High-strength light-weight tethered unmanned aerial vehicle cable

Abstract

The utility model belongs to cable field discloses a kind of high-strength light-weight tethered unmanned aerial vehicle cables, including conductor, the conductor is made of 30 0.08 silver-plated copper wire same direction bundle, re-twist, conductor outer layer is wrapped with insulating layer, and the insulating layer is radiation crosslinking PTFE film;The insulating layer is wrapped with shielding layer outside, and the shielding layer is aluminum foil, the sheath layer is equipped with outside the shielding layer, and the sheath layer is made of 16 spindle high-strength aviation fiber;The conductor, insulating layer and shielding layer form composite structure, and the composite structure has four groups and is evenly distributed in sheath layer.This scheme high-strength aviation fiber braided sheath layer can independently bear all mechanical load of cable, so that internal wire core is in zero stress environment, ensure that power transmission efficiency and high-frequency signal fidelity are not influenced by unmanned aerial vehicle dynamic flight.

Description

Technical Field

[0001] This utility model relates to the field of cable technology, and more specifically, to a high-strength, lightweight tethered unmanned aerial vehicle (UAV) cable. Background Technology

[0002] Tethered drone cables, as a key connection component between drones and ground equipment, are widely used in military reconnaissance, fire rescue, and power line inspection. However, existing tethered cables suffer from the following problems and drawbacks:

[0003] 1. Excessive cable weight: Traditional PVC / PU insulation materials have a high density, which increases the overall weight of the cable and limits the flight time and maneuverability of the drone.

[0004] 2. Conductors are prone to oxidation: Ordinary copper conductors are prone to oxidation during long-term use, which leads to increased resistance and affects the efficiency of power transmission and signal stability.

[0005] 3. The sheath is easily worn: Ordinary nylon braided sheaths have insufficient mechanical strength and are easily worn or even broken due to friction and bending in complex environments, reducing the service life of the cable.

[0006] 4. Severe signal interference: The multi-core structure lacks effective shielding measures, and electromagnetic interference (EMI) and crosstalk can easily lead to signal distortion, affecting the communication quality between the UAV and the control system.

[0007] Therefore, there is an urgent need for a high-strength, lightweight, and interference-resistant tethered drone cable to meet the requirements of high reliability, long life and stable transmission. Utility Model Content

[0008] The purpose of this invention is to address the shortcomings of existing technologies by proposing a high-strength, lightweight tethered drone cable.

[0009] To achieve the above objectives, the present invention adopts the following technical solution:

[0010] A high-strength, lightweight tethered unmanned aerial vehicle (UAV) cable includes a conductor, which is formed by stranding and re-stranding 30 strands of 0.08 silver-plated copper wire in the same direction. The conductor is wrapped with an insulation layer, which is a radiation-crosslinked PTFE film.

[0011] The insulating layer is wrapped with a shielding layer, which is aluminum foil. The shielding layer is covered with a sheath layer, which is made of 16 spindles of high-strength aerospace fiber.

[0012] The conductor, insulation layer, and shielding layer form a composite structure, and there are four groups of the composite structure evenly distributed within the sheath layer.

[0013] As a further description of the above technical solution: a filling material is provided inside the sheath layer and in the gap of the composite structure, and the filling material is polyethylene tape.

[0014] As a further description of the above technical solution: the insulating layers in the four sets of composite structures are symmetrically set in red and black in pairs.

[0015] As a further description of the above technical solution: the aluminum foil thickness of the shielding layer is 0.02-0.05mm, and the thickness of the radiation crosslinked PTFE film is 0.1-0.3mm.

[0016] As a further description of the above technical solution: the outer surface of the sheath layer is provided with anti-wear texture.

[0017] As a further description of the above technical solution: the anti-wear texture is a spiral groove or a diamond-shaped raised texture, and the texture depth is 0.2-0.5mm.

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

[0019] I. The high-strength aviation fiber braided sheath layer of this solution can independently bear the entire mechanical load of the cable, so that the internal core is in a zero-stress environment, ensuring that the power transmission efficiency and high-frequency signal fidelity are not affected by the dynamic flight of the UAV.

[0020] II. The conductor in this design is made of 30 strands of 0.08mm silver-plated copper wire twisted together. The silver layer effectively prevents copper oxidation, reduces resistance, and ensures long-term stable power and signal transmission. In addition, the silver-plated conductor can simultaneously carry 48V power and 100Mbps signal, eliminating the need for additional fiber optic cables through frequency division multiplexing.

[0021] Third, the NTC characteristics of the PTFE insulation layer in this design provide adaptive temperature drift compensation capability for the cable of this invention. Combined with the silver-plated conductor and aluminum foil shielding layer, stable co-cable transmission of power and signals is achieved over a wide temperature range. The PTFE insulation layer is 30% lighter than traditional PVC / PU materials, reducing the load on drones.

[0022] IV. The aluminum foil shielding layer of this solution combines four independent composite structure designs to effectively suppress electromagnetic interference (EMI) and crosstalk between lines, ensuring distortion-free transmission of high-definition video and control signals. Furthermore, the four composite structures are evenly distributed, improving the overall balance and torsional resistance of the cable and preventing internal damage caused by torsion during use. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of this utility model;

[0024] Figure 2 This is a cross-sectional view of the present invention.

