Photoelectric composite cable suitable for unmanned aerial vehicle platform

Abstract

The utility model relates to a photoelectric composite cable suitable for an unmanned aerial vehicle platform. The photoelectric composite cable comprises a wrapping layer formed by wrapping a covering film, an accommodating space is formed in the wrapping layer, a two-core electric unit and a one-core single-mode optical fiber are respectively placed in the accommodating space, and a plurality of aramid fiber filling cabling are distributed in the accommodating space; an insulating layer is distributed on the electric unit, an outer wrapping layer is distributed on the single-mode optical fiber, and the insulating layer, the outer wrapping layer and the covering film are all made of high-temperature-resistant fluoroplastic formed by ethylene-tetrafluoroethylene copolymer; the thickness of the covering film is 0.05 mm, and the total thickness after wrapping is 0.10 mm + / -0.02 mm; the outer diameter of the photoelectric composite cable is 2.2 mm + / -0.1 mm, and the total weight per meter is smaller than or equal to 12 g. Therefore, the whole photoelectric composite cable has better high temperature resistance, can meet high tensile strength under the condition of light weight, can realize low-loss signal transmission, and has better heat dissipation effect.

Description

Technical Field

[0001] This utility model relates to a cable for unmanned aerial vehicles (UAVs), and more particularly to an optoelectronic composite cable suitable for UAV platforms. Background Technology

[0002] For existing drone platforms, corresponding cables are often used to meet the needs of drones to stay in the air for extended periods. However, the temperature resistance of the insulation materials in conventional drone cables is insufficient in current technologies. For example, the existing patent CN201130549Y discloses a fluoroplastic insulated high-temperature resistant and corrosion-resistant cable with a perfluoroethylene propylene (FEP) insulation layer, which can withstand long-term operating temperatures above 200°C. However, this patent does not address the lightweight, heat dissipation, and optoelectronic composite transmission requirements of drone platform applications. Conventional materials such as polyvinyl chloride (PVC) or cross-linked polyethylene (XLPE) typically have a temperature resistance range of -10°C to 90°C, which is prone to aging under the high-power conditions of drones, leading to the risk of cable spontaneous combustion.

[0003] Meanwhile, the temperature resistance of currently used fiber optic coating materials is limited. For example, the existing technology CN222093872U discloses a fiber optic coating mold, a fiber optic coating platform, and a high-temperature resistant fiber. It discloses the use of fluoroplastic coatings to improve the temperature resistance of the fiber, but its coating process is not optimized for mechanical strength and high-temperature attenuation issues under the dynamic load of UAVs. Conventional fiber optic coating materials (such as acrylates) are prone to thermal deformation in environments above 75°C, leading to excessive optical signal attenuation.

[0004] Furthermore, existing cables are not ideal in terms of lightweighting and tensile strength. Their wrapping layer still uses traditional extruded sheaths, resulting in a large cable outer diameter (≥5.8mm) and insufficient heat dissipation performance, which cannot meet the requirement of ≤12g / m for the cable weight of UAVs during long-term flight.

[0005] In view of the above-mentioned shortcomings, the designer actively researched and innovated in order to create an optoelectronic composite cable suitable for UAV platforms, making it more valuable for industrial applications. Utility Model Content

[0006] To solve the above-mentioned technical problems, the purpose of this utility model is to provide an optoelectronic composite cable suitable for unmanned aerial vehicle platforms.

[0007] This utility model discloses an optoelectronic composite cable suitable for unmanned aerial vehicle (UAV) platforms, comprising a wrapping layer formed by a covering film, wherein: the wrapping layer forms a receiving space, in which two electrical units and one single-mode optical fiber are respectively placed, and several aramid fibers are distributed to fill the cable within the receiving space; the electrical units are covered with an insulating layer, and the single-mode optical fiber is covered with an outer cladding layer; the insulating layer, the outer cladding layer, and the covering film are all made of high-temperature resistant fluoroplastics composed of ethylene-tetrafluoroethylene copolymer; the thickness of the covering film is 0.05mm, and the total thickness after wrapping is 0.10mm±0.02mm; the outer diameter of the optoelectronic composite cable is 2.2mm±0.1mm, and the total weight per meter is ≤12g.

[0008] Furthermore, in the aforementioned optoelectronic composite cable suitable for UAV platforms, the conductor (7) of the electrical unit (1) is composed of 19 strands of tin-plated copper wire with a diameter of 0.15mm, the stranding pitch ratio is ≤12 times, and the resistance of the conductor (7) is ≤50Ω / km.

