CN112071500B - Ultra-light high-speed transmission six-type Ethernet cable for aerospace and manufacturing method thereof - Google Patents
Ultra-light high-speed transmission six-type Ethernet cable for aerospace and manufacturing method thereof Download PDFInfo
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B11/00—Communication cables or conductors
- H01B11/02—Cables with twisted pairs or quads
- H01B11/06—Cables with twisted pairs or quads with means for reducing effects of electromagnetic or electrostatic disturbances, e.g. screens
- H01B11/08—Screens specially adapted for reducing cross-talk
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B11/00—Communication cables or conductors
- H01B11/02—Cables with twisted pairs or quads
- H01B11/06—Cables with twisted pairs or quads with means for reducing effects of electromagnetic or electrostatic disturbances, e.g. screens
- H01B11/10—Screens specially adapted for reducing interference from external sources
- H01B11/1008—Features relating to screening tape per se
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B13/00—Apparatus or processes specially adapted for manufacturing conductors or cables
- H01B13/06—Insulating conductors or cables
- H01B13/16—Insulating conductors or cables by passing through or dipping in a liquid bath; by spraying
- H01B13/165—Insulating conductors or cables by passing through or dipping in a liquid bath; by spraying by spraying
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/0009—Details relating to the conductive cores
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/02—Disposition of insulation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01B—CABLES; CONDUCTORS; INSULATORS; SELECTION OF MATERIALS FOR THEIR CONDUCTIVE, INSULATING OR DIELECTRIC PROPERTIES
- H01B7/00—Insulated conductors or cables characterised by their form
- H01B7/17—Protection against damage caused by external factors, e.g. sheaths or armouring
- H01B7/18—Protection against damage caused by wear, mechanical force or pressure; Sheaths; Armouring
- H01B7/22—Metal wires or tapes, e.g. made of steel
Abstract
The invention relates to an ultra-light high-speed transmission six-type Ethernet cable for aerospace and a manufacturing method thereof, and the ultra-light high-speed transmission six-type Ethernet cable for aerospace comprises a conductor (1); an insulating layer (2); a first aluminium-plastic strip (3); the aluminum-plastic composite belt also comprises a second aluminum-plastic belt (4); a metal fiber composite belt (5) wrapping the second aluminum-plastic belt (4), and an elastomer sheath (6) wrapping the metal fiber composite belt (5). The manufacturing method specifically comprises the following steps: s1: forming a cladding silver layer (12) on the surface of the iron wire (11) to manufacture the conductor (1); s2: forming an insulating layer (2) on the surface of the conductor (1); s3: forming a first cavity (31); s4: forming a second cavity (41); s5: the second aluminum-plastic belt (4), the metal fiber composite belt (5) and the elastomer sheath (6) are extruded and molded together by a machine head of extrusion equipment.
Description
Technical Field
The invention relates to a network cable, in particular to an ultra-light high-speed transmission six-type Ethernet network cable for aerospace.
The invention also relates to a manufacturing method of the ultra-light high-speed transmission six-type Ethernet cable for aerospace.
Background
The basic requirements of aerospace cables are light weight, small diameter, high temperature resistance and good wear resistance, and in addition, they should be resistant to fuel oils, lubricating oils and other chemical solvents. At present, China aerospace cables take national military standard GJB773A-2000 general Specification for fluorine-containing polymer insulated wires and cables for aerospace as a main system, the types of used related conductors and sizing materials are limited, and the weight reduction space of products is extremely limited.
The weight reduction of the aircraft is very important for aerospace aircraft, and the weight reduction of the aircraft means that the carrying capacity is increased, the mechanical performance is improved, the flight distance or range is increased, and the consumption of fuel oil or propellant is reduced.
Therefore, the development of ultra-light new materials and new processes has great significance to the development of aerospace industry.
Chinese utility model patent publication specification CN203982884U, the open date is 20141203, disclose a network communication cable, including the oversheath, and the shielded wire of setting in the oversheath hinders, it hinders to be equipped with at least one shielded wire in the oversheath, the shielded wire hinders and is equipped with two piece at least insulation heart yearns in, insulation heart yearn includes conductor and insulating layer, the insulating layer is around the conductor around the package, the insulating layer is foaming polyethylene, the insulating layer thickness is 0.4 ± 0.04mm, conductor diameter is 0.4 ± 0.003mm, it has a PE filler strip to fill between the insulation heart yearn insulating layer, insulation heart yearn winds outward and has the plastic-aluminum area to divide the screen, the plastic-aluminum area divides the screen to be equipped with the inner sheath outward, the shielded wire hinders outward and has the PET to wind the package, it is equipped with the total layer. The tensile effect is not good, and the net wires are easy to lose effectiveness due to tensile deformation.
