Highly shielded aerial conductor

Abstract

The utility model provides a kind of high shielding aviation conductor, it is related to aviation wire technical field.Specifically: aviation conductor includes the inner conductor, insulating layer, shielding layer and sheath layer sequentially arranged from inside to outside;The shielding layer is braided structure, and the braided structure includes several mutually parallel left direction metal-plated copper band and several mutually parallel right direction metal-plated copper band;And the braided structure is single layer setting or double layer setting.The utility model is shielded by the braided structure of the shielding layer of unique design, and the shielding efficiency of traditional metal round wire stranded braided conductor shielding layer is improved 1~1.5 times, can effectively reduce the dosage of wave-proof sleeve in avionics equipment, reduce the weight of equipment complete machine, meet the harsh requirements of high-end aerospace field to weight.

Description

Technical Field

[0001] This utility model relates to the field of aviation wire technology, and more specifically, to a highly shielded aviation wire. Background Technology

[0002] Shielded aviation wires are a type of special wire used in the aerospace field. They are mainly used for electrical and control signal transmission to meet the application requirements of high-temperature scenarios in the aerospace field. They are an indispensable component for electrical and signal transmission between electronic devices in airborne, missile-borne, and spaceborne fields, and are widely used in scenarios such as aero-engine control systems, fuel monitoring systems, avionics and flight control systems, and weapon radar guidance systems.

[0003] With the development of aerospace and weaponry, the requirements for shielded aviation cables are becoming increasingly stringent, and high reliability has become the mainstream requirement. Traditional shielded aviation cables use multiple round wires twisted together as a shielding layer, with a shielding efficiency of only -40dB. They are easily affected by external electromagnetic interference and cannot meet the requirements for high reliability.

[0004] Specifically, existing conventional shielded aviation conductors generally use silver-plated copper stranded wire as the conductor material, with PTFE extruded sintered insulation or PTFE raw material tape wrapped and sintered insulation core wire. After the core wire is stranded, it is shielded with tinned copper wire braid. It also adopts FEP / PFA sheath structure and can work for a long time in the range of -65℃ to +200℃.

[0005] For example, patent CN200320114283.X discloses a special high-temperature shielded cable. The core wire is made of silver-plated copper wire stranded together. The outer wall of the core wire is wrapped with an F4 film insulation layer, an ethylene propylene rubber insulation layer and a shielding layer made of tin-plated copper wire from the inside to the outside. The cable has good insulation and is more resistant to high temperatures.

[0006] For example, patent CN201420029857.1 discloses a lightweight fluoroplastic insulated cable for aerospace applications. This cable consists of a conductive core, a round conductor braided shielding layer, a fluoroplastic insulation layer, and an outer sheath. The conductive core is formed by extruding a silicone rubber insulation layer onto silver-plated copper wire stranded conductors. Three conductive cores are twisted together to form the cable core, with flame-retardant filler rope filling the gaps between them. The cable core is surrounded by a round conductor braided shielding layer, an outer sheath, and a fluoroplastic insulation layer. The resulting cable has a simple structure, stable performance, and meets the performance requirements of aerospace cables. It is characterized by high temperature resistance, flame retardancy, and radiation protection. Furthermore, the cable is flexible, lightweight, and easy to lay.

[0007] For example, patent CN201020271862.5 discloses an aviation-grade fluoroplastic F46 insulated shielded wire, which uses tin-plated copper as the inner conductor, a high-temperature heat insulation layer extruded on the outside of the inner conductor as the insulation layer, tin-plated copper wires braided in parallel as the shielding layer, and F46 (FEP) extruded on the outermost layer as the sheath layer.

[0008] For example, patent CN202211406595.1 discloses a cable containing a fluoroplastic insulating metal film layer and its preparation method. It uses a silver-plated copper conductor as the inner conductor, fluoroplastic extrusion as the insulation layer, chemical silver / copper plating on the surface of the fluoroplastic insulation layer as the shielding layer, several core wires are twisted together and wrapped and fixed, polyvinyl chloride is extruded on the surface as the sheath, and the outermost layer of metal round wires is braided as the overall shielding layer.

