A silver-coated conductor crosslinked ethylene-tetrafluoroethylene copolymer insulated electric wire cable
Patent Information
- Application Number
- CN202521956285.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-09-11
- Publication Date
- 2026-10-27
- Estimated Expiration
- 2035-09-11
AI Technical Summary
而在现在使用的导线中，乙烯一四氟乙烯共聚物绝缘导线具有优异的耐辐照性能，但其耐温等级低，其他导线虽然耐温等级高，但耐辐照性能都比较差，同时，上述各种航空导线的耐高温冲击性能都很差，无法满足人们的需求
（1）本实用新型采用镀银铜导体，有效的解决了铜导体容易氧化，同时导体内通交流电时由于楞次定律产生趋肤效应，采用交联乙烯-四氟乙烯共聚物绝缘，保证电缆长期特殊环境下耐辐照性能，耐温，耐辐照，高温冲击性能等，在减少产品外径条件下提高电缆整体的结构稳定性，采用分层绞合设计的内芯体提升整体结构稳定性，减薄绝缘厚度，外层单丝镀银厚度大于内层单丝镀银厚度，降低成本同时保证整体导电性能，强化柔软性与导电性，适配轻量化需求，过渡层结构和绝缘结构，提升耐温性与绝缘可靠性，适配极端环境，屏蔽内层、缓冲隔离层和镀银铜线编织层组成的复合屏蔽层，增强电线电缆的抗干扰能力，适配高频信号传输，护套内层和护套外层组成的护套层能够电线电缆的强化耐环境性能，延长使用寿命。
Smart Images
Figure CN224907603U_ABST
Abstract
Description
Technical Field
[0001] This utility model belongs to the field of wire and cable technology, specifically a silver-plated conductor cross-linked ethylene-tetrafluoroethylene copolymer insulated wire and cable. Background Technology
[0002] Wires and cables are wire products used to transmit electrical energy, transmit information, or realize electromagnetic energy conversion. They are composed of conductors, insulation layers, sheath layers, and other structures. They are the "blood vessels" and "nerves" of power systems, communication networks, industrial equipment, transportation, and other fields. Insulated wires and cables are a type of wire and cable with insulation layers as the core structural feature. They are mainly used to realize the insulated transmission of electrical energy or signals and avoid leakage, short circuits, and signal interference.
[0003] Currently used aerospace conductors mainly consist of PTFE insulated conductors (temperature resistance 250℃), ethylene-tetrafluoroethylene copolymer insulated conductors (temperature resistance 150℃), and PTFE insulated conductors (temperature resistance 200℃). These conductors are characterized by high temperature resistance and resistance to acids, alkalis, and oils. However, in certain special applications, conductors are required to have excellent temperature resistance, radiation resistance, and resistance to short-term high-temperature shock. Simultaneously, reducing the outer diameter and weight of the conductors while ensuring electrical performance remains a constant pursuit in aerospace conductors. Among the conductors currently in use, ethylene-tetrafluoroethylene copolymer insulated conductors have excellent radiation resistance, but their temperature resistance is low. Other conductors, while having high temperature resistance, generally have poor radiation resistance. Furthermore, the high-temperature shock resistance of all the aforementioned aerospace conductors is very poor, failing to meet current requirements. Utility Model Content
[0004] The present invention aims to solve the technical problems existing in the prior art; to this end, the present invention proposes a silver-plated conductor cross-linked ethylene-tetrafluoroethylene copolymer insulated wire and cable.
[0005] A silver-plated conductor cross-linked ethylene-tetrafluoroethylene copolymer insulated wire and cable includes an inner core and an insulation layer disposed on the outside of the inner core; the inner core is made of silver-plated copper conductor; a composite shielding layer with anti-interference capability is disposed on the outside of the insulation layer; and a sheath layer is disposed on the outside of the composite shielding layer.
[0006] As a further aspect of this utility model: the inner core incorporates several groups of silver-plated copper conductors in a layered stranding design. The silver-plated conductors are stranded according to the rule of "one conductor in the center + layers increasing from the outermost layer," with each layer stranding in the opposite direction (e.g., alternating left and right directions). This reduces the looseness and deformation of the conductor bundle, improves the overall structural stability, and the layered stranding with the opposite stranding direction increases the tightness of the conductor bundle, reduces the gaps when wrapping the insulation layer, indirectly reduces the insulation thickness, and further reduces weight. The silver plating thickness of the outer monofilament is greater than that of the inner monofilament, and the outer layer directly contacts the insulation layer. The thicker silver plating enhances corrosion resistance and conductivity. The inner layer reduces the amount of silver used, lowering costs while ensuring overall conductivity.