Disclosure of Invention
The invention aims to provide an ultra-light high-speed transmission six-type Ethernet cable for aerospace, which has a better tensile effect and is not easy to lose effectiveness due to tension.
Another object of the present invention is to provide a method for manufacturing the above-mentioned six types of ethernet cable for aerospace ultra-light high-speed transmission, which has better tensile strength and lighter weight.
Aiming at the technical theme of the ultra-light high-speed transmission six-type Ethernet cable for aerospace, the ultra-light high-speed transmission six-type Ethernet cable for aerospace comprises conductors; an insulating layer surrounding the conductor; the first aluminum-plastic belt wraps the insulating layer; the second aluminum-plastic belt wraps at least 2 first aluminum-plastic belts; a metal fiber composite belt wrapping the second aluminum-plastic belt, and an elastomer sheath wrapping the metal fiber composite belt. A second aluminum-plastic belt wrapping at least 2 first aluminum-plastic belts is adopted, and the aluminum-plastic belt is lighter, straight, smooth, uniform, free of impurities, free of folds and speckles; the first aluminum-plastic belt and the conductor are difficult to adhere to each other and are easy to slide under the action of external force, when the first aluminum-plastic belt and the conductor are pulled, the second aluminum-plastic belt and the elastomer sheath are deformed or displaced together, the mutual influence between the first aluminum-plastic belt and the conductor is small, the conductor is less damaged, the whole network cable is more tensile, and the conductor is prevented from losing efficacy under the action of huge tensile force; and first plastic-aluminum area and second plastic-aluminum area can play the shielding effect, also have dampproofing function, can promote the shielding effect jointly with the metal fiber composite tape, also have the effect that does not restrict each other and slide between first plastic-aluminum area and the first plastic-aluminum area, and when the product received radial or vertical external force, the internal pair twist core of first plastic-aluminum area can produce certain slip and not directly receive external force and influence, has guaranteed the normal transmission of pair twist core signal.
The core of the network cable is an insulated wire core, namely a conductor and an insulated part. The traditional network cable conductor adopts the wire drawing and stranding process, and the insulation adopts the common extrusion or physical (chemical) foaming way to extrude. Limited by the problems of processing precision and assembly precision of an extruder head, the insulation concentricity of 95 percent or more of six types of network cables is difficult to stably reach by many manufacturers, and the sampling qualification rate of the high-end network cable market in recent years is only about 30 percent. In order to solve the problems that the electric conductivity is not reduced, the weight is not reduced, and the insulation concentricity stability is not reduced, the company successfully introduces a bimetal cladding technology and an insulation cold spraying technology by using the processing experience accumulated in the aspect of additive manufacturing through repeated trial production and tests, and the purpose is achieved: under the condition that the outer diameter of the conductor is not changed, the skin effect of the conductor is fully facilitated, and a bimetal cladding technology is introduced, so that the electric conductivity can reach 120% IACS, and the weight is reduced by more than 10%; under the condition that the outer diameter of the core wire is not changed, a non-metal cold spraying technology is introduced, so that the insulation concentricity is stabilized at about 100%. The introduction of the two processing technologies obviously improves the transmission rate and the transmission stability of the six types of network cables compared with the traditional CAT6, and reduces the whole weight of the cable core part by more than 5%.
As a further improvement of the ultra-light high-speed transmission six types of Ethernet cables for aerospace, the conductors comprise iron wires and cladding silver layers, the iron wires are wrapped by the cladding silver layers, and the cladding silver layers are wrapped by the insulating layers.
Compared with the traditional electroplating or hot-dip process, the cladding layer has the obvious advantages of firmer cladding layer and adjustable cladding layer thickness, and the conductivity of the composite metal can be improved by more than 5 percent compared with the traditional silver-plated copper stranded wire or bare copper stranded wire for a network cable; the skin effect of current is fully utilized, a silver layer (melting point 960.5 ℃) is hot-clad outside a low-cost iron wire (melting point 1539 ℃) so that the cost of the conductor is reduced by more than 20%; compared with the traditional bare copper stranded wire or silver-plated copper stranded wire for the mesh wire, the weight of the conductor can be reduced by more than 10 percent;
as a further improvement of the ultra-light high-speed transmission six-type Ethernet cable for aerospace, when more than 2 insulating layers are wrapped by the first aluminum-plastic tape, the opposite sides of the insulating layers close to each other are attached, one side of the insulating layer close to the first aluminum-plastic tape is attached to the inner wall of the first aluminum-plastic tape, and a first cavity is formed between the first aluminum-plastic tape and the insulating layer. The purpose of reserving the cavity without placing the filling material is to reserve enough space for generating slippage between the wire cores, and further improve the effect of preventing failure due to tensile strength.
