A high-temperature resistant tethered drone cable

Abstract

This utility model belongs to the field of cable technology and discloses a high-temperature resistant tethered drone cable, comprising: a conductor layer composed of multiple strands of alloy wire twisted together; an insulation layer covering the conductor layer, the insulation layer being made of polytetrafluoroethylene (PTFE) composite material; a dual-mode shielding layer covering the insulation layer, the dual-mode shielding layer comprising an inner shielding layer and an outer shielding layer from the inside out; and a sheath covering the dual-mode shielding layer, the sheath being made of polyurethane composite material. In this design, the conductor layer uses a high-conductivity alloy wire twisted structure to replace traditional copper cables, reducing weight. The outer shielding layer uses lightweight LCP fibers combined with a conductive coating to achieve a balance between high strength and low weight. The dual-mode shielding layer reflects high-frequency interference through the inner alloy wire braiding and absorbs low-frequency magnetic fields through the outer LCP conductive fiber, improving the overall shielding effectiveness.

Description

Technical Field

[0001] This utility model relates to the field of cables, and more specifically, to a high-temperature resistant tethered drone cable. Background Technology

[0002] With the rapid development of drone technology, tethered drones are widely used in fields such as communication relay, power line inspection, and disaster relief. However, traditional tethered cables face the following technical bottlenecks:

[0003] 1. Weight bottleneck: Traditional copper conductor cables weigh more than 40g / m per unit length, which significantly increases the payload of drones and reduces their endurance and maneuverability.

[0004] 2. Signal attenuation problem: In kilometer-level transmission scenarios, the attenuation rate of high-frequency signals (such as 500MHz) exceeds 3dB / 100m, which seriously affects the communication quality.

[0005] 3. Insufficient environmental adaptability: Under high temperature conditions (>70℃), the resistance of the insulation material decreases by 50%, leading to safety hazards; at the same time, the bending fatigue life of the metal shielding layer is less than 5,000 cycles, which is difficult to meet the requirements of long-term dynamic use.

[0006] Existing technologies struggle to balance lightweight design, high shielding effectiveness, and environmental tolerance, necessitating a novel cable structure to overcome these technological bottlenecks. Utility Model Content

[0007] The purpose of this invention is to solve the problems of existing tethered drone cables, such as heavy weight, easy damage from dynamic bending, and poor adaptability to extreme environments, and to provide a lightweight, highly reliable, high-temperature resistant and corrosion-resistant cable structure.

[0008] To solve the above problems, the present invention adopts the following technical solution:

[0009] A high-temperature resistant tethered drone cable, comprising:

[0010] The conductor layer is made of multiple strands of alloy wire twisted together;

[0011] An insulating layer, covering the conductor layer, is made of polytetrafluoroethylene composite material;

[0012] A dual-mode shielding layer is wrapped around the insulating layer, and the dual-mode shielding layer includes an inner shielding layer and an outer shielding layer from the inside to the outside;

[0013] A sheath, covering the dual-mode shielding layer, is made of polyurethane composite material.

[0014] As a further description of the above technical solution: the conductor layer is made of 13 strands of alloy wire with a diameter of 0.28 mm twisted together.

[0015] As a further description of the above technical solution: the inner shielding layer is woven from alloy wires, and the outer shielding layer is woven from LCP fibers with a conductive coating on the surface.

[0016] As a further description of the above technical solution: the conductive coating is a metal coating or a conductive polymer coating.

[0017] As a further description of the above technical solution: the alloy wire of the conductor layer is a copper-nickel alloy or a silver-plated copper wire.

[0018] Compared with existing technologies, the advantages of this utility model are:

[0019] I. Lightweight Design: The conductor layer of this solution adopts a high-conductivity alloy wire twisted structure to replace the traditional copper cable, reducing weight. The outer shielding layer uses lightweight LCP fiber, combined with a conductive coating, to achieve a balance between high strength and low weight.

[0020] II. High-efficiency electromagnetic shielding: The dual-mode shielding layer uses an inner layer of woven alloy wire to reflect high-frequency interference, while the outer layer of LCP conductive fibers absorbs low-frequency magnetic fields, thus improving the overall shielding effectiveness. The interconnection of the inner and outer shielding layers forms a closed conductive path, reducing the residual electromagnetic wave attenuation rate to <1dB / 100m.

[0021] III. Excellent Environmental Adaptability: The insulation layer uses PTFE-based composite material, maintaining >90% insulation performance at 70℃, with a temperature tolerance range of -60℃ to 200℃. The sheath is made of polyurethane, resistant to salt spray corrosion and wear, and the shielding layer's bending fatigue life is increased to >10,000 cycles.

[0022] IV. High reliability: The ultra-high tensile strength of LCP fibers and the mechanical protection of the sheath work together to ensure the long-term stability of the cable under complex working conditions. Attached Figure Description

[0023] Figure 1 This is a cross-sectional view of the cable of this utility model;

[0024] Figure 2 This is a schematic diagram of the structure of the dual-mode shielding layer of this utility model;

[0025] Figure 3 This is a schematic diagram of the structure of the LCP fiber of this utility model.

[0026] Explanation of the labels in the diagram:

[0027] 1. Conductor layer; 2. Insulating layer; 3. Dual-mode shielding layer; 31. Inner shielding layer; 32. Outer shielding layer; 321. LCP fiber; 322. Conductive coating; 4. Sheath. Detailed Implementation

[0028] The technical solutions of the present utility model will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present utility model. Obviously, the described embodiments are only some embodiments of the present utility model, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present utility model without creative effort are within the protection scope of the present utility model.

