Lightweight ultra-high temperature resistant data cable
Patent Information
- Application Number
- CN202522601266.8
- Authority / Receiving Office
- CN · China
- Patent Type
- Utility models(China)
- Current Assignee / Owner
- Filing Date
- 2025-12-08
- Publication Date
- 2026-11-03
- Estimated Expiration
- 2035-12-08
AI Technical Summary
Existing ordinary data cables have excessive outer diameter and weight, which cannot meet the strict size and weight requirements of aerospace, weaponry and other applications. At the same time, their performance degrades in ultra-high temperature environments.
It adopts a lightweight, ultra-high temperature resistant insulated wire and a high-silica glass fiber tubular core stranded structure, combined with a wrapped insulation layer and sheath, including a silver-plated copper wire braided shielding layer, a polyimide/PTFE composite film inner sheath, and a PTFE raw material tape outer sheath, which reduces the weight and outer diameter of the cable and improves its ultra-high temperature resistance.
It achieves lightweighting and improved ultra-high temperature resistance of the cable, with a 25% reduction in outer diameter, a 30% reduction in weight, and a wider insulation temperature range, meeting the requirements for use in ultra-high temperature environments.
Smart Images
Figure CN224934530U_ABST
Abstract
Description
Technical Field
[0001] This utility model relates to the field of cable technology, and in particular to a lightweight data cable resistant to ultra-high temperature. Background Technology
[0002] Existing standard data cables have excessively large outer diameters and weights, making them unsuitable for applications where users have strict requirements regarding cable size and weight.
[0003] The insulation, core, and sheath of existing ordinary data cables are generally constructed using an extrusion structure, which involves extruding molten plastic through an extruder and tightly and continuously wrapping it around the outside of the corresponding structure. This extrusion structure results in excessive product weight and outer diameter. Under the stringent requirements for cable size and weight in applications such as aerospace, weaponry, and power and energy systems, existing ordinary data cables usually cannot meet the requirements. Existing ordinary data cables have a narrow operating temperature range and are not suitable for ultra-high temperature environments. The materials used in the conductor, insulation, shielding, and sheath of existing ordinary data cables have relatively low temperature resistance. In environments with large temperature changes or ultra-high temperatures, the cable sheath and insulation will soften and deform, leading to a decrease or even loss of cable transmission performance, resulting in cable failure and inability to be used normally. Utility Model Content
[0004] In view of the above-mentioned defects or deficiencies in the prior art, it is desirable to provide a lightweight, ultra-high temperature resistant data cable suitable for applications with strict requirements on cable size and weight.
[0005] This utility model provides a lightweight ultra-high temperature resistant data cable, comprising a cable core consisting of two lightweight ultra-high temperature resistant insulated wires and two high-silica glass fiber tubular filler cores twisted together. The outer side of the cable core is sequentially provided with a calcined mica tape sheath, a silver-plated copper wire braided shielding layer, a polyimide / polytetrafluoroethylene composite film inner sheath, and a polytetrafluoroethylene raw material tape outer sheath.
[0006] Furthermore, on any cross-section of the cable core, two high-silica glass fiber tubular fillers are located on both sides between two lightweight ultra-high temperature resistant insulated wires.
[0007] Furthermore, the lightweight ultra-high temperature resistant insulated wire includes a conductor and an insulation layer. The insulation layer is composed of a polyimide / polytetrafluoroethylene composite film insulation layer, a polytetrafluoroethylene raw material tape insulation layer, and a calcined mica tape insulation layer. The polyimide / polytetrafluoroethylene composite film insulation layer is wrapped around the outside of the conductor, the polytetrafluoroethylene raw material tape insulation layer is wrapped around the outside of the polyimide / polytetrafluoroethylene composite film insulation layer, and the calcined mica tape insulation layer is wrapped around the outside of the polytetrafluoroethylene raw material tape insulation layer.
[0008] Furthermore, the conductor is composed of several silver-plated copper wire cores.
[0009] Furthermore, the calcined mica tape sheath is wrapped around the outside of the cable core, the silver-plated copper wire braided shielding layer is woven around the outside of the calcined mica tape sheath, and the polyimide / polytetrafluoroethylene composite film inner sheath and the polytetrafluoroethylene raw material tape outer sheath are sequentially wrapped around the outside of the silver-plated copper wire braided shielding layer.
