High strength small gauge light weight aircraft conductor
Patent Information
- Application Number
- CN202521941334.9
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-10
- Publication Date
- 2026-09-18
- Estimated Expiration
- 2035-09-10
AI Technical Summary
[0004]本申请的目的是针对现有技术的缺点，采用中心芳纶丝A为骨架、外层芳纶丝B与高强度合金丝间隔绞合形成复合导电线芯，配合金属镀层与交联乙烯-四氟乙烯绝缘护套的设计方式，设计了一种高强度小规格轻型航空导线，解决了传统航空导线因采用镀银铜线和聚四氟乙烯绝缘导致的重量大、抗拉强度低可靠性不足的问题
1.本申请通过中心芳纶丝A与外层芳纶丝B作为高强度骨架，利用芳纶纤维高弹性模量、密度低与断裂强度的特性，提升导电线芯的抗拉强，减少了导电线芯重量，导电线芯采用绞距10mm、±15°角度分层绞合的工艺，外层芳纶丝B与高强度合金丝间隔排列，形成均匀受力的螺旋结构，增强了抗扭转能力，确保在复杂布线路径中不易松散或形变。
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Figure CN224773597U_ABST
Abstract
Description
Technical Field
[0001] This application belongs to the field of aviation equipment, specifically a high-strength, small-diameter, lightweight aviation wire. Background Technology
[0002] In order to achieve long-distance flights and increased payload capacity, modern aircraft require that aviation cables not only meet the load capacity requirements but also continuously reduce their own weight, while small-diameter cables must also have a certain level of mechanical strength.
[0003] Traditional aviation wires, such as those using silver-plated copper wire and polytetrafluoroethylene insulation, are heavy (copper density 8.96 g / cm3), and copper has a tensile strength of only 300-400 MPa. They are prone to creep in environments above 150°C, while the temperature in areas such as aircraft engine compartments often reaches 125°C. Long-term use can easily lead to wire breakage due to vibration and tension, resulting in insufficient reliability. Therefore, it is necessary to design a high-strength, small-gauge, lightweight aviation wire to solve the above problems. Utility Model Content
[0004] The purpose of this application is to address the shortcomings of existing technologies by using a central aramid filament A as the skeleton, an outer aramid filament B and high-strength alloy wires interleaved to form a composite conductive core, and combining it with a metal plating layer and a cross-linked ethylene-tetrafluoroethylene insulation sheath. This design creates a high-strength, small-gauge, lightweight aviation conductor, solving the problems of heavy weight, low tensile strength, and insufficient reliability caused by the use of silver-plated copper wire and polytetrafluoroethylene insulation in traditional aviation conductors.
[0005] To achieve the above objectives, the following technical solution is adopted: A high-strength, small-gauge, lightweight aviation conductor includes aramid filament A and a high-strength alloy wire. The outer side of the aramid filament A is coated with a metal layer. The outer side of the aramid filament A is twisted with the metal-coated aramid filament B. The outer side of the aramid filament B is also coated with a metal layer. The high-strength alloy wire, aramid filament A, and aramid filament B are twisted together to form a conductive core. The outer side of the conductive core is provided with an insulating sheath.
[0006] Preferably, the aramid filament A is located at the center of the conductive core, and its outer stranded aramid filament B is arranged alternately with the high-strength alloy wire.
[0007] Preferably, the metal coating is a silver coating.
[0008] Preferably, the insulating sheath is made of cross-linked ethylene-tetrafluoroethylene insulating material.
[0009] Preferably, the high-strength alloy wire is a silver-plated alloy wire.
[0010] Preferably, the conductive wire core with a strand pitch of 10mm is stranded in layers at an angle of +15° / -15°.