[0007] As a further embodiment of this utility model: the insulating layer includes a transition layer structure of a nickel-plated or polyimide film connected to the outer wall of the inner core and an insulating structure disposed on the outside of the transition layer structure. The nickel-plated layer can enhance the adhesion between the conductor and XL-ETFE and prevent the insulating layer from peeling off from the conductor at high temperatures. The polyimide film has the characteristic of being resistant to high temperatures above 260°C, which can buffer the difference in thermal expansion coefficients between the inner core and the insulating layer and reduce stress cracking of the insulating layer caused by temperature cycling.
[0008] As a further embodiment of this utility model: the insulation structure is set as a cross-linked ethylene-tetrafluoroethylene copolymer with a low degree of cross-linking in the inner layer and a high degree of cross-linking in the outer layer. The inner layer retains a certain degree of flexibility to prevent the insulation layer from cracking when the conductor is bent; the high degree of cross-linking in the outer layer enhances the wear resistance and chemical corrosion resistance.
[0009] As a further embodiment of this invention: the composite shielding layer includes an inner shielding layer tightly fitted to the insulation structure, a buffer isolation layer connected to the sheath layer, and a silver-plated copper wire braided layer disposed between the inner shielding layer and the buffer isolation layer. The inner shielding layer is made of semi-conductive XL-ETFE, and conductive particles such as carbon black are added to the inner shielding layer to tightly fit with the insulation layer, which can balance the electric field on the surface of the insulation layer and reduce the risk of partial discharge. The silver-plated copper wire braided layer has a silver layer thickness of ≥5μm, which enhances the shielding effect against high-frequency electromagnetic interference. At the same time, the silver plating layer improves the corrosion resistance of the braided layer. The buffer isolation layer is made of fiberglass cloth or polytetrafluoroethylene (PTFE) tape. Fiberglass cloth enhances the overall tensile strength (especially at high temperatures, to prevent the braided wires of the shielding layer from breaking). PTFE tape has a low coefficient of friction, which reduces the wear of the shielding layer during the extrusion of the sheath layer, and at the same time improves the synergistic effect of chemical corrosion resistance.
[0010] As a further embodiment of this utility model: the silver-plated copper wire braided layer is formed into a tubular structure by cross-braiding multiple strands of silver-plated copper wire, and the silver-plated copper wire braided layer is assisted in bonding with the buffer isolation layer by an adhesive.
[0011] As a further embodiment of this utility model: the sheath layer includes an inner sheath layer that is tightly fitted with the buffer isolation layer and an outer sheath layer that is connected to the inner sheath layer; the outer surface of the outer sheath layer is provided with several sets of micro-textures for dispersing external force impacts.
[0012] As a further embodiment of this utility model: the inner and outer layers of the sheath adopt an asymmetrical sheath structure with a thinner inner layer and a thicker outer layer. The inner layer of the sheath is thin and flexible (thickness 0.1-0.2mm), reducing the compression of the composite shielding layer; the outer layer of the sheath is thick (0.2-0.4mm) and dense, enhancing impact resistance and weather resistance.
[0013] Compared with the prior art, the beneficial effects of this utility model are: (1) This utility model uses silver-plated copper conductors, which effectively solves the problem of copper conductors being easily oxidized. At the same time, when alternating current is passed through the conductor, the skin effect is generated due to Lenz's law. Cross-linked ethylene-tetrafluoroethylene copolymer insulation is used to ensure the long-term radiation resistance, temperature resistance, radiation resistance, and high-temperature impact resistance of the cable under special environments. The overall structural stability of the cable is improved while reducing the outer diameter of the product. The inner core with layered stranding design improves the overall structural stability. The insulation thickness is reduced. The silver plating thickness of the outer single filament is greater than that of the inner single filament, which reduces the cost while ensuring the overall conductivity. The flexibility and conductivity are enhanced to meet the requirements of lightweighting. The transition layer structure and insulation structure improve the temperature resistance and insulation reliability to meet extreme environments. The composite shielding layer composed of the shielding inner layer, buffer isolation layer and silver-plated copper wire braided layer enhances the anti-interference ability of the wire and cable and is suitable for high-frequency signal transmission. The sheath layer composed of the inner sheath layer and the outer sheath layer can enhance the environmental resistance of the wire and cable and extend its service life. Attached Figure Description
[0014] Figure 1 This is a schematic diagram of the overall design of this utility model.
[0015] Figure 2 This is a partial structural diagram of the inner core in this utility model.
[0016] Figure 3 This is a partial structural diagram of the insulating layer in this utility model.