[0010] Furthermore, the cross-section of the lightweight ultra-high temperature resistant insulated wire is 0.2 mm. 2 .
[0011] Compared with the prior art, the beneficial effects of this utility model are: The conductor of this invention is made of silver-plated copper wire core, which has good conductivity and is also characterized by high temperature resistance, small size, and light weight. The insulation layer is composed of a polyimide / polytetrafluoroethylene composite film insulation layer, a polytetrafluoroethylene raw material tape insulation layer, and a calcined mica tape insulation layer. All three insulation layers adopt a wrapped structure, which makes the outer diameter of the cable insulation layer smaller and the weight lighter compared with the insulation layer in extruded data cables. At the same time, the polyimide / polytetrafluoroethylene composite film insulation layer, polytetrafluoroethylene raw material tape insulation layer, and calcined mica tape insulation layer have a wider temperature range for insulation use, which can effectively improve the ultra-high temperature resistance of the insulation layer. In this invention, during cable stranding, a high-silica glass fiber tubular filler is installed on each side between two lightweight ultra-high temperature resistant insulated wires. The high-silica glass fiber tubular filler has a tubular structure, which can effectively reduce the dielectric constant of the cable. It also has the advantages of thinness, light weight, easy compression, and high strength, and can effectively fill the gap between the two lightweight ultra-high temperature resistant insulated wires. At the same time, compared with extruded fillers, the filler of this application can also effectively reduce the weight and outer diameter of the cable, making the cable core more rounded while ensuring the temperature resistance and tensile strength of the product. This utility model consists of a calcined mica tape sheath, a silver-plated copper wire braided shielding layer, a polyimide / PTFE composite film inner sheath, and a PTFE raw material tape outer sheath arranged sequentially on the outside of the cable core. The calcined mica tape sheath, the polyimide / PTFE composite film inner sheath, and the PTFE raw material tape outer sheath all adopt a wrapping structure. Compared with the sheath in extruded data cables, this results in a smaller outer diameter and lighter weight for the cable sheath, while the inherent properties of the materials ensure the cable's resistance to overheating.
[0012] It should be understood that the description in this utility model description section is not intended to limit the key or essential features of the embodiments of this utility model, nor is it intended to restrict the scope of this utility model. Other features of this utility model will become readily apparent from the following description. Attached Figure Description
[0013] Other features, objects, and advantages of this invention will become more apparent from the following detailed description of non-limiting embodiments with reference to the accompanying drawings: Figure 1 A schematic diagram of the structure of a lightweight, ultra-high temperature resistant data cable provided in this embodiment of the present invention; Figure 2 This is a structural schematic diagram of a lightweight, ultra-high temperature resistant insulated wire. The diagram labels are as follows: 1. Cable core; 2. Calcined mica tape sheath; 3. Silver-plated copper wire braided shielding layer; 4. Polyimide / PTFE composite film inner sheath; 5. PTFE raw material tape outer sheath. 11. Lightweight ultra-high temperature resistant insulated wire; 12. High silica glass fiber tubular core; 111. Conductor; 112. Conductor; 1111, Silver-plated copper wire core; 1121. Polyimide / PTFE composite film insulation layer; 1122. PTFE raw material tape insulation layer; 1123. Calcined mica tape insulation layer. Detailed Implementation
[0014] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the relevant invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, only the parts relevant to the invention are shown in the accompanying drawings.
[0015] It should be noted that, where there is no conflict, the embodiments and features in the embodiments of this utility model can be combined with each other. The present utility model will now be described in detail with reference to the accompanying drawings and embodiments.
[0016] Please refer to Figures 1-2 An embodiment of this utility model provides a high-temperature resistant data cable, comprising a cable core 1 consisting of two lightweight high-temperature resistant insulated wires 11 and two high-silica glass fiber tubular filler cores 12 twisted together. The outer side of the cable core 1 is sequentially provided with a calcined mica tape sheath 2, a silver-plated copper wire braided shielding layer 3, a polyimide / polytetrafluoroethylene composite film inner sheath 4, and a polytetrafluoroethylene raw material tape outer sheath 5.