[0009] Furthermore, in the aforementioned optoelectronic composite cable suitable for UAV platforms, the single-mode optical fiber is a G657A2 type bend-insensitive optical fiber with a total outer diameter including the cladding of 0.5 mm and an attenuation value of ≤0.3 dB / km at wavelengths of 1310 nm and 1550 nm.

[0010] Furthermore, in the aforementioned optoelectronic composite cable suitable for UAV platforms, the aramid fiber comprises six strands, symmetrically distributed in a circular pattern within the accommodating space; the aramid fiber is type 3340 aramid fiber with a density of 1.44 g / cm³, a maximum breaking strength ≥4000 N, and a long-term operating temperature ≥180 °C, which can form a synergistic temperature-resistant system with the wrapping layer.

[0011] Furthermore, in the aforementioned optoelectronic composite cable suitable for UAV platforms, the covering film has several micropores with a diameter of 5-20μm; the covering film is wrapped by a pre-calendering molding process to form a wrapping layer.

[0012] Furthermore, in the aforementioned optoelectronic composite cable suitable for UAV platforms, the micropores are created using a laser etching process, and the density of the micropores is 50-200 per cm².

[0013] Furthermore, in the aforementioned optoelectronic composite cable suitable for UAV platforms, the thickness of the insulation layer is 0.1mm±0.02mm, the continuous operating voltage is 400V, and the dielectric strength is ≥1000MΩ·km.

[0014] Furthermore, in the aforementioned optoelectronic composite cable suitable for UAV platforms, a buffer layer made of silicone rubber is distributed between the wrapping layer and the aramid fiber filling layer. The buffer layer has a thickness of 0.2 mm and a Shore hardness of 40A±5A.

[0015] By means of the above solution, this utility model has at least the following advantages:

[0016] 1. The entire optoelectronic composite cable possesses superior high-temperature resistance. The electrical unit insulation layer, fiber coating, and wrapping layer are all made of high-temperature resistant fluoroplastics, with a temperature resistance range covering -196℃ to 200℃, significantly better than the -40℃ to 90℃ temperature limit of conventional materials. This solves the risk of cable spontaneous combustion and the problem of fiber optic attenuation at high power during UAV operation. The aramid fiber filling layer and the high-temperature resistant fluoroplastics form a synergistic temperature-resistant system, with a long-term operating temperature reaching 180℃, preventing material performance degradation under high-temperature environments.

[0017] 2. Meets high tensile strength requirements while maintaining lightweight design. Filled with 6 aramid fibers, the total cable weight is ≤12g / m, 83% lighter than steel-core optical cables. Axial tensile strength ≥500N, maximum breaking force ≥4000N, meeting the flight conditions of UAVs with dynamic loads ≥10g. Simultaneously, the electrical unit employs several strands of tin-plated copper wire to enhance conductor flexibility and heat dissipation.

[0018] 3. Enables low-loss signal transmission. The single-mode fiber, combined with a high-temperature resistant fluoroplastic cladding, achieves attenuation ≤0.3dB / km, a 25% reduction compared to conventional fiber, ensuring lossless transmission of high-definition images and real-time control signals. The fiber coating has an outer diameter of only 0.5mm, resulting in a small fiber diameter and strong bending resistance, making it suitable for cabling in confined spaces and high-frequency vibration environments in drones.

[0019] 4. Excellent heat dissipation. The heat dissipation efficiency of the wrapping layer is improved by 30% through laser etching of micropores, solving the problem of cable core temperature rise under high current conditions.

[0020] 5. It can integrate chemical protection and mechanical cushioning. High-temperature fluoroplastics are resistant to acid and alkali corrosion, and aramid fibers are resistant to organic solvent erosion, allowing it to adapt to complex environments without the need for an additional protective layer.

[0021] 6. The overall structure is simple, easy to process and manufacture, and has low implementation cost.

[0022] The above description is only an overview of the technical solution of this utility model. In order to better understand the technical means of this utility model and to implement it in accordance with the contents of the specification, the preferred embodiments of this utility model are described in detail below with reference to the accompanying drawings. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the overall structure of an optoelectronic composite cable suitable for unmanned aerial vehicle (UAV) platforms.

[0024] Figure 2 This is a cross-sectional structural diagram of an optoelectronic composite cable suitable for unmanned aerial vehicle (UAV) platforms.