[0017] Figure 4 This is a partial structural diagram of the composite shielding layer in this utility model.
[0018] Figure 5 This is a partial structural diagram of the sheath layer in this utility model.
[0019] In the diagram: 1. Inner core; 2. Insulation layer; 3. Composite shielding layer; 4. Sheath layer; 5. Transition layer structure; 6. Insulation structure; 7. Inner shielding layer; 8. Buffer isolation layer; 9. Silver-plated copper wire braided layer; 10. Inner sheath layer; 11. Outer sheath layer. Detailed Implementation
[0020] The technical solution of this utility model will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of this utility model, and not all embodiments. Based on the embodiments of this utility model, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the protection scope of this utility model.
[0021] Example 1 Please see Figure 1 - Figure 5 This application provides a silver-plated conductor cross-linked ethylene-tetrafluoroethylene copolymer insulated wire and cable, including an inner core 1 and an insulation layer 2 disposed on the outside of the inner core 1; the inner core 1 is made of silver-plated copper conductor; a composite shielding layer 3 with anti-interference capability is disposed on the outside of the insulation layer 2; and a sheath layer 4 is disposed on the outside of the composite shielding layer 3.
[0022] In this invention, the inner core 1 incorporates several groups of silver-plated copper conductors in a layered stranding design. The silver-plated conductors are stranded according to the rule of "one conductor in the center + layers increasing from the outermost layer," with each layer stranding in the opposite direction, such as alternating left and right directions. This reduces the looseness and deformation of the conductor bundle, improves the overall structural stability, and the layered stranding with the opposite stranding direction increases the tightness of the conductor bundle, reduces the gaps when wrapping the insulation layer, indirectly reduces the insulation thickness, and further reduces weight. The silver plating thickness of the outer single-wire is greater than that of the inner single-wire, and the outer layer directly contacts the insulation layer. The thicker silver plating enhances corrosion resistance and conductivity. The inner layer reduces the amount of silver used, lowering costs while ensuring overall conductivity.
[0023] In this embodiment, three sets of silver-plated copper conductors are twisted to the left on the outside of one silver-plated copper conductor, and then six sets of silver-plated copper conductors are twisted to the right on the outside to form the inner core 1.
[0024] In this invention, the insulating layer 2 includes a transition layer structure 5 of nickel-plated or polyimide film connected to the outer wall of the inner core 1 and an insulating structure 6 disposed on the outside of the transition layer structure 5. The nickel plating layer can enhance the adhesion between the conductor and XL-ETFE and prevent the insulating layer 2 from peeling off from the conductor at high temperatures. The polyimide film has the characteristic of being resistant to high temperatures above 260°C, which can buffer the difference in thermal expansion coefficients between the inner core 1 and the insulating layer 2 and reduce stress cracking of the insulating layer 2 caused by temperature cycling.
[0025] In this embodiment, a transition layer structure 5 is produced on the outside of the inner core 1, and then an insulating structure 6 is formed on the outside of the transition layer structure 5.
[0026] In this invention, the insulation structure 6 is a cross-linked ethylene-tetrafluoroethylene copolymer with a low degree of cross-linking in the inner layer and a high degree of cross-linking in the outer layer. The inner layer retains a certain degree of flexibility to prevent the insulation layer 2 from cracking when the conductor is bent; the high degree of cross-linking in the outer layer enhances the wear resistance and chemical corrosion resistance.
[0027] In this invention, the composite shielding layer 3 includes an inner shielding layer 7 tightly fitted to the insulating structure 6, a buffer isolation layer 8 connected to the sheath layer 4, and a silver-plated copper wire braided layer 9 disposed between the inner shielding layer 7 and the buffer isolation layer 8. The inner shielding layer 7 is made of semi-conductive XL-ETFE, and conductive particles such as carbon black are added to the inner shielding layer 7 to tightly fit with the insulating layer 2, which can balance the electric field on the surface of the insulating layer 2 and reduce the risk of partial discharge. The silver-plated copper wire braided layer 9 has a silver layer thickness of ≥5μm, which enhances the shielding effect against high-frequency electromagnetic interference. At the same time, the silver plating layer improves the corrosion resistance of the braided layer. The buffer isolation layer 8 is made of glass fiber cloth or polytetrafluoroethylene (PTFE) tape. The glass fiber cloth enhances the overall tensile strength, especially at high temperatures, to prevent the braided wires of the shielding layer from breaking. The PTFE tape has a low coefficient of friction, which reduces the wear of the shielding layer during the extrusion of the sheath layer, and at the same time improves the synergistic effect of chemical corrosion resistance.
