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CN-122000117-A - Ultra-stable phase bundled flat cable and preparation method thereof

CN122000117ACN 122000117 ACN122000117 ACN 122000117ACN-122000117-A

Abstract

The invention discloses an ultra-stable phase bunched flat cable and a preparation method thereof, and relates to the technical field of cable manufacture, wherein the cable is of a multi-core bunched structure and comprises at least two independent wire core units, each wire core unit sequentially comprises an inner conductor, an insulating layer, a compensating layer, an outer conductor and a shielding layer from inside to outside, and further comprises an outer sheath, wherein the outer sheath is coated on the outer sides of the shielding layers of all the wire core units; through the collaborative design of gradient insulation, bimetal compensation, high-frequency shielding and cross-linking sheath, narrow space suitability and wide temperature range phase stability are optimized, high-frequency signal transmission accuracy and long-term reliability under space radiation environment are improved, and the strict requirements of an aerospace system are met.

Inventors

  • LIU JUNCHAO
  • WANG CHILONG
  • Xin Haohao
  • ZOU LIANGLONG
  • YANG TAO
  • ZHANG JINGJING
  • Cheng Jincao
  • PENG XU
  • YE HUA
  • JIANG HUAPING

Assignees

  • 淮南文峰光电科技股份有限公司

Dates

Publication Date
20260508
Application Date
20260127

Claims (10)