As a further improvement of the ultra-light high-speed transmission six-type Ethernet cable for aerospace, one side, close to the second aluminum-plastic belt, of the first aluminum-plastic belt is attached to the inner wall of the second aluminum-plastic belt, the adjacent first aluminum-plastic belts are attached to opposite sides, close to each other, of the first aluminum-plastic belt, and a second cavity is formed between the first aluminum-plastic belt and the second aluminum-plastic belt. The cavity ensures that the twisted shielding core and the total shielding aluminum-plastic belt are not tightly bonded, when external force is applied, the twisted shielding core for transmission slides with the total shielding and the sheath part, and the effect of preventing failure due to tensile strength is further improved.
As a further improvement of the ultra-light high-speed transmission six types of Ethernet cables for aerospace, the metal fiber composite belt is a silver-plated copper or nickel-plated copper fiber composite belt. The shielding effectiveness of the strip reaches more than 44dB, and the shielding effectiveness is better when the frequency is higher; the density of the adopted fiber-copper-silver (nickel) metal fiber composite belt is only 15% of that of the copper wire, and the weight of the composite belt is reduced by more than 80% compared with that of a metal braided shield as a shielding layer;
as a further improvement of the ultra-light high-speed transmission six-type Ethernet cable for aerospace, the elastomer protective sleeve is a weather-resistant modified elastomer.
The traditional Ethernet cable adopts polyvinyl chloride or fluorinated ethylene propylene as a sheath, and has high material density, poor softness and weather resistance. By adopting the weather-resistant modified elastomer, the weight of the sheath layer is reduced by more than 35%, and the flexibility and the environmental aging resistance are both obviously improved.
As a further improvement of the ultra-light high-speed transmission six types of Ethernet cables for aerospace, the outer diameter of the iron wire is 0.4mm, and the thickness of the cladding silver layer is 0.1 mm. The electrical conductivity of the conductor can reach 120% IACS (the electrical conductivity of metal or alloy is characterized by the International interconnected coater Standard, which generally defines the electrical conductivity of Standard Annealed pure Copper as 100% IACS) when the cladding thickness of the outer conductor is 0.1mm when the outer diameter of the inner conductor is 0.4 mm;
aiming at the manufacturing method of the ultra-light high-speed transmission six-type Ethernet cable for aerospace, the invention specifically comprises the following steps:
s1: the iron wire is drawn to pass through a nozzle cavity of cladding equipment to carry out laser cladding, and a cladding silver layer is uniformly formed on the surface of the iron wire to manufacture a conductor; the conductor adopts a bimetal cladding technology, the inner metal molecules and the outer metal molecules are tightly combined together through cladding, and the cladding thickness of the outer metal can be controlled at will; compared with the traditional electroplating or hot-dip process, the laser cladding layer has the obvious advantages of firmer and adjustable cladding layer thickness, and the conductivity of the composite metal can be improved by more than 5 percent compared with the traditional silver-plated copper stranded wire or bare copper stranded wire for the mesh wire; the skin effect of current is fully utilized, a silver layer (melting point 960.5 ℃) is hot-clad outside a low-cost iron wire (melting point 1539 ℃) so that the cost of the conductor is reduced by more than 20%; compared with the traditional bare copper stranded wire or silver-plated copper stranded wire for the mesh wire, the weight of the conductor can be reduced by more than 10 percent;
s2: the conductor is drawn to pass through a cavity of a cold spraying equipment port, and an insulating layer with uniform thickness is formed on the surface of the conductor;
s3: wrapping at least 2 conductors with insulating layers in the S2 by using a first aluminum-plastic tape, and attaching opposite sides, close to each other, of adjacent insulating layers to each other when wrapping the conductors, so that one side, close to the first aluminum-plastic tape, of each insulating layer is attached to the inner wall of the first aluminum-plastic tape; forming a first cavity existing between the insulating layer and the first aluminum-plastic tape;
s4: wrapping at least 2 first aluminum-plastic belts wrapped with the insulating layers in the S3 by using second aluminum-plastic belts, and attaching opposite sides of the adjacent first aluminum-plastic belts close to each other when wrapping, so that one side of each first aluminum-plastic belt close to each second aluminum-plastic belt is attached to the inner wall of each second aluminum-plastic belt to form a second cavity between the first aluminum-plastic belts and the second aluminum-plastic belts;
s5: and S4, wrapping the second aluminum-plastic belt wrapped with the first aluminum-plastic belt with a metal fiber composite belt, wrapping the metal fiber composite belt with an elastomer sheath, and extruding and molding together by a machine head of an extrusion device.