[0025] Explanation of the labels in the diagram:

[0026] 1. Conductor; 2. Insulation layer; 3. Shielding layer; 4. Sheath layer; 5. Anti-wear texture; 6. Filler material. Detailed Implementation

[0027] 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.

[0028] Please see Figure 1-2 A high-strength, lightweight tethered drone cable includes a conductor 1, which is composed of 30 strands of 0.08mm silver-plated copper wire, twisted and re-twisted in the same direction. The silver-plated copper wire is more resistant to oxidation than pure copper, reducing signal attenuation and making it suitable for high-frequency signal transmission. The silver-plated conductor can simultaneously carry 48V power and 100Mbps signals, avoiding the need for additional fiber optic cables through frequency division multiplexing. The conductor 1 is wrapped with an insulation layer 2, which is a radiation-crosslinked PTFE film with a thickness of 0.1-0.3mm. Polytetrafluoroethylene (PTFE) has a unique negative temperature coefficient (NTC) resistivity characteristic, meaning its volume resistivity (ρ) gradually decreases as temperature increases. Therefore, the radiation-crosslinked PTFE insulation layer 2 exhibits a negative temperature coefficient resistivity characteristic. When the conductor 1 heats up due to load, the resistance of the insulation layer 2 decreases, forming dynamic compensation, suppressing overall circuit resistance fluctuations, and improving power transmission efficiency and signal stability under high-temperature environments.

[0029] The insulation layer 2 is wrapped with a shielding layer 3, which is made of aluminum foil with a thickness of 0.02-0.05 mm, effectively suppressing electromagnetic interference. A sheath layer 4 is provided outside the shielding layer 3, made of 16 spindles of high-strength aerospace fiber, providing excellent tensile and abrasion resistance. Through the 100% mechanical load-bearing design of the sheath layer 4 woven from 16 spindles of high-strength aerospace fiber, the following is achieved:

[0030] 1. Mechanical decoupling: The sheath layer 4 independently bears all tensile, bending and torsional stresses, while the internal conductor 1 and the composite structure are in a "free floating" state.

[0031] 2. Zero-stress transmission: The wire core only transmits electrical signals and power, completely avoiding performance degradation caused by mechanical deformation.

[0032] Among them, high-strength aerospace fibers can be selected from ultra-high molecular weight polyethylene (UHMWPE) or aramid (such as... Fiber with a tensile strength >20GPa and a density of only 1.0~1.4g / cm³ 3 .

[0033] Furthermore, conductor 1, insulation layer 2, and shielding layer 3 form a composite structure. There are four sets of composite structures evenly distributed within the sheath layer 4. The aluminum foil shielding, combined with the four independent composite structure designs, effectively suppresses electromagnetic interference and crosstalk between lines and enhances torsional resistance. Filling material 5, made of polyethylene tape, is placed within the sheath layer 4 and in the gaps of the composite structure to ensure structural stability. The insulation layers 2 in the four composite structures are symmetrically set in red and black in pairs, employing a red and black dual-color design for easy polarity identification during installation.

[0034] The outer surface of the sheath layer 4 is provided with anti-abrasion texture 41, which can significantly improve abrasion resistance. The anti-abrasion texture 41 can be a spiral groove or a diamond-shaped raised texture, with a texture depth of 0.2-0.5mm, which ensures abrasion resistance without affecting the flexibility of the cable.

[0035] 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-strength, lightweight tethered unmanned aerial vehicle (UAV) cable, characterized in that: It includes a conductor (1), which is made of 30 strands of 0.08 silver-plated copper wires twisted and re-twisted in the same direction. The conductor (1) is wrapped with an insulating layer (2), which is a radiation cross-linked PTFE film. The insulating layer (2) is wrapped with a shielding layer (3), which is aluminum foil. The shielding layer (3) is provided with a sheath layer (4) outside the shielding layer (3), which is made of 16 spindles of high-strength aviation fiber. The conductor (1), the insulation layer (2) and the shielding layer (3) form a composite structure, and there are four sets of the composite structure, which are evenly distributed in the sheath layer (4).

2. The high-strength, lightweight tethered UAV cable according to claim 1, characterized in that: The sheath layer (4) is provided with a filling material (5) in the gap of the composite structure, and the filling material (5) is polyethylene tape.

3. The high-strength, lightweight tethered UAV cable according to claim 1, characterized in that: The insulating layers (2) in the four composite structures are symmetrically set in red and black in pairs.

4. The high-strength, lightweight tethered UAV cable according to claim 1, characterized in that: The aluminum foil of the shielding layer (3) has a thickness of 0.02-0.05 mm, and the radiation crosslinked PTFE film has a thickness of 0.1-0.3 mm.

5. The high-strength, lightweight tethered UAV cable according to claim 1, characterized in that: The outer surface of the sheath layer (4) is provided with anti-wear texture (41).

6. A high-strength, lightweight tethered UAV cable according to claim 5, characterized in that: The wear-resistant texture (41) is a spiral groove or a diamond-shaped raised texture with a texture depth of 0.2-0.5mm.

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