[0009] In the aforementioned conventional shielded aviation conductors and some of the listed examples, metal round wires are used in parallel braid as the conductor shielding layer, with a shielding efficiency of ≤-40dB. The electromagnetic shielding effect is limited and susceptible to external electromagnetic interference. In some examples, a novel method of chemically plating silver / copper onto the insulating surface is used to improve the electromagnetic shielding effect, further enhanced by the outer layer of metal round wires in parallel braid. However, the quality of the chemically plated metal on the fluoroplastic surface is significantly inferior to that of metal-plated surfaces, especially in terms of coating adhesion. When the conductor is bent, the coating on the fluoroplastic surface is extremely prone to loosening and peeling off.

[0010] In view of the above, this utility model is hereby proposed. Utility Model Content

[0011] The purpose of this invention is to provide a high-shield aviation wire, mainly to solve the problem of low shielding efficiency of shielding layers in conventional aviation cables; and to address the problem of low coating adhesion and difficulty in comprehensively improving shielding efficiency when some existing technologies modify non-metallic materials by surface chemical plating with metal to improve shielding efficiency.

[0012] In order to achieve the above-mentioned objectives of this utility model, the following technical solution is adopted: A highly shielded aviation wire includes an inner conductor, an insulation layer, a shielding layer, and a sheath layer arranged sequentially from the inside out. The shielding layer is a braided structure, and the braided structure includes several parallel left-facing plated copper strips and several parallel right-facing plated copper strips. Furthermore, the braided structure can be a single layer or a double layer.

[0013] Preferably, the left-facing plated copper strip and / or the right-facing plated copper strip comprises a strip-shaped copper layer and a metal plating layer loaded on the surface of the strip-shaped copper layer; Furthermore, the material of the metal plating layer includes at least one of silver, nickel, and tin.

[0014] More preferably, the thickness of the metal coating is ≥2μm.

[0015] Preferably, the width of the left-facing plated copper strip and / or the right-facing plated copper strip is 0.5mm to 1mm, and the thickness is 0.04mm to 0.05mm.

[0016] Preferably, when the braided structure is a single layer, the intersection angle between the left-facing plated copper strip and the right-facing plated copper strip is 50°~72°.

[0017] Preferably, when the braided structure is a single layer, the ratio of the area covered by the copper-plated strip to the total area of ​​the braided core wire in any single unit area is 85% to 90%.

[0018] Preferably, when the braided structure is double-layered, the intersection angle of the inner braided structure is lower than that of the outer braided structure for the intersection angle of the left-facing plated copper strip and the right-facing plated copper strip.

[0019] More preferably, when the braided structure is a double-layer configuration: in the inner braided structure, the intersection angle between the left-facing plated copper strip and the right-facing plated copper strip is 50°~60°; In the outer braided structure, the intersection angle between the left-facing plated copper strip and the right-facing plated copper strip is 60°~72°.

[0020] Preferably, when the braided structure is a double-layer configuration, the ratio of the area covered by the copper-plated strip to the total area of ​​the braided core wire is lower in the inner layer than in the outer layer.

[0021] More preferably, when the braided structure is a double-layer configuration: in the inner braided structure, in any single-sided unit area, the ratio of the area covered by the copper-plated strip to the total area of ​​the braided core wire is 85% to 87%; In the outer braided structure, the ratio of the area covered by the metallized copper strip to the total area of ​​the braided core wire is 87% to 90% per unit area on any one side.

[0022] Compared with the prior art, the beneficial effects of this utility model are as follows: This utility model relates to a structure of copper-plated strip braiding that replaces the existing metal round wire braiding structure and serves as a shielding layer for aerospace wires. It eliminates the gaps between the roots of the metal round wires and significantly improves the electromagnetic shielding effect of the wire.

[0023] This invention provides single-layer or double-layer braided strip structures. For the double-layer copper-plated strip braided shielding structure, in addition to eliminating the gaps between the metal round wires, the complementary braiding angles and densities of the inner and outer layers further eliminate electromagnetic leakage and interference from the cross gaps of each strand. Furthermore, the shielding efficiency of the single-layer copper-plated strip braided conductor can reach -80dB, which is twice the shielding efficiency of traditional metal round wire stranded braided conductors. The shielding efficiency of the double-layer copper-plated strip braided conductor can reach -100dB, which is 1.5 times higher than the traditional method.