  1. 1. The ultra-stable phase bunched flat cable is of a multi-core bunched structure and comprises at least two independent wire core units, wherein each wire core unit sequentially comprises an inner conductor (1), an insulating layer (2), a compensating layer (3), an outer conductor (4) and a shielding layer (5) from inside to outside, and is characterized by further comprising an outer sheath (6), and the outer sheath (6) is coated on the outer sides of the shielding layers (5) of all the wire core units; The insulation layer (2) is of a three-layer co-extrusion physical foaming structure and consists of an inner high-density layer (21), a middle medium-density layer (22) and an outer low-density layer (23), the inner high-density layer (21) is of a solid structure, the middle medium-density layer (22) and the outer low-density layer (23) are of a physical foaming structure, the three layers are subjected to synchronous co-extrusion molding, and the densities of the layers are sequentially decreased from inside to outside; The compensation layer (3) consists of a polyimide isolation base layer (31), an inner layer copper compensation belt (32) and an outer layer stainless steel compensation belt (33), wherein the polyimide isolation base layer (31) is coated on the outer side of the insulation layer (2), the inner layer copper compensation belt (32) is wrapped on the outer side of the polyimide isolation base layer (31), the outer layer stainless steel compensation belt (33) is wrapped on the outer side of the inner layer copper compensation belt (32) in an opposite spiral angle, and the inner layer copper compensation belt (32) is positioned in a wrapping gap of the outer layer stainless steel compensation belt (33) to form an inner-outer nested double-spiral structure; The insulating layer (2) is mutually attached to the compensating layer (3), and the compensating layer (3) is mutually attached to the outer conductor (4); the outer sheath (6) is a fluoroplastic flat outer sheath and is formed by a multi-core co-extrusion process.
  2. 2. The ultra-stable phase bundled flat cable of claim 1, wherein the inner conductor (1) is a graphene-copper alloy single wire, and is prepared by adding 3% of graphene and 1% of nickel into pure copper, and the specification is 0.30-1.0 mm.
  3. 3. The ultra-stable phase bundled flat cable as claimed in claim 1, wherein each layer of the insulating layer (2) has parameters of: the thickness of the inner high-density layer (21) is 0.08-0.1 mm, and the density is 1.8-2.0 g/cm < 3 >; the thickness of the middle-layer middle-density layer (22) is 0.3 mm-0.5 mm, the density is 1.2g/cm < 3 > -1.4 g/cm < 3 >, and the foaming degree is 40% -50%; The thickness of the outer low-density layer (23) is 0.08-0.1 mm, the density is 0.8-1.0 g/cm3, and the foaming degree is 65-70%.
  4. 4. The ultra-stable phase bundled flat cable as claimed in claim 1, wherein the component parameters of the compensation layer (3) are as follows: Polyimide isolating base layer 31) a thickness of 0.05mm to 0.1mm; The inner copper compensation belt (32) is a copper belt with the purity of more than or equal to 99.9%, the thermal expansion coefficient is 16 multiplied by 10 -6 /℃～18×10 -6 /DEG C, the thickness is 0.02-0.05 mm, the wrapping helix angle is 30-45 DEG, and the wrapping pitch is 3-5 times of the outer diameter of the insulating layer (2); The outer layer stainless steel compensation belt (33) is a stainless steel belt with a thermal expansion coefficient of 8 multiplied by 10 -6 /℃～12×10 -6 /DEG C, the thickness of the stainless steel compensation belt is 0.01 mm-0.03 mm, the wrapping helix angle is-30 DEG to-45 DEG, the wrapping pitch is 2-3 times of the outer diameter of the insulating layer (2), and the wrapping overlapping rate is more than or equal to 30%.
  5. 5. The ultra-stable phase bunched flat cable of claim 1, wherein the outer conductor (4) is a double-sided silver-plated polyimide composite tape, the thickness is 0.035 mm-0.05 mm, and the lapping overlapping rate is not lower than 45%.
  6. 6. The ultra-stable phase bunched flat cable of claim 1, wherein the shielding layer (5) is a silver-plated fiber braiding layer and is braided by 200-600D silver-plated fibers, and the braiding density is more than or equal to 90%.
  7. 7. The ultra-stable phase bunched flat cable of claim 1, wherein the outer sheath (6) is made of cross-linked ethylene tetrafluoroethylene material, and is subjected to electron beam irradiation treatment after co-extrusion.
  8. 8. A preparation method of an ultra-stable phase bundled flat cable is characterized by comprising the following steps: ① The preparation of the inner conductor (1) comprises the steps of adding 3% of graphene and 1% of nickel into pure copper, carrying out high-temperature mixed melting at 1100-1300 ℃ and then drawing into a metal rod, and drawing into a graphene-copper alloy single wire with the specification of 0.30-1.0 mm through a plurality of dies to serve as the inner conductor (1); ② Forming an insulating layer (2), namely sequentially forming an inner high-density solid layer, a middle medium-density physical foaming layer and an outer low-density physical foaming layer on the outer side of an inner conductor (1) by adopting a synchronous coextrusion process to form a three-layer gradient density foaming insulating layer (2), and cooling and shaping for later use; ③ Wrapping the outer side of the insulating layer (2) with a polyimide isolation base layer (31), wrapping an inner layer copper compensation belt (32) on the outer side of the isolation base layer at a helix angle of 30-45 degrees, wrapping an outer layer stainless steel compensation belt (33) on the outer side of the inner layer copper compensation belt (32) at a helix angle of-30-45 degrees, and clamping the inner layer copper compensation belt (32) into a wrapping gap of the outer layer stainless steel compensation belt (33) to form a nested double-helix compensation layer (3); ④ The outer conductor (4) and the shielding layer (5) are processed, namely a double-sided silver-plated polyimide composite belt is wrapped on the outer side of the compensation layer (3) to serve as the outer conductor (4), the wrapping overlapping rate is not lower than 45%, and 200D-600D silver-plated fibers are adopted to weave the shielding layer (5) with the weaving density being more than or equal to 90%, so that a single wire core unit is obtained; ⑤ And forming the multi-core bundling and the outer sheath (6), namely arranging at least two core units in parallel, coating the outer sides of the shielding layers (5) of all the core units with a cross-linked ethylene tetrafluoroethylene material by adopting a coextrusion process to form a flat outer sheath (6), and carrying out electron beam irradiation treatment after the coextrusion is finished to obtain the ultra-stable phase bundling flat cable.
  9. 9. The method of claim 8, wherein in the step ②, supercritical nitrogen or carbon dioxide is injected into the middle and outer foaming layers as foaming medium, the temperature of the co-extrusion die is controlled to 320-350 ℃, the cooling water temperature is controlled to 25-35 ℃, and the density of each layer is ensured to decrease from inside to outside.
  10. 10. The method of manufacturing a ultra-stable phase bundled flat cable according to claim 8, wherein in the step ③, the winding tension of the inner copper compensation tape (32) is controlled to be 5-8N, the winding tension of the outer stainless steel compensation tape (33) is controlled to be 4-7N, and the shaping temperature is 120-150 ℃ through hot air shaping treatment after the winding.