[0017] In this embodiment, the calcined mica tape sheath 2, the silver-plated copper wire braided shielding layer 3, the polyimide / polytetrafluoroethylene composite film inner sheath 4, and the polytetrafluoroethylene raw material tape outer sheath 5 are all high-temperature resistant materials, which can improve the cable's resistance to ultra-high temperatures.
[0018] In a preferred embodiment, such as Figure 1 As shown, on any cross-section of the cable core 1, two high-silica glass fiber tubular filler cores 12 are located on both sides between two lightweight ultra-high temperature resistant insulated wires 11.
[0019] In this embodiment, during cable stranding, two lightweight ultra-high temperature resistant insulated wires 11 are tangent to each other. A high-silica glass fiber tubular filler 12 is provided on each side between the two lightweight ultra-high temperature resistant insulated wires 11. The high-silica glass fiber tubular filler 12 has a tubular filler structure, which can effectively reduce the dielectric constant of the cable. At the same time, it has the advantages of thinness, light weight, easy compression, and high strength, which can effectively fill the gap between the two lightweight ultra-high temperature resistant insulated wires 11. Compared with extruded fillers, high-silica glass fiber tubular fillers can also effectively reduce the weight and outer diameter of the cable, reducing the outer diameter by about 25% and the weight by about 30%. The filler of this application ensures the temperature resistance and tensile strength of the product while making the cable core more rounded.
[0020] In a preferred embodiment, such as Figure 2 As shown, the lightweight ultra-high temperature resistant insulated wire 11 includes a conductor 111 and an insulation layer 112. The insulation layer 112 is composed of a polyimide / polytetrafluoroethylene composite film insulation layer 1121, a polytetrafluoroethylene raw material tape insulation layer 1122, and a calcined mica tape insulation layer 1123. The polyimide / polytetrafluoroethylene composite film insulation layer 1121 is wrapped around the outside of the conductor 111, the polytetrafluoroethylene raw material tape insulation layer 1122 is wrapped around the outside of the polyimide / polytetrafluoroethylene composite film insulation layer 1121, and the calcined mica tape insulation layer 1123 is wrapped around the outside of the polytetrafluoroethylene raw material tape insulation layer 1122.
[0021] Preferably, conductor 111 is composed of several silver-plated copper wire cores 1111.
[0022] In this embodiment, conductor 111 is composed of silver-plated copper wire core 1111, which has good conductivity and also features high temperature resistance, small size, and light weight. Insulation layer 112 is composed of polyimide / polytetrafluoroethylene composite film insulation layer 1121, polytetrafluoroethylene raw material tape insulation layer 1122, and calcined mica tape insulation layer 1123. All three layers adopt a wrapped structure, which makes the outer diameter of the insulation layer smaller and the weight lighter compared to the insulation layer in extruded data cables. At the same time, the polyimide / polytetrafluoroethylene composite film insulation layer 1121, polytetrafluoroethylene raw material tape insulation layer 1122, and calcined mica tape insulation layer 1123 have a wider temperature range for insulation use, which can effectively improve the ultra-high temperature resistance of the insulation layer.
[0023] In a preferred embodiment, such as Figure 1 As shown, the calcined mica tape sheath 2 is wrapped around the outside of the cable core 1, the silver-plated copper wire braided shielding layer 3 is braided around the outside of the calcined mica tape sheath 2, and the polyimide / polytetrafluoroethylene composite film inner sheath 4 and the polytetrafluoroethylene raw material tape outer sheath 5 are wrapped around the outside of the silver-plated copper wire braided shielding layer 3 in sequence.
[0024] In this embodiment, the calcined mica tape sheath 2, the polyimide / polytetrafluoroethylene composite film inner sheath 4, and the polytetrafluoroethylene raw material tape outer sheath 5 all adopt a wrapping structure. Compared with the sheath in the extruded data cable, this makes the cable's outer diameter smaller and lighter, while the material's own properties ensure the cable's resistance to overheating.