[0024] The application of this utility model can reduce the amount of anti-wave sleeves used in traditional avionics equipment to wrap aviation wires, reduce the overall weight of the equipment, meet the stringent weight requirements of the aerospace field, and can be widely used in high-temperature working fields such as radar communication, electronic countermeasures, aircraft, rockets, missile guidance mechanisms, and nuclear power. Attached Figure Description

[0025] To more clearly illustrate the specific embodiments of this utility model or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of this utility model. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0026] Figure 1 This is a schematic diagram of the structure of the high-shield aviation wire of this utility model; Figure 2 This is a schematic diagram of the structure of the stranded inner conductor of the high-shield aviation wire of this utility model.

[0027] Figure label: 1-Inner conductor; 2-Insulating layer; 12-Insulated core wire; 3-Shielding layer; 4-Sheath layer; 101 - Metal-plated copper wire. Detailed Implementation

[0028] The technical solution of this utility model will be clearly and completely described below with reference to the accompanying drawings and specific embodiments. However, those skilled in the art will understand that the embodiments described below are only some embodiments of this utility model, not all embodiments, and are only used to illustrate this utility model, and should not be regarded as limiting the scope of this utility model. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the protection scope of this utility model. Where specific conditions are not specified in the embodiments, conventional conditions or conditions recommended by the manufacturer shall be followed. Where the manufacturers of reagents or instruments are not specified, they are all conventional products that can be purchased commercially.

[0029] In the description of this utility model, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating the orientation or positional relationship, are based on the orientation or positional relationship shown in the accompanying drawings and are only for the convenience of describing this utility model and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this utility model. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0030] In the description of this utility model, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "joining" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this utility model based on the specific circumstances.

[0031] This utility model is achieved through the following technical solution: a high-shield aviation conductor, comprising an inner conductor 1, an insulation layer 2, a shielding layer 3, and a sheath layer 4 arranged sequentially from the inside out; the shielding layer 3 is a braided structure, and the braided structure includes several parallel left-facing plated copper strips and several parallel right-facing plated copper strips; and the braided structure is a single-layer or double-layer arrangement. Figure 1 The diagram shows a feasible high-shield aviation wire.

[0032] This invention primarily improves the design of the shielding layer by using a shielding layer structure made of metal-plated copper strip braiding to replace the existing round wire strand braiding structure. The shielding efficiency of the metal-plated copper strip braided wire can reach -80dB to -100dB, which is 1 to 1.5 times higher than the shielding efficiency of the traditional metal round wire strand braided wire (-40dB). Furthermore, by improving the shielding efficiency, the amount of wave-shielding sleeves used to wrap aviation wires in traditional avionics equipment can be effectively reduced, thereby reducing the overall weight of the equipment and meeting the stringent weight requirements of the aerospace field.

[0033] In a preferred embodiment, the left-facing plated copper strip and / or the right-facing plated copper strip includes a strip-shaped copper layer and a metal plating layer loaded on the surface of the strip-shaped copper layer; wherein the material of the metal plating layer includes at least one of silver, nickel, and tin.

[0034] In a more preferred embodiment, the width of the left-facing plated copper strip and / or the right-facing plated copper strip is 0.5mm to 1mm, including but not limited to any one or any two of the following values: 0.5, 0.55, 0.6, 0.65, 0.7, 0.75, 0.8, 0.85, 0.9, 0.95, and 1 (mm); the thickness of the left-facing plated copper strip and / or the right-facing plated copper strip is 0.04mm to 0.05mm, including but not limited to any one or any two of the following values: 0.041, 0.042, 0.043, 0.044, 0.045, 0.046, 0.047, 0.048, 0.049, and 0.05 (mm).

[0035] In a more preferred embodiment, the thickness of the metal coating is ≥2μm; in a further preferred embodiment, the thickness of the metal coating is 2μm~5μm.

[0036] In a preferred embodiment, when the braided structure is a single layer, the intersection angle between the left-facing plated copper strip and the right-facing plated copper strip is 50°~72°, including but not limited to any one or any two of the following values: 50, 52, 54, 55, 56, 58, 60, 62, 64, 65, 66, 68, 70, and 72 (°).

[0037] It is worth noting that the intersection angles described in this utility model are all measured as acute angles; and since the left-facing plated copper strips or the right-facing plated copper strips are parallel to each other, there is the same intersection angle between any left-facing plated copper strip and any right-facing plated copper strip.