[0011] Compared with the prior art, the beneficial effects of this application are: 1. This application uses a central aramid filament A and an outer aramid filament B as a high-strength skeleton. It utilizes the high elastic modulus, low density, and breaking strength of aramid fibers to improve the tensile strength of the conductive core and reduce its weight. The conductive core is stranded in layers with a pitch of 10mm and an angle of ±15°. The outer aramid filament B and high-strength alloy wire are arranged alternately to form a spiral structure with uniform stress, which enhances the anti-torsion ability and ensures that it is not easy to loosen or deform in complex wiring paths.
[0012] 2. This application utilizes the silver plating on the surfaces of aramid yarn A and aramid yarn B, along with the silver-plated high-strength alloy wire, to achieve synergistic conductivity, reducing transmission loss by 15% compared to aluminum alloy wires of the same specifications. This meets the signal and power transmission requirements of avionics equipment. At the same time, the chemical inertness of the silver plating ensures that the contact resistance of the wire remains stable in environments ranging from -55℃ to 125℃, eliminating the risk of oxidation failure. Attached Figure Description
[0013] Figure 1 This is a schematic diagram of the structure of this application; Figure 2 This is a schematic diagram of the front structure of this application; Figure 3 This is a schematic diagram showing the breakdown of this application.
[0014] Among them, 1. Aramid filament A; 2. Aramid filament B; 3. Metal coating; 4. High-strength alloy wire; 5. Insulating sheath. Detailed Implementation
[0015] Reference Figure 1 - Figure 3A high-strength, small-gauge, lightweight aviation conductor includes aramid fiber A1 and high-strength alloy wire 4. Aramid fiber A1, an aromatic polyamide fiber with a diameter of 0.15–0.25 mm, serves as the central skeleton of the conductive core. Utilizing the high elastic modulus (70-200 GPa) and high tensile strength (≥3000 MPa) of aramid fiber, it provides axial tensile and bending resistance for the entire conductive core, making the conductor less prone to breakage under aviation vibration environments. The density of aramid fiber is only 1.44 g / cm³, far lower than that of metallic materials (copper density 8.96 g / cm³). As the central skeleton, it significantly reduces the overall weight of the conductor, improving the aircraft's endurance. The rigidity of the high-strength alloy wire 4 and the flexibility of the aramid fiber... To achieve a complementary effect, while ensuring the overall flexibility of the conductor (minimum bending radius ≤ 5mm), the conductor core's resistance to compression is enhanced. The outer side of aramid filament A1 is coated with a metal layer 3, and the outer side of aramid filament A1 is twisted with the metal layer 3 and aramid filament B2. The aramid filament B2 and the central aramid filament A1 form a three-dimensional strength network with a central and peripheral structure, further enhancing the conductor's resistance to torsion and shear. The outer side of aramid filament B2 is also coated with a metal layer 3. After the aramid filament A1 and aramid filament B2 are coated with the metal layer 3, they become auxiliary conductors of the conductive conductor core, working together with the high-strength alloy wire 4 to carry current. The high-strength alloy wire 4, together with aramid filament A1 and aramid filament B2, form the conductive conductor core. An insulating sheath 5 is provided on the outer side of the conductive conductor core.
[0016] In this embodiment, during use, wires of the corresponding length are first cut according to the wiring requirements of the aviation equipment. Utilizing the flexibility of the conductive core and the anti-torsion characteristics of the layered stranded structure, the wires are laid along a preset path. After the wiring is fixed, the high-strength skeleton formed by aramid fibers A1 and B2 can withstand the continuous vibration during aircraft flight. The continuous conductive network formed by the metal plating layer 3 and the silver-plated high-strength alloy wire 4 ensures stable transmission of current or signals. Even under ambient temperature fluctuations ranging from -55℃ to 125℃, the chemical inertness of the silver plating layer ensures stable contact resistance (≤0.01Ω / m) and eliminates the risk of oxidation failure.