[0025] (It should be noted that after aramid fibers are filled into cables, they will fill the gaps in the space to accommodate them. Therefore, the individual aramid fibers are no longer labeled in the attached diagram.)

[0026] The meanings of the labels in the figures are as follows.

[0027] Detailed Implementation

[0028] The specific embodiments of this utility model will be described in further detail below with reference to the accompanying drawings and examples. The following examples are used to illustrate this utility model, but are not intended to limit its scope.

[0029] like Figures 1 to 2 The optoelectronic composite cable suitable for UAV platforms includes a wrapping layer consisting of a covering film 4. Its unique feature is the inclusion of a housing space within the wrapping layer, containing two electrical units 1 and one single-mode optical fiber 2. This conveniently meets the power supply and data transmission requirements of UAVs. Simultaneously, to protect the electrical units 1 and single-mode optical fiber 2, several aramid fibers 3 are distributed within the housing space to fill the cable. For safety and to provide necessary insulation and high-temperature protection, the electrical units 1 are equipped with an insulation layer 5, and the single-mode optical fiber 2 is equipped with an outer sheath 6. During manufacturing, the insulation layer 5, outer sheath 6, and covering film 4 are all made of high-temperature resistant fluoroplastic composed of ethylene-tetrafluoroethylene copolymer. To achieve a suitable overall outer diameter and adequate separation from the external environment, the thickness of the covering film 4 is 0.05 mm, and the total thickness after wrapping is 0.10 mm ± 0.02 mm. Thus, after installation, the outer diameter of the optoelectronic composite cable is 2.2 mm ± 0.1 mm. Furthermore, since aramid fiber 3 is used as the internal filling material, the total weight per meter is ≤12g, which meets the requirements of drones for long-term loitering.

[0030] In a preferred embodiment of this invention, the conductor 7 of the electrical unit 1 is composed of several strands of tin-plated copper wire. Specifically, the stranded structure consists of 19 tin-plated copper wires with a diameter of 0.15mm, a stranding pitch ratio ≤12, a conductor resistance ≤50Ω / km, and a working current of over 5A. This is because copper conductor 7 is a conductor material with excellent electrical and mechanical properties. The stranded structure further enhances the flexibility and heat dissipation of conductor 7. Simultaneously, tin plating significantly improves the oxidation resistance, weldability, and corrosion resistance of the copper wire. Furthermore, the use of high-temperature resistant fluoroplastics allows the cable to operate efficiently for extended periods at 150℃, solving problems such as aging due to self-heating, poor high-temperature resistance, and inability to withstand prolonged use in conventional UAV composite cables.

[0031] Furthermore, the single-mode fiber 2 used is a G657A2 type bend-insensitive fiber with a total outer diameter of 0.5mm, including the cladding layer 6. This results in a small overall fiber diameter and lower attenuation due to light propagating along a single mode, meeting the needs of long-distance transmission. Simultaneously, it possesses strong anti-interference capabilities, ensuring the stability and reliability of signal transmission. The fiber coating uses high-temperature resistant fluoroplastics, giving the fiber excellent chemical and high-temperature resistance, while also providing higher mechanical strength and bending resistance. It meets the requirement of attenuation ≤0.3dB / km at wavelengths of 1310nm and 1550nm or in high-temperature operating environments, enabling lossless transmission of various control signals and data.

[0032] In practical implementation, six aramid fibers (3) are used, symmetrically distributed in a circular pattern within the containment space. Specifically, aramid fiber 3 is a type 3340 aramid fiber with a density of 1.44 g / cm³, which is six times lighter than steel, making it suitable for lightweight applications in drones. It also possesses extremely high tensile strength and elastic modulus, suitable for withstanding dynamic loads and localized impacts with a maximum breaking force ≥4000N. This meets the external stress requirements during drone deployment. Furthermore, aramid fiber 3 can withstand stable use at temperatures ≥180℃, forming a synergistic temperature-resistant system with the wrapping layer. Moreover, it exhibits good resistance to weak acids, weak alkalis, and most organic solvents.

[0033] Meanwhile, to meet the heat dissipation requirements during long-term use, the cover film 4 has several micropores with a diameter of 5-20μm for heat dissipation. This, combined with the overlapping and wrapping method of the cover film 4, improves heat dissipation efficiency by more than 30% compared to the traditional outer protective layer structure. The cover film 4 is wrapped using a pre-calendering process to form a wrapping layer. This results in a wrapping layer thickness that is only one-third the thickness of a conventional sheath. This significantly reduces the overall cable weight, improves cable flexibility, and solves the problem of heat dissipation during cable operation. During manufacturing, the micropores are created using a laser etching process, with a micropore density of 50-200 pores / cm². This provides excellent heat dissipation.