[0038] In a preferred embodiment, when the braided structure is a single layer, the ratio of the area covered by the copper-plated strip to the total area of ​​the braided core wire in any single unit area is 85% to 90%, which is the braiding density as commonly understood is 85% to 90%.

[0039] It is worth noting that the braiding density in this utility model conforms to the conventional definition in braided structures; braiding density refers to the percentage of the area covered by the copper-plated strip in the braided structure to the total area of ​​the braided core wire, which reflects the density of the shielding layer; furthermore, this parameter is essentially a measure of the braided structure's ability to block electromagnetic waves. The higher the density, the smaller the mesh, the fewer electromagnetic leakage paths, and the stronger the shielding effectiveness.

[0040] In a preferred embodiment, when the braided structure is double-layered, the intersection angle of the inner braided structure is lower than that of the outer braided structure for the intersection angle of the left-facing plated copper strip and the right-facing plated copper strip.

[0041] In a more preferred embodiment, when the braided structure is double-layered, in the inner braided structure, the intersection angle between the left-facing and right-facing copper-plated strips is 50°~60°, including but not limited to any one or any two of the following values: 50, 51, 52, 53, 54, 55, 56, 57, 58, 59, 60 (°); and in the outer braided structure, the intersection angle between the left-facing and right-facing copper-plated strips is 60°~72°, including but not limited to any one or any two of the following values: 60, 61, 62, 63, 64, 65, 66, 67, 68, 69, 70, 71, 72 (°).

[0042] In a preferred embodiment, when the braiding structure is double-layered, the ratio of the area covered by the copper-plated strip to the total area of ​​the braided core wire is lower in the inner layer than in the outer layer.

[0043] In a more preferred embodiment, when the braiding structure is double-layered, in the inner braiding structure, the ratio of the area covered by the copper-plated strip to the total area of ​​the braided core wire in any single unit area is 85% to 87%; meanwhile, in the outer braiding structure, the ratio of the area covered by the copper-plated strip to the total area of ​​the braided core wire in any single unit area is 87% to 90%.

[0044] In a preferred embodiment, the weaving structure has 16 or 24 spindles.

[0045] It is worth noting that the number of spindles in the braided structure refers to the number of copper strip rolls used simultaneously by the braiding machine. The more spindles, the higher the braiding density and uniformity. Specifically, in this invention, 16 spindles are suitable for low braiding density (85%~88%) requirements and have a lower cost; 24 spindles can achieve high braiding density (88%~90%) and better shielding performance.

[0046] This utility model also relates to the inner conductor 1, the insulation layer 2, and the sheath layer 4; those skilled in the art can design or combine the above structure using any conventional or unconventional technical features; any conductor cable obtained under the premise of satisfying the features of the shielding layer 3 of this utility model belongs to an embodiment of this utility model.

[0047] In one preferred embodiment, the material of the inner conductor 1 includes, but is not limited to, silver-plated copper, nickel-plated copper, tin-plated copper, etc.; in some more preferred embodiments, the thickness of the plating layer is ≥2μm.

[0048] In a preferred embodiment, the inner conductor 1 is obtained by stranding and pressing together plated copper wires 101; the number of plated copper wires 101 in the inner conductor 1 can vary, including 7, 10, 14, 19, 21, 24, 30, 42, and 45 wires. Figure 2 As shown, only 7 wires are drawn for example purposes, and it does not mean that this utility model can only use 7 wires.

[0049] In a more preferred embodiment, the diameter of any one of the metal-plated copper wires 101 can be of various specifications, such as 0.05mm, 0.08mm, 0.1mm, 0.12mm, etc.

[0050] In a preferred embodiment, the insulating layer 2 comprises at least one of fluoroplastic extrusion or fluoroplastic film wrapping.

[0051] As an optional implementation, when using the fluoroplastic extrusion method, the insulating material used can be solid polytetrafluoroethylene extruded and sintered at high temperature, with a density of 2.1 g / cm³. 3 ~2.3g / cm 3 .

[0052] As an optional implementation, when using the fluoroplastic film for wrapping, the density of the polytetrafluoroethylene film can be 1.5 g / cm³. 3 ~1.6g / cm 3 Or 2.1g / cm 3 ~2.3g / cm 3 More preferably, the density of the polytetrafluoroethylene raw material film used is 1.5 g / cm³. 3~1.6g / cm 3 It is obtained by high-temperature sintering after wrapping multiple layers of raw material film in both directions, with each layer having an overlap rate of over 50%.