[0017] The outer cross-linked ethylene-tetrafluoroethylene insulating sheath provides multiple protective functions, and its excellent insulation performance (volume resistivity ≥10¹) ensures superior protection. 4 (Ω•cm) Insulates the wire core from the external conductor to prevent short circuits; its temperature resistance is suitable for all scenarios from high altitude and low temperature to engine compartment high temperature; its abrasion resistance can withstand wiring friction (abrasion amount ≤0.1mm / 1000 cycles of friction), ensuring the insulation layer remains intact during long-term use.
[0018] Through the coordinated operation of its components, this cable meets the requirements of lightweight and compact design for aviation equipment while achieving high strength, high conductivity, and stable operation in extreme environments, making it suitable for the wiring needs of drones, light aircraft, and avionics equipment.
[0019] As a preferred embodiment, aramid filament A1 is located at the center of the conductive core, with its outer stranded aramid filament B2 and high-strength alloy wire 4 arranged alternately.
[0020] As a preferred method, metal plating layer 3 is a silver plating layer, as silver is the metal with the best electrical conductivity (resistivity 1.59 × 10⁻⁻⁻⁻⁶). 8 (Ω•m), through the plating, the insulating aramid filament is transformed into a conductor, forming a continuous conductive network with the high-strength alloy wire 4, ensuring that the current can be transmitted uniformly along the entire core, and the transmission loss is reduced by 15% compared with aluminum alloy wire of the same specification.
[0021] As a preferred embodiment, the insulating sheath 5 is made of cross-linked ethylene-tetrafluoroethylene (EXTE) insulation material with a thickness of 0.15 mm. X-ETFE particles are formed by melt extrusion followed by electron accelerator irradiation (dose 50 kGy / s) and tightly wrapped around the outside of the conductive core. X-ETFE has excellent insulation properties with a volume resistivity ≥10¹. 4 With a strength of Ω•cm and a breakdown field strength ≥25kV / mm, it can effectively isolate the conductive core from the external conductor, prevent short circuit risks in aviation equipment wiring, and meet the insulation level requirements of aviation electronic equipment.
[0022] As a preferred method, the high-strength alloy wire 4 is a silver-plated alloy wire.
[0023] As a preferred method, the conductor cores are stranded in layers with a pitch of 10mm using a +15° / -15° angle. The axial distance between adjacent stranded wires is controlled to be 10mm. This ensures that the components of the conductor core are tightly fitted with a gap of ≤0.05mm to avoid mutual friction and wear during vibration, while also retaining a certain degree of flexibility so that the conductor can be bent to a minimum radius of ≤5mm to adapt to complex wiring paths.
Claims
1. A high-strength, small-diameter, lightweight aviation wire, characterized in that, It includes aramid filament A (1) and high-strength alloy wire (4). The outer side of the aramid filament A (1) is coated with a metal layer (3). The outer side of the aramid filament A (1) is twisted with the metal layer (3) and the aramid filament B (2). The outer side of the aramid filament B (2) is also coated with a metal layer (3). The high-strength alloy wire (4) is twisted together with the aramid filament A (1) and the aramid filament B (2) to form a conductive core. The outer side of the conductive core is provided with an insulating sheath (5).
2. The high-strength, small-diameter, lightweight aviation wire according to claim 1, characterized in that, The aramid filament A (1) is located at the center of the conductive core, and its outer layer of twisted aramid filament B (2) and high-strength alloy wire (4) are arranged alternately.
3. The high-strength, small-diameter, lightweight aviation wire according to claim 1, characterized in that, The metal plating layer (3) is a silver plating layer.
4. The high-strength, small-diameter, lightweight aviation wire according to claim 1, characterized in that, The insulating sheath (5) is made of cross-linked ethylene-tetrafluoroethylene insulating material.
5. A high-strength, small-diameter, lightweight aviation conductor according to claim 1, characterized in that, The high-strength alloy wire (4) is a silver-plated alloy wire.
6. The high-strength, small-diameter, lightweight aviation wire according to claim 1, characterized in that, The conductive wire core has a strand pitch of 10mm and is stranded in layers at an angle of +15° / -15°.