The processing is carried out synchronously with the extrusion of the sheath, and the overall processing time of the product is shortened by more than 40 percent compared with the processing time of the traditional network cable;
as a further improvement of the manufacturing method of the present invention, in step S2, the uniform thickness of the insulation layer is formed on the surface of the conductor by melting PTFE and driving PTFE into the surface of the conductor at high speed by the cold spraying equipment from the periphery of the conductor as the conductor is drawn through the cavity of the cold spraying equipment. Compared with the traditional extrusion molding or pushing process, the cold spraying technology of PTFE has the characteristic of extremely uniform thickness (the concentricity can reach 100 percent), and has very important significance for reducing the attenuation index of the data transmission cable and stabilizing the characteristic impedance. According to the characteristic impedance and attenuation required values, the thickness of the coating can be adjusted at will, and the minimum thickness can reach 0.001mm, which cannot be reached by an extrusion molding or pushing process.
As a further improvement of the manufacturing method, the metal fiber composite belt is longitudinally wrapped and molded by copper fibers, nickel fibers and silver fibers. The shielding effectiveness of the strip reaches more than 44dB, and the shielding effectiveness is better when the frequency is higher; the density of the adopted copper-nickel-silver-fiber metal fiber composite belt is reduced, and the weight of the shielding layer is greatly reduced compared with that of the metal braid layer;
as a further improvement of the manufacturing method of the invention, in S1, the outer diameter of the iron wire is 0.4mm, and the thickness of the cladding silver layer is controlled to be 0.1 mm. The electrical conductivity of the conductor can reach 120% IACS (the electrical conductivity of metal or alloy is characterized by the International interconnected coater Standard, which generally defines the electrical conductivity of Standard Annealed pure Copper as 100% IACS) when the cladding thickness of the outer conductor is 0.1mm when the outer diameter of the inner conductor is 0.4 mm;
the invention is mainly used for signal transmission in the aerospace field, and has the outstanding advantages of ultra-light weight, high transmission rate, strong solar radiation resistance, mould resistance, salt mist resistance, strong electromagnetic interference resistance and the like.
Drawings
Fig. 1 is a schematic structural diagram of the embodiment.
Reference numerals: 1. a conductor; 11. iron wires; 12. cladding a silver layer; 2. an insulating layer; 3. a first aluminum-plastic tape; 31. a first cavity; 4. a second aluminum-plastic tape; 41. a second cavity; 5. a metal fiber composite tape; 6. an elastomeric sheath.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Example 1
Fig. 1 shows an ultra-light high-speed transmission type six ethernet network line for aerospace, comprising a conductor 1; an insulating layer 2 surrounding the conductor 1; a first aluminum-plastic tape 3 wrapping the insulating layer 2; the plastic-aluminum composite material is characterized by also comprising a second plastic-aluminum belt 4 wrapping 2 first plastic-aluminum belts 3; a metal fiber composite tape 5 wrapping the second aluminum-plastic tape 4, and an elastomer sheath 6 wrapping the metal fiber composite tape 5.
A second aluminum-plastic belt 4 wrapping 4 first aluminum-plastic belts 3 is adopted, and the aluminum-plastic belt is light, flat, smooth, uniform, free of impurities, free of wrinkles and speckles; the first aluminum-plastic belt 3 and the conductor 1 are deformed or displaced together when being pulled, the second aluminum-plastic belt 4 and the elastomer sheath 6 are deformed or displaced together, the mutual influence between the first aluminum-plastic belt 3 and the conductor 1 is small, the damage to the conductor 1 is small, the whole network cable is more tensile, and the conductor is prevented from losing efficacy due to the action of huge tensile force; and first plastic-aluminum area 3 and second plastic-aluminum area 4 can play the shielding effect, also have dampproofing function, can promote the shielding effect jointly with the metal fiber composite tape, also have the effect that does not restrict each other and slide between first plastic-aluminum area 3 and the first plastic-aluminum area 3, when the product received radial or vertical external force, the internal pair twist core of first plastic-aluminum area can produce certain slip and not directly receive the external force influence, has ensured the normal transmission of pair twist core signal.
In this embodiment, the conductor 1 includes an iron wire 11 and a silver cladding layer 12, the iron wire 11 is wrapped by the silver cladding layer 12, and the silver cladding layer 12 is wrapped by the insulating layer 2. Compared with the traditional electroplating or hot-dip process, the cladding layer has the obvious advantages of firmer cladding layer and adjustable cladding layer thickness, and the conductivity of the composite metal can be improved by more than 5 percent compared with the traditional silver-plated copper stranded wire or bare copper stranded wire for a network cable; the skin effect of current is fully utilized, a silver layer (melting point 960.5 ℃) is hot-clad outside a low-cost iron wire (melting point 1539 ℃) so that the cost of the conductor is reduced by more than 20%; compared with the traditional bare copper stranded wire or silver-plated copper stranded wire for the mesh wire, the weight of the conductor can be reduced by more than 10 percent;
in this embodiment, when 2 insulating layers 2 are wrapped up in first plastic-aluminum strip 3, the opposite sides that insulating layers 2 are close to each other are laminated, one side of insulating layer 2 close to first plastic-aluminum strip 3 is laminated with the inner wall of first plastic-aluminum strip 3, and first cavity 31 exists between first plastic-aluminum strip 3 and insulating layer 2.