[0028] In this utility model, the silver-plated copper wire braided layer 9 is formed by multiple strands of silver-plated copper wire in a cross-braiding manner to form a tubular structure. The silver-plated copper wire braided layer 9 is bonded to the buffer isolation layer 8 with the help of an adhesive.
[0029] In this embodiment, a shielding inner layer 7 is formed on the outside of the insulating structure 6, and six silver-plated copper wires are braided into a silver-plated copper wire braided layer 9 on the outside of the shielding inner layer 7, so that the silver-plated copper wire braided layer 9 is tightly attached to the outside of the shielding inner layer 7. An adhesive is used to attach a buffer isolation layer 8 to the outside of the silver-plated copper wire braided layer 9.
[0030] In this utility model, the sheath layer 4 includes an inner sheath layer 10 that is tightly fitted to the buffer isolation layer 8 and an outer sheath layer 11 that is connected to the inner sheath layer 10; the outer surface of the outer sheath layer 11 is provided with several sets of micro-textures for dispersing external force impact.
[0031] In this utility model, the inner layer 10 and the outer layer 11 of the sheath adopt an asymmetrical sheath structure with a thinner inner layer and a thicker outer layer. The inner layer 10 is thin and flexible with a thickness of 0.1 to 0.2 mm, which reduces the compression of the composite shielding layer 3. The outer layer 11 is 0.2 to 0.4 mm thick and dense, which enhances the impact resistance and weather resistance.
[0032] In this embodiment, an inner sheath 10 is formed on the outside of the buffer isolation layer 8, and then an outer sheath 11 is formed on the outside of the inner sheath 10.
[0033] The above embodiments are only used to illustrate the technical methods of this utility model and are not intended to limit it. Although this utility model has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical methods of this utility model without departing from the spirit and scope of the technical methods of this utility model.
Claims
1. A silver-plated conductor cross-linked ethylene-tetrafluoroethylene copolymer insulated wire and cable, characterized in that, include: Inner core (1) and insulating layer (2) disposed on the outside of inner core (1); The inner core (1) is made of silver-plated copper conductor; A composite shielding layer (3) with anti-interference capability is provided on the outside of the insulating layer (2). The outer side of the composite shielding layer (3) is provided with a sheath layer (4). The inner core (1) has several groups of silver-plated copper conductors in a layered stranding design, with each layer stranding in the opposite direction; The outer monofilament silver plating thickness is greater than that of the inner monofilament silver plating thickness.
2. The silver-plated conductor cross-linked ethylene-tetrafluoroethylene copolymer insulated wire and cable according to claim 1, characterized in that, The insulating layer (2) includes a transition layer structure (5) of a nickel-plated or polyimide film connected to the outer wall of the inner core (1) and an insulating structure (6) disposed outside the transition layer structure (5).
3. The silver-plated conductor cross-linked ethylene-tetrafluoroethylene copolymer insulated wire and cable according to claim 2, characterized in that, The insulating structure (6) is configured as a cross-linked ethylene-tetrafluoroethylene copolymer with a low degree of cross-linking in the inner layer and a high degree of cross-linking in the outer layer.
4. The silver-plated conductor cross-linked ethylene-tetrafluoroethylene copolymer insulated wire and cable according to claim 1, characterized in that, The composite shielding layer (3) includes a shielding inner layer (7) that is tightly fitted to the insulating structure (6), a buffer isolation layer (8) connected to the sheath layer (4), and a silver-plated copper wire braided layer (9) disposed between the shielding inner layer (7) and the buffer isolation layer (8).
5. The silver-plated conductor cross-linked ethylene-tetrafluoroethylene copolymer insulated wire and cable according to claim 4, characterized in that, The silver-plated copper wire braided layer (9) is formed into a tubular structure by cross-braiding multiple strands of silver-plated copper wire. The silver-plated copper wire braided layer (9) is bonded to the buffer isolation layer (8) with the help of adhesive.
6. The silver-plated conductor cross-linked ethylene-tetrafluoroethylene copolymer insulated wire and cable according to claim 4, characterized in that, The sheath layer (4) includes an inner sheath layer (10) that is tightly fitted to the buffer isolation layer (8) and an outer sheath layer (11) that is connected to the inner sheath layer (10). The outer surface of the outer sheath (11) is provided with several sets of tiny textures for dispersing external force impacts.
7. The silver-plated conductor cross-linked ethylene-tetrafluoroethylene copolymer insulated wire and cable according to claim 6, characterized in that, The inner layer (10) and outer layer (11) of the sheath adopt an asymmetrical sheath structure with a thinner inner layer and a thicker outer layer.