. It also possesses excellent radiation resistance, retaining 70% of its strength after a 25Mrad dose of radiation, and excellent mechanical properties, with a tensile strength exceeding 50MPa. This effectively protects the inner conductor core of the cable, ensuring its inherent mechanical properties and durability, and guaranteeing its use in aerospace environments.

[0043] This utility model provides an aerospace-grade amplitude- and phase-stable radio frequency coaxial cable, which features high and low temperature resistance, capable of long-term use within a temperature range of -65℃ to 200℃, and short-term high temperature up to 300℃. It also exhibits excellent radiation resistance, retaining 70% of its strength after 25Mrad radiation. Furthermore, it possesses superior mechanical properties, with a tensile strength exceeding 50MPa, effectively protecting the inner conductor core and ensuring the cable's inherent mechanical properties and durability. This allows for use in aerospace environments. It also exhibits amplitude and phase stability, maintaining a temperature phase within 850PPM within a temperature range of -45℃ to 85℃, with mechanical phase stability within ±15° and mechanical amplitude stability within ±0.2dB.

[0044] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of this utility model, and not to limit it; although the utility model has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of this utility model.

Claims

1. A spaceflight grade, stable amplitude and stable phase, radio frequency, coaxial cable, characterized by, The device comprises an inner conductor core (1), an insulation layer (2), an outer conductor (3), a protective layer (4), an outer shielding layer (5), and a sheath layer (6) arranged coaxially from the inside to the outside. The insulation layer (2) is made of an insulating film (21) and covers the outside of the inner conductor core (1). The outer conductor (3) is wrapped around the outside of the insulation layer (2) with a strip. The protective layer (4) is wrapped around the outside of the outer conductor (3) with a strip. The outer shielding layer (5) is covered by a wire and covers the outside of the protective layer (4). The sheath layer (6) is wrapped around the outside of the outer shielding layer (5) with a cross-linked ethylene-tetrafluoroethylene copolymer (61). The sheath layer (6) retains more than 70% of its strength and has a tensile strength of more than 50 MPa after 25 Mrad radiation.

2. A space qualified, stable amplitude and stable phase, radio frequency, coaxial cable according to claim 1, characterized in that, The insulating film (21) forms the insulating layer (2) by wrapping the core wire. The insulating film (21) is a microporous polytetrafluoroethylene film. The inner conductor core (1) is a single-core silver-plated copper metal core. The insulating layer (2) is wrapped with the insulating film (21). The insulating film (21) has a thickness of 0.050 and 0.076 mm.

3. A space qualified, stable amplitude and stable phase, radio frequency, coaxial cable according to claim 2, wherein, The insulating layer (2) has a 2 / 3 overlap in its insulating film (21), and the insulating film (21) is wrapped in 3 layers. The outer conductor (3) is wrapped with silver-plated copper strip to form a tubular structure.

4. A space qualified, stable amplitude and stable phase, radio frequency, coaxial cable according to claim 1, wherein, The outer conductor (3) is wrapped with silver-plated copper strip with a 1 / 2 overlap. The outer conductor (3) is spirally wrapped with silver-plated copper strip to form a spiral tubular structure. The protective layer (4) is wrapped with a protective film (41) and covered on the outside of the outer conductor (3).

5. The aerospace-grade amplitude- and phase-stabilized radio frequency coaxial cable according to claim 4, characterized in that, The protective layer film (41) is made of microporous polytetrafluoroethylene film. The protective layer film (41) wraps around and covers the outside of the outer conductor (3). The protective layer (4) is made of microporous polytetrafluoroethylene film with a thickness of 0.05 mm. The protective layer (4) is made of microporous polytetrafluoroethylene film with a 1 / 2 overlap for wrapping.

6. A space qualified, stable amplitude and stable phase, radio frequency, coaxial cable according to claim 1, wherein, The outer shielding layer (5) is made of silver-plated copper wires interlaced and covered on the outside of the protective layer (4), and the coverage of the outer shielding layer (5) over the protective layer (4) is greater than or equal to 93%.

7. A space qualified, stable amplitude and stable phase, radio frequency, coaxial cable according to claim 1, wherein, The sheath layer (6) is a tubular structure extruded from cross-linked ethylene-tetrafluoroethylene copolymer (61), and the single-sided wall thickness of the tubular structure extruded from cross-linked ethylene-tetrafluoroethylene copolymer (61) is greater than or equal to 0.1 mm.

8. A space qualified, stable amplitude and stable phase, radio frequency, coaxial cable according to claim 1, wherein, The sheath layer (6) is a tubular structure extruded from cross-linked ethylene-tetrafluoroethylene copolymer (61) and subjected to irradiation cross-linking catalysis with an irradiation catalyst amount of 25Mrad.

9. A space qualified, stable amplitude and stable phase, radio frequency, coaxial cable according to claim 1, wherein, It exhibits resistance to high and low temperatures, capable of long-term use within a temperature range of -65℃ to 200℃, and can withstand short-term high temperatures up to 300℃. It also possesses excellent radiation resistance, retaining 70% of its strength after 25Mrad of radiation. Furthermore, it exhibits superior mechanical properties, with a tensile strength exceeding 50MPa. It demonstrates stable amplitude and phase, maintaining a temperature phase within 850PPM within a temperature range of -45℃ to 85℃, and achieving mechanical phase stability within ±15° and mechanical amplitude stability within ±0.2dB.

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