The purpose of reserving the cavity without placing the filling material is to reserve enough space for generating slippage between the wire cores, and further improve the effect of preventing failure due to tensile strength.
In this embodiment, one side of the first aluminum-plastic tape 3 close to the second aluminum-plastic tape 4 is attached to the inner wall of the second aluminum-plastic tape 4, the number of the first aluminum-plastic tapes 3 is 4, the circle center of the second aluminum-plastic tape 4 is taken as an axis, and the interval is 900Distributed, the adjacent first aluminum-plastic belts 3 are attached to the opposite sides close to each other, and the first aluminum-plastic belts 3 and the second aluminum-plastic beltsA second cavity 41 is arranged between the plastic belts 4.
The cavity ensures that the twisted shielding core and the total shielding aluminum-plastic belt are not tightly bonded, when external force is applied, the twisted shielding core for transmission slides with the total shielding and the sheath part, and the effect of preventing failure due to tensile strength is further improved.
In the present embodiment, the metal fiber composite tape 5 includes copper fibers, nickel fibers, and silver fibers. The shielding effectiveness of the strip reaches more than 44dB, and the shielding effectiveness is better when the frequency is higher; the density of the adopted copper-nickel-silver-fiber metal fiber composite belt can be reduced, and the weight of the metal fiber composite belt is greatly reduced relative to that of the metal braid layer as a shielding layer;
in this embodiment, the elastomeric protective sleeve 6 is a weatherable modified elastomer.
The traditional Ethernet cable adopts polyvinyl chloride or fluorinated ethylene propylene as a sheath, and has high material density, poor softness and weather resistance. By adopting the weather-resistant modified elastomer, the weight of the sheath layer is reduced by more than 35%, and the flexibility and the environmental aging resistance are both obviously improved.
In this embodiment, the outer diameter of the iron wire is 0.4mm, and the thickness of the cladding silver layer is 0.1 mm. The electrical conductivity of the conductor can reach 120% IACS (the electrical conductivity of metal or alloy is characterized by the International interconnected coater Standard, which generally defines the electrical conductivity of Standard Annealed pure Copper as 100% IACS) when the cladding thickness of the outer conductor is 0.1mm when the outer diameter of the inner conductor is 0.4 mm;
example 2
The invention also adopts a manufacturing method of the ultra-light high-speed transmission six-type Ethernet cable for aerospace, which comprises the following steps:
s1: the iron wire 11 is drawn to pass through a nozzle cavity of cladding equipment for laser cladding, and a cladding silver layer 12 is uniformly formed on the surface of the iron wire 11 to manufacture the conductor 1; the conductor adopts a bimetal cladding technology, the inner metal molecules and the outer metal molecules are tightly combined together through cladding, and the cladding thickness of the outer metal can be controlled at will; compared with the traditional electroplating or hot-dip process, the laser cladding layer has the obvious advantages of firmer and adjustable cladding layer thickness, and the conductivity of the composite metal can be improved by more than 5 percent compared with the traditional silver-plated copper stranded wire or bare copper stranded wire for the mesh wire; the skin effect of current is fully utilized, a silver layer (melting point 960.5 ℃) is hot-clad outside a low-cost iron wire (melting point 1539 ℃) so that the cost of the conductor is reduced by more than 20%; compared with the traditional bare copper stranded wire or silver-plated copper stranded wire for the mesh wire, the weight of the conductor can be reduced by more than 10 percent;
s2: the conductor 1 is drawn to pass through a cavity of a cold spraying equipment port, and an insulating layer 2 with uniform thickness is formed on the surface of the conductor 1;
s3: wrapping 2 conductors 1 with the insulating layers 2 in the S2 by using the first aluminum-plastic tape 3, wherein when wrapping, the adjacent insulating layers 2 are attached to opposite sides close to each other, and the insulating layers 2 are attached to the inner wall of the first aluminum-plastic tape 3 at one side close to the first aluminum-plastic tape 3; forming a first cavity 31 existing between the insulating layer 2 and the first aluminum-plastic tape 3;
s4: wrapping 4 first aluminum-plastic tapes 3 wrapped with the insulating layer 2 in the step S3 with second aluminum-plastic tapes 4, wherein during wrapping, the adjacent opposite sides of the first aluminum-plastic tapes 3 are attached to each other, so that the first aluminum-plastic tapes 3 are attached to the inner wall of the second aluminum-plastic tape 4 and close to one side of the second aluminum-plastic tape 4, and a second cavity 41 existing between the first aluminum-plastic tapes 3 and the second aluminum-plastic tape 4 is formed;
s5: and (5) wrapping the second aluminum-plastic belt 4 wrapped with the first aluminum-plastic belt 3 in the step (S4) with a metal fiber composite belt 5, wrapping the metal fiber composite belt 5 with an elastomer sheath 6, and extruding and molding together by a head of an extrusion device. The processing is carried out synchronously with the extrusion of the sheath, and the overall processing time of the product is shortened by more than 40 percent compared with the processing time of the traditional network cable;
in this embodiment, in step S2, a uniform thickness of the insulating layer 2 is formed on the surface of the conductor 1 by melting PTFE, and driving PTFE from the periphery of the conductor 1 to the surface of the conductor 1 at a high speed by a cold spray apparatus while the conductor 1 is drawn through the cavity of the cold spray apparatus. Compared with the traditional extrusion molding or pushing process, the cold spraying technology of PTFE has the characteristic of extremely uniform thickness (the concentricity can reach 100 percent), and has very important significance for reducing the attenuation index of the data transmission cable and stabilizing the characteristic impedance. According to the characteristic impedance and attenuation required values, the thickness of the coating can be adjusted at will, and the minimum thickness can reach 0.001mm, which cannot be reached by an extrusion molding or pushing process.