[0029] Example 1

[0030] Please see Figure 1-3 A high-temperature resistant tethered drone cable, comprising:

[0031] Conductor layer 1: It is made of 13 alloy wires with a diameter of 0.28mm twisted together with a 12D pitch, which reduces weight while ensuring conductivity.

[0032] Insulation layer 2: Covering the conductor layer 1, it is made of polytetrafluoroethylene (PTFE) based composite material, which has excellent high temperature resistance and insulation properties. The insulation performance retention rate is >90% at 70℃, and the temperature range tolerable is -60℃ to 200℃.

[0033] Dual-mode shielding layer 3: Covering the insulation layer 2, including an inner shielding layer 31 and an outer shielding layer 32. The inner shielding layer 31 is woven from alloy wires, and the porosity is ≤15% through tight weaving, ensuring reflection shielding against electromagnetic waves (especially high-frequency interference), forming the first electromagnetic barrier.

[0034] The outer shielding layer 32 is woven from LCP (liquid crystal polymer) fibers 321 with a conductive coating 322 on the surface, enhancing flexibility and anti-interference capabilities. The LCP fibers 321, being ultra-high molecular weight fibers, impart extremely high tensile strength to the outer layer (1000D fibers provide 2000MPa tensile strength, approximately 1.5 times that of steel cables). The conductive coating 322 is applied to the LCP surface, forming a Faraday cage. The LCP has a lower density than metals, achieving both lightweight and high strength.

[0035] The dual-mode shielding layer 3 forms a complete closed conductive path through the outer conductive layer and the inner alloy mesh via grounding or interconnection, further absorbing / attenuating residual electromagnetic waves, especially suppressing low-frequency magnetic field interference (such as 50Hz power frequency magnetic field).

[0036] The sheath 4, which covers the dual-mode shielding layer 3, is made of polyurethane (PUR) composite material and has the characteristics of high and low temperature resistance, salt spray corrosion resistance and mechanical wear resistance.

[0037] This embodiment solves the core problems of lightweighting, signal fidelity, and environmental tolerance of tethered drone cables through material innovation and structural optimization, significantly expanding the application potential of drones in harsh environments such as high temperature and strong interference.

[0038] Example 2

[0039] This embodiment is a further improvement based on Embodiment 1. Compared with Embodiment 1, the alloy wire of conductor layer 1 is a copper-nickel alloy or silver-plated copper wire, which further improves conductivity. The conductive coating 322 is a metal coating (such as silver or copper) or a conductive polymer coating (such as PEDOT:PSS), forming a continuous conductive layer.

[0040] Insulation layer 2 is made of a composite material with polytetrafluoroethylene (PTFE) as the matrix and polyimide (PI) nanofibers dispersed therein. The PI nanofibers have extremely fine diameters (50-80 nm), and this nanoscale structure effectively hinders the propagation of electrical trees (insulation breakdown paths caused by partial discharge). The PI nanofibers form a physical barrier within the PTFE, interrupting the continuous growth path of electrical trees, thereby significantly improving the high-voltage breakdown resistance of the insulation material and extending its service life. By reinforcing PTFE with PI nanofibers, the chemical resistance and high-temperature resistance of PTFE are retained, while the dielectric properties and anti-electrical treeing ability are optimized through the nanofibers, resulting in a dielectric loss of <0.0003 (1 GHz).

[0041] The sheath 4 is made of a composite material with polyurethane (PUR) as the soft matrix and dispersed alumina nanoparticles as fillers. Polyurethane (PUR), as the soft matrix, provides flexibility, oil resistance, and environmental adaptability, absorbing frictional vibrations through elastic deformation and reducing surface adhesion. The alumina nanoparticles (Al2O3) are highly dispersed within the PUR, forming micron-sized "hard islands" (similar to sand grains embedded in rubber), which bear mechanical loads and resist the cutting action of abrasive particles.

[0042] The above description is merely a preferred embodiment of this utility model; however, the protection scope of this utility model is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the technical scope disclosed in this utility model, based on the technical solution and its improved concept, should be included within the protection scope of this utility model.

Claims

1. A high-temperature resistant tethered unmanned aerial vehicle (UAV) cable, characterized in that: include: The conductor layer (1) is made of multiple strands of alloy wire twisted together; An insulating layer (2) is wrapped around the conductor layer (1), and the insulating layer (2) is made of polytetrafluoroethylene composite material; A dual-mode shielding layer (3) is wrapped around the insulating layer (2). The dual-mode shielding layer (3) includes an inner shielding layer (31) and an outer shielding layer (32) from the inside to the outside. The inner shielding layer (31) is woven from alloy wires, and the outer shielding layer (32) is woven from LCP fibers (321) with a conductive coating (322) on the surface. The sheath (4) covers the outside of the dual-mode shielding layer (3) and is made of polyurethane composite material.

2. The high-temperature resistant tethered UAV cable according to claim 1, characterized in that: The conductor layer (1) is made of 13 strands of alloy wire with a diameter of 0.28 mm twisted together.

3. The high-temperature resistant tethered UAV cable according to claim 1, characterized in that: The conductive coating (322) is a metal coating or a conductive polymer coating.

4. The high-temperature resistant tethered UAV cable according to claim 2, characterized in that: The alloy wire of the conductor layer (1) is a copper-nickel alloy or a silver-plated copper wire.

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