Description

Ultra-stable phase bundled flat cable and preparation method thereof Technical Field The invention relates to the technical field of cable manufacturing, in particular to an ultra-stable phase bundling flat cable and a preparation method thereof. Background In aerospace systems such as satellite antennas, phased array radars and the like, a phase stabilizing cable is a core component for guaranteeing accurate transmission of high-frequency microwave signals, and the phase stability, the mechanical reliability and the environmental suitability of the phase stabilizing cable directly influence the detection precision and the communication quality of the system; With the development of aerospace systems to high integration, high frequency band and wide temperature range, the existing phase-stabilizing cable still has an optimization space when being adapted to a more severe scene: The multi-core cable with the traditional circular sheath is insufficient in adaptability in narrow spaces such as a satellite cabin body and a radar array, the problem of disordered arrangement and uneven heat dissipation is easy to occur, the traditional insulating layer adopts a physical foaming structure, but gradient density design is not optimized for aerospace scenes, and better balance is difficult to realize between mechanical support and low dielectric loss; therefore, it is necessary to design an ultra-stable phase bundled flat cable and a manufacturing method thereof. Disclosure of Invention The invention aims to provide an ultra-stable phase bunched flat cable and a preparation method thereof, which are used for solving the problems of poor laying suitability, insufficient balance between mechanical support and low dielectric loss of an insulating layer, poor phase stability in a wide temperature range and easy attenuation of performance in a space radiation environment of the existing stable phase cable for aerospace in the background technology, and improving the high-frequency signal transmission accuracy and long-term operation reliability of the existing stable phase cable for aerospace in satellite antennas and phased array radar systems. In order to achieve the above purpose, the present invention provides the following technical solutions: In a first aspect, an ultra-stable phase bunched flat cable is provided, the cable is of a multi-core bunched structure, and comprises at least two independent wire core units, each wire core unit sequentially comprises an inner conductor, an insulating layer, a compensation layer, an outer conductor and a shielding layer from inside to outside, and further comprises an outer sheath, wherein the outer sheath is coated on the outer sides of the shielding layers of all the wire core units; The insulation layer is of a three-layer co-extrusion physical foaming structure and consists of an inner high-density layer, a middle medium-density layer and an outer low-density layer, wherein the inner high-density layer is of a solid structure, the middle medium-density layer and the outer low-density layer are of a physical foaming structure, the three layers are formed by synchronous co-extrusion, the density of each layer is gradually decreased from inside to outside, the dielectric property and the mechanical strength of the insulation layer can be cooperatively optimized through the gradient density design of the three layers, the inner high-density layer is of the solid structure, reliable radial support can be provided, the stress deformation of a wire core unit is avoided, the physical foaming structure of the middle medium-density layer and the outer low-density layer can effectively reduce the overall dielectric constant, and the signal transmission efficiency is improved; The compensation layer consists of a polyimide isolation base layer, an inner layer copper compensation belt and an outer layer stainless steel compensation belt, wherein the polyimide isolation base layer is coated on the outer side of the insulation layer, the inner layer copper compensation belt is wrapped on the outer side of the polyimide isolation base layer, the outer layer stainless steel compensation belt is wrapped on the outer side of the inner layer copper compensation belt by opposite spiral angles, the inner layer copper compensation belt is positioned in a wrapping gap of the outer layer stainless steel compensation belt to form an inner nested double-spiral structure, the inner layer copper compensation belt and the outer layer stainless steel compensation belt adopt nested structures wrapped by opposite spiral angles, the difference of thermal expansion coefficients of two metal materials can be utilized, the thermal stress generated when the temperature of a cable is changed is dynamically offset, the polyimide isolation base layer can effectively isolate the potential difference between the insulation layer and the compensation layer, and the partial discharge risk is avoided; the insulating