In the present embodiment, the metal fiber composite tape 5 is formed by longitudinally wrapping copper fibers, nickel fibers, and silver fibers. The shielding effectiveness of the strip reaches more than 44dB, and the shielding effectiveness is better when the frequency is higher; the density of the adopted copper-nickel-silver-fiber metal fiber composite belt is reduced, and the weight of the shielding layer is greatly reduced compared with that of the metal braid layer;
in this example, in S1, the outer diameter of the iron wire is 0.4mm, and the thickness of the silver layer 12 is controlled to be 0.1 mm. The electrical conductivity of the conductor can reach 120% IACS (the electrical conductivity of metal or alloy is characterized by the International interconnected coater Standard, which generally defines the electrical conductivity of Standard Annealed pure Copper as 100% IACS) when the cladding thickness of the outer conductor is 0.1mm when the outer diameter of the inner conductor is 0.4 mm;
the beneficial effect of this embodiment does:
the method adopts a bimetal cladding technology, and the specific process is that an iron wire passes through a nozzle cavity of cladding equipment under the traction action, and a silver layer with any thickness is uniformly formed outside the iron wire to form a conductor.
The technical advantages are as follows:
conductivity: compared with the traditional electroplating or hot-dip process, the laser cladding layer has the obvious advantages of firmer and adjustable cladding layer thickness, and the conductivity of the composite metal can be improved by more than 5 percent compared with the traditional silver-plated copper stranded wire or bare copper stranded wire for the mesh wire;
in the aspect of cost: the skin effect of current is fully utilized, a silver layer (melting point 960.5 ℃) is hot-clad outside a low-cost iron wire (melting point 1539 ℃) so that the cost of the conductor is reduced by more than 20%;
in terms of weight: compared with the traditional bare copper stranded wire or silver-plated copper stranded wire for the mesh wire, the weight of the conductor can be reduced by more than 10 percent;
insulation: the PTFE cold spraying technology is adopted, and the specific process is that the conductor passes through a cold spraying opening cavity under the traction action, so that a PTFE plastic layer with extremely uniform thickness is formed outside the conductor.
The technical advantages are as follows:
1. transmission characteristics: compared with the traditional extrusion molding or pushing process, the cold spraying has the characteristic of extremely uniform thickness (the concentricity can reach 100 percent), and has very important significance for reducing the attenuation index of the data transmission cable and stabilizing the characteristic impedance.
2. The process aspect is as follows: according to the characteristic impedance and attenuation required values, the thickness of the coating can be adjusted at will, and the minimum thickness can reach 0.001mm, which cannot be reached by an extrusion molding or pushing process.
Total shielding: the metal fiber composite belt synthesized by copper-nickel-silver-fiber is longitudinally wrapped and shielded, and the specific technological process is that the metal fiber composite belt enters a machine head together with a cable core from the machine head for molding when a sheath is extruded.
The technical advantages are as follows:
1. shielding effectiveness: the test and verification of an aviation standard component detection center E5061B vector network analyzer prove that the shielding effectiveness of the strip reaches more than 44dB, and the shielding effectiveness is better when the frequency is higher;
2. processing efficiency: the processing is carried out synchronously with the extrusion of the sheath, and the overall processing time of the product is shortened by more than 40 percent compared with the processing time of the traditional network cable;
3. in terms of weight: the density of the adopted copper-nickel-silver-fiber metal fiber composite belt is only 1.3g/cm3, and the weight of the shielding layer is reduced by 85 percent relative to that of the metal braid layer;
the most core improvement point of the invention is as follows: the conductor adopts a metal cladding technology, the insulation adopts a non-attribute cold spraying technology, and the shielding layer adopts a metal fiber composite belt longitudinal wrapping technology.