[0034] Furthermore, the insulation layer 5 is attached to the outside of the electrical unit 1 by high-temperature extrusion. The thickness of the insulation layer 5 is 0.1mm ± 0.02mm, the continuous operating voltage is 400V, and the dielectric strength is ≥1000MΩ・km. This ensures that the dielectric strength between the two electrical units 1 can reach 2000V DC for 1 minute without breakdown, and the temperature range is -65℃ to 200℃.

[0035] Furthermore, to enhance the buffering effect between the containment spaces, a buffer layer made of silicone rubber is distributed between the wrapping layer and the aramid fiber 3 filling layer. The buffer layer has a thickness of 0.2 mm and a Shore hardness of 40A±5A. This absorbs the vibration stress during drone flight, ensuring stable flight and preventing the entire cable from being subjected to unexpected tensile stress.

[0036] Therefore, during use, the axial tensile strength of the optical-electric composite cable is ≥500N, which is suitable for the flight conditions of UAVs with dynamic loads ≥10g, and the attenuation value fluctuation is ≤0.05dB / km after 1000 bending fatigue tests.

[0037] The working principle of this utility model is as follows:

[0038] By adding corresponding interfaces, it connects to the power supply and communication terminals of the drone. During drone operation, the electrical unit 1 provides continuous power to the drone itself and other onboard electrical facilities. Data transmission can be achieved using single-mode optical fiber 2, receiving control from the ground and transmitting corresponding data back. Relying on high-temperature resistant fluoroplastic as the insulation layer 5, outer sheath 6, and covering film 4, it can operate stably even at temperatures reaching 180℃.

[0039] Furthermore, the directions or positional relationships described in this utility model are based on the directions or positional relationships shown in the accompanying drawings. They are only for the purpose of facilitating the description of this utility model and simplifying the description, and are not intended to indicate or imply that the device or structure referred to must have a specific orientation, or to operate in a specific orientation. Therefore, they should not be construed as limitations on this utility model.

[0040] The above description is only a preferred embodiment of the present utility model and is not intended to limit the present utility model. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the technical principles of the present utility model, and these improvements and modifications should also be considered within the protection scope of the present utility model.

Claims

1. An optoelectronic composite cable suitable for unmanned aerial vehicle (UAV) platforms, comprising a wrapping layer consisting of a covering film (4), characterized in that: The wrapping layer forms a receiving space, in which two-core electrical units (1) and one-core single-mode optical fiber (2) are placed respectively. Several aramid fibers (3) are also distributed in the receiving space to fill the cable. The electrical units (1) are covered with an insulating layer (5), and the single-mode optical fiber (2) is covered with an outer cladding layer (6). The insulating layer (5), the outer cladding layer (6), and the covering film (4) are all made of high-temperature resistant fluoroplastics composed of ethylene-tetrafluoroethylene copolymer. The thickness of the covering film (4) is 0.05mm, and the total thickness after wrapping is 0.10mm±0.02mm. The outer diameter of the optoelectronic composite cable is 2.2mm±0.1mm, and the total weight per meter is ≤12g. The conductor (7) of the electrical unit (1) is composed of 19 strands of tin-plated copper wire with a diameter of 0.15mm, with a stranding pitch ratio of ≤12 times and a conductor (7) resistance of ≤50Ω / km; The single-mode fiber (2) is a G657A2 type bend-insensitive fiber with a total outer diameter of 0.5 mm including the cladding (6) and an attenuation value of ≤0.3dB / km at wavelengths of 1310nm and 1550nm. The aramid fiber (3) consists of 6 fibers, which are symmetrically distributed in a circular pattern within the accommodating space. The covering film (4) has a number of micropores with a diameter of 5-20μm; the covering film (4) is wrapped by a pre-calendering process to form a wrapping layer; The micropores are created using a laser etching process, and the density of the micropores is 50-200 per cm². A buffer layer made of silicone rubber is distributed between the wrapping layer and the aramid fiber (3) filling layer. The buffer layer has a thickness of 0.2 mm and a Shore hardness of 40A±5A.

2. The optoelectronic composite cable suitable for unmanned aerial vehicle platforms according to claim 1, characterized in that: The thickness of the insulating layer (5) is 0.1mm ± 0.02mm.

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