[0053] The insulating material used has a density of 2.1 g / cm³. 3 ~2.3g / cm 3 Polytetrafluoroethylene is obtained by high-temperature sintering after being wrapped in multiple layers of semi-oriented machined film in both directions. The orientation degree of the semi-oriented film is 1.1~1.8, and the overlap rate of each layer is more than 67%.

[0054] In a preferred embodiment, the thickness of the insulating layer 2 is 0.2 mm to 0.3 mm.

[0055] In a preferred embodiment, the combined structure of the inner conductor 1 and the insulating layer 2 is an insulated core wire 12, and the number of the insulated core wires 12 can be 1, 2, 3, or 4. Figure 1 As shown, only two insulated core wires 12 are drawn for example, and it does not mean that this utility model can only use two insulated core wires 12.

[0056] In a preferred embodiment, the sheath layer 4 includes, but is not limited to, high-temperature extrusion of perfluoroethylene propylene (FEP) and high-temperature extrusion of soluble polytetrafluoroethylene (PFA).

[0057] In a preferred embodiment, the thickness of the sheath layer 4 is 0.35mm to 0.4mm.

[0058] Although the present invention has been illustrated and described with specific embodiments, it should be understood that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit it; those skilled in the art should understand that modifications can be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features therein, without departing from the spirit and scope of the present invention; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention; therefore, this means that all such substitutions and modifications that fall within the scope of the present invention are included in the appended claims.

Claims

1. A high-shield aviation wire, characterized in that, The high-shield aviation wire comprises, from the inside out, an inner conductor, an insulation layer, a shielding layer, and a sheath layer; The shielding layer is a braided structure, and the braided structure includes several parallel left-facing plated copper strips and several parallel right-facing plated copper strips. Furthermore, the braided structure can be a single layer or a double layer.

2. The high-shield aviation conductor according to claim 1, characterized in that, The left-facing plated copper strip and / or the right-facing plated copper strip includes a strip-shaped copper layer and a metal plating layer loaded on the surface of the strip-shaped copper layer. Furthermore, the material of the metal plating layer includes at least one of silver, nickel, and tin.

3. The high-shield aviation conductor according to claim 2, characterized in that, The thickness of the metal coating is ≥2μm.

4. The high-shield aviation conductor according to claim 1, characterized in that, The width of the left-facing plated copper strip and / or the right-facing plated copper strip is 0.5mm to 1mm, and the thickness is 0.04mm to 0.05mm.

5. The high-shield aviation conductor according to claim 1, characterized in that, When the braided structure is a single layer, the intersection angle between the left-side plated copper strip and the right-side plated copper strip is 50°~72°.

6. The high-shield aviation conductor according to claim 1, characterized in that, When the braided structure is a single layer, the ratio of the area covered by the copper-plated strip to the total area of ​​the braided core wire in any single unit area is 85% to 90%.

7. The high-shield aviation conductor according to claim 1, characterized in that, When the braided structure is double-layered, the intersection angle of the inner braided structure is lower than that of the outer braided structure for the intersection angle of the left-facing plated copper strip and the right-facing plated copper strip.

8. The high-shield aviation conductor according to claim 7, characterized in that, When the braided structure is a double-layer configuration: in the inner braided structure, the intersection angle between the left-facing plated copper strip and the right-facing plated copper strip is 50°~60°; In the outer braided structure, the intersection angle between the left-facing plated copper strip and the right-facing plated copper strip is 60°~72°.

9. The high-shield aviation conductor according to claim 1, characterized in that, When the braided structure is a double-layer configuration, the ratio of the area covered by the copper-plated strip to the total area of ​​the braided core wire is lower in the inner layer than in the outer layer.

10. The high-shield aviation conductor according to claim 9, characterized in that, When the braided structure is a double-layer configuration: in the inner braided structure, in any single-sided unit area, the ratio of the area covered by the metal-plated copper strip to the total area of ​​the braided core wire is 85%~87%; In the outer braided structure, the ratio of the area covered by the metallized copper strip to the total area of ​​the braided core wire is 87% to 90% per unit area on any one side.

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