The performance advantage is as follows: compared with a network cable produced by the traditional processing technology, the transmission characteristic is higher in network speed, smaller in attenuation and more stable in signal transmission; the weight of the whole product is reduced by more than 30%, and the method is particularly suitable for the field of aerospace.
The cladding and cold spraying process is applied to six types of Ethernet cables of high-end cables, and transmission characteristic indexes such as characteristic impedance, attenuation, near-end crosstalk and the like of each cable pair are more stable and uniform;
the adopted conductor (cladding silver-clad iron, the density of 8.1g/cm3), the shielding layer (fiber-copper-silver (nickel) composite belt, the density of 1.3g/cm3) and the sheath layer (weather-resistant modified elastomer, the density of 0.96g/cm3) are all light low-density materials.
Data transmission cables, especially high-speed network cables, put high demands on the electrical conductivity and insulation concentricity of the conductors. The traditional net wire conductor for aerospace adopts a silver-plated copper stranded wire, and a single wire adopts an electroplating or hot-dip plating process, so that the limitation of the stability of a plating layer and the thickness of the plating layer is met, and the improvement of the conductivity of the conductor by the process is limited; in addition, the traditional network cable insulating layer adopts an extrusion process, and the concentricity of the traditional network cable insulating layer is difficult to reach 98 percent or even more than 95 percent no matter an adjustment-free machine head, an adjustable machine head or a U7 adjustment-free fine adjustment machine head is adopted.
The conductor adopts a bimetal cladding technology, inner and outer metal molecules are tightly combined together through cladding, the cladding thickness of the outer metal can be controlled at will, and the conductivity of the conductor can reach 120% IACS (International Annealed Copper Standard is used for representing the conductivity of metal or alloy, generally defining the conductivity of Standard Annealed pure Copper as 100% IACS) through repeated trial-manufacture and test when the outer diameter of the inner conductor is 0.4mm and the cladding thickness of the outer conductor is 0.1 mm;
2. the insulation adopts a non-metal cold spraying technology, low-dielectric-constant PTFE is melted in equipment and then is driven into the surface of a conductor from the periphery at a high speed to form a uniform insulating layer, and the insulating concentricity can reach 100%;
3. the shielding layer adopts a metal fiber composite belt longitudinal wrapping process to replace a metal weaving process, so that the overall processing time of the product is greatly shortened; the density of the used material is only 15% of that of the copper wire for braided shielding, and the single-layer weight reduction can reach more than 80%.
The introduction of the related technology leads the total weight of the product to be reduced by more than 25%, the characteristic impedance can be stably controlled to be 100 +/-5 omega, and the indexes of attenuation and near-end crosstalk are improved by more than 5%.
Fig. 1 shows a high-speed transmission ultra-light six-type network cable structure (SFTP (secure File Transfer Protocol) double-shielded structure):
fig. 1 is sequentially from inside to outside: the manufacturing method comprises the steps of iron wire cladding a silver layer, cold spraying a PTFE (polytetrafluoroethylene) layer, mylar, a metal fiber composite belt and a modified elastomer. (Maila is an aluminum plastic belt)
The foregoing is a more detailed description of the invention in connection with specific preferred embodiments and it is not intended that the invention be limited to these specific details. For those skilled in the art to which the invention pertains, several equivalent substitutions or obvious modifications can be made without departing from the spirit of the invention, and all the properties or uses are considered to be within the scope of the invention.