[0025] In a preferred embodiment, such as Figure 1 As shown, the cross-section of the lightweight ultra-high temperature resistant insulated wire is 0.2 mm. 2 .
[0026] Working principle: In the structural design and material selection of the conductor 111, insulation layer 112, core filler, and sheath of this application, the transmission performance and miniaturization of the cable are fully considered. The insulation layer 112 adopts a wrapped structure, which makes the outer diameter of the cable insulation layer smaller and the weight lighter. Compared with extruded data cables, the outer diameter of the cable insulation layer of this application is reduced by about 15%, and the weight is reduced by about 18%. The core filler adopts a high-silica glass fiber tubular core 12. The braided tubular core can effectively reduce the dielectric constant of the cable, making the outer diameter of the cable core smaller, the weight lighter, and the product more flexible. Compared with extruded data cables, the outer diameter of the cable core of this application is reduced by about 20%, and the weight is reduced by about 30%. The calcined mica tape sheath 2, the polyimide / PTFE composite film inner sheath 4, and the PTFE raw material tape outer sheath 5 adopt a wrapping structure. A cable core stabilizing device can also be added during wrapping to stabilize the movement trajectory of the film during cable wrapping, making the cable more round. The wrapping structure makes the cable size smaller, and the weight is reduced by about 10% compared with the outer sheath of extruded data cables. At the same time, it also has good ultra-high temperature resistance.
[0027] In the description of this specification, the terms "connection," "installation," and "fixing," etc., should be interpreted broadly. For example, "connection" can be a fixed connection, a detachable connection, or an integral connection; it can be a direct connection or an indirect connection through an intermediate medium. Those skilled in the art can understand the specific meaning of the above terms in this application according to the specific circumstances.
[0028] In the description of this specification, the terms "one embodiment," "some embodiments," etc., refer to specific features, structures, materials, or characteristics described in connection with that embodiment or example, which are included in at least one embodiment or example of this application. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.
[0029] The above are merely preferred embodiments of this application and are not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.
Claims
1. A lightweight, ultra-high temperature resistant data cable, characterized in that, The cable core consists of two lightweight, ultra-high temperature resistant insulated wires and two high-silica glass fiber tubular filler cores twisted together. The outer side of the cable core is sequentially provided with a calcined mica tape sheath, a silver-plated copper wire braided shielding layer, a polyimide / polytetrafluoroethylene composite film inner sheath, and a polytetrafluoroethylene raw material tape outer sheath.
2. The lightweight ultra-high temperature resistant data cable according to claim 1, characterized in that, At any cross-section of the cable core, two high-silica glass fiber tubular fillers are located on both sides between two lightweight ultra-high temperature resistant insulated wires.
3. The lightweight ultra-high temperature resistant data cable according to claim 2, characterized in that, The lightweight ultra-high temperature resistant insulated wire includes a conductor and an insulation layer. The insulation layer is composed of a polyimide / polytetrafluoroethylene composite film insulation layer, a polytetrafluoroethylene raw material tape insulation layer, and a calcined mica tape insulation layer. The polyimide / polytetrafluoroethylene composite film insulation layer is wrapped around the outside of the conductor, the polytetrafluoroethylene raw material tape insulation layer is wrapped around the outside of the polyimide / polytetrafluoroethylene composite film insulation layer, and the calcined mica tape insulation layer is wrapped around the outside of the polytetrafluoroethylene raw material tape insulation layer.
4. The lightweight ultra-high temperature resistant data cable according to claim 3, characterized in that, The conductor is composed of several silver-plated copper wire cores.
5. A lightweight, ultra-high temperature resistant data cable according to claim 1, characterized in that, The calcined mica tape sheath is wrapped around the outside of the cable core, the silver-plated copper wire braided shielding layer is braided around the outside of the calcined mica tape sheath, and the polyimide / polytetrafluoroethylene composite film inner sheath and the polytetrafluoroethylene raw material tape outer sheath are wrapped around the outside of the silver-plated copper wire braided shielding layer in sequence.
6. The lightweight ultra-high temperature resistant data cable according to claim 1, characterized in that, The cross-section of the lightweight, ultra-high temperature resistant insulated wire is 0.2 mm. 2 .