Claims (8)
1. A manufacturing method of an ultra-light high-speed transmission six-type Ethernet cable for aerospace is characterized by comprising the following steps:
s1: the iron wire (11) is drawn to pass through a nozzle cavity of cladding equipment to carry out laser cladding, and a cladding silver layer (12) is uniformly formed on the surface of the iron wire (11) to prepare the conductor (1);
s2: the conductor (1) is pulled to pass through a cavity of a cold spraying equipment port, and an insulating layer (2) with uniform thickness is formed on the surface of the conductor (1);
s3: wrapping at least 2 conductors (1) with insulating layers (2) in the S2 by using a first aluminum-plastic tape (3), and attaching opposite sides of adjacent insulating layers (2) close to each other when wrapping, so that one side of the insulating layer (2) close to the first aluminum-plastic tape (3) is attached to the inner wall of the first aluminum-plastic tape (3); forming a first cavity (31) between the insulating layer (2) and the first aluminum-plastic tape (3);
s4: wrapping at least 2 first aluminum-plastic belts (3) wrapped with the insulating layer (2) in the step S3 by using a second aluminum-plastic belt (4), wherein during wrapping, the adjacent opposite sides of the first aluminum-plastic belts (3) are attached to each other, so that the first aluminum-plastic belt (3) is attached to one side of the second aluminum-plastic belt (4) close to the inner wall of the second aluminum-plastic belt (4) to form a second cavity (41) between the first aluminum-plastic belt (3) and the second aluminum-plastic belt (4);
s5: wrapping the second aluminum-plastic belt (4) wrapped with the first aluminum-plastic belt (3) in the step S4 with a metal fiber composite belt (5), wrapping the metal fiber composite belt (5) with an elastomer sheath (6), and extruding and molding by a head of an extruding device together;
in step S2, the specific method for forming the insulating layer (2) with uniform thickness on the surface of the conductor (1) is to melt PTFE, and when the conductor (1) is pulled to pass through the cavity of the cold spraying equipment opening, the PTFE is driven into the surface of the conductor (1) from the periphery of the conductor (1) at high speed by the cold spraying equipment;
in S1, the outer diameter of the iron wire (11) is 0.4mm, the thickness of the cladding silver layer (12) is controlled to be 0.1mm, and the conductor conductivity is controlled to 120% IACS;
wherein the metal fiber composite belt (5) adopts a fiber-copper-silver or nickel metal fiber composite belt, and the processing technology is longitudinal wrapping molding.
2. An ultra-light high-speed transmission six-type ethernet cable for aerospace manufactured by the manufacturing method of claim 1, comprising a conductor (1); an insulating layer (2) surrounding the conductor (1); a first aluminum-plastic tape (3) wrapping the insulating layer (2); the method is characterized in that: the device also comprises a second aluminum-plastic belt (4) wrapping at least 2 first aluminum-plastic belts (3); the metal fiber composite belt (5) wraps the second aluminum-plastic belt (4), and the elastomer sheath (6) wraps the metal fiber composite belt (5).
3. An ultra-light high-speed transmission six-type ethernet cable for aerospace according to claim 2, wherein said conductor (1) comprises iron wire (11) and a cladded silver layer (12), said cladded silver layer (12) wrapping said iron wire (11), and said insulating layer (2) wrapping said cladded silver layer (12).
4. An ultra-light high-speed transmission type six Ethernet cable for aerospace according to claim 2 or 3, wherein when the first aluminum-plastic tape (3) wraps more than 2 insulation layers (2), the insulation layers (2) are attached to opposite sides close to each other, one side of the insulation layer (2) close to the first aluminum-plastic tape (3) is attached to the inner wall of the first aluminum-plastic tape (3), and a first cavity (31) is formed between the first aluminum-plastic tape (3) and the insulation layer (2).
5. An ultra-light high-speed transmission type six Ethernet cable for aerospace according to claim 4, wherein one side of the first aluminum-plastic strip (3) close to the second aluminum-plastic strip (4) is attached to the inner wall of the second aluminum-plastic strip (4), the adjacent first aluminum-plastic strips (3) are attached to the opposite sides close to each other, and a second cavity (41) is formed between the first aluminum-plastic strip (3) and the second aluminum-plastic strip (4).
6. An ultra-light high-speed transmission six-category ethernet cable for aerospace according to claim 2 or 3, wherein said metal fiber composite tape (5) is a silver-plated copper or nickel-plated copper fiber composite tape.
7. An ultra-light high-speed transmission six-type ethernet cable for aerospace according to claim 2 or 3, wherein the elastomer sheath (6) is a weather-resistant modified elastomer.
8. The ultra-light high-speed transmission six-type Ethernet cable for aerospace according to claim 3, wherein the outer diameter of the iron wire is 0.4mm, and the thickness of the cladding silver layer is 0.1 mm.
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| CN202010997210.8A CN112071500B (en) | 2020-09-21 | 2020-09-21 | Ultra-light high-speed transmission six-type Ethernet cable for aerospace and manufacturing method thereof |
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| CN112071500B true CN112071500B (en) | 2021-06-22 |
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| GB1448618A (en) * | 1974-11-15 | 1976-09-08 | Gen Cable Corp | Telecommunication cable |
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| GB1448618A (en) * | 1974-11-15 | 1976-09-08 | Gen Cable Corp | Telecommunication cable |
| CN202189618U (en) * | 2011-07-19 | 2012-04-11 | 安徽宏源特种电缆集团有限公司 | High performance extraordinary super category 5 cable |
| CN203311873U (en) * | 2013-06-03 | 2013-11-27 | 安徽国华电缆集团有限公司 | Cable for mobile device |
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| CN112071500A (en) | 2020-12-11 |
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