小型轻量多层横向水密分支电缆结构及工艺优化

    Small, Lightweight, Multi-layer, Horizontally Waterproof Branch Cable Structure and Process Optimization

    • 摘要: 针对现有分支电缆在水下和动态应用场景中存在的体积大、重量重、防水性能有限、分支体结构不便安装等问题,提出了一种小型轻量多层横向水密分支电缆及其制造方法。该电缆通过引入航空航天领域的高强度镀银铜合金导体,创新性地采用聚四氟乙烯(PTFE)绕包绝缘工艺以实现线缆的极限小型化和轻量化,并设计了独特的多层横向排布分支体和椭圆柱体硫化密封结构。试验结果表明,本电缆在横向水压1.5 MPa下不漏水,具有优异的耐弯曲(10000次以上)、耐弯折(10000次以上)和抗拉(主缆抗拉≥200 N,分支抗拉≥50 N)性能,能够满足在水下高频率活动对分支电缆造成弯折、弯曲、拉拽的使用要求。该技术为水下设备、船舶和海洋工程等领域提供了高性能、高可靠性的线缆解决方案。

       

      Abstract: Aiming to address the drawbacks of existing branched cables for underwater and dynamic applications, including excessive bulk, high weight, inadequate waterproofing performance, and inconvenient installation of the branch structure, this paper presents a novel compact and lightweight multi-layer transverse watertight branched cable, along with its corresponding manufacturing method. By leveraging high-strength silver-plated copper alloy conductors maturely applied in the aerospace industry, the proposed cable innovatively adopts a polytetrafluoroethylene (PTFE) wrapping insulation process to achieve extreme miniaturization and weight reduction. Furthermore, a unique multi-layer transversely arranged branch configuration and an elliptical cylindrical vulcanization sealing structure are specially designed. Experimental results indicate that the proposed cable maintains zero water leakage under a transverse water pressure of 1.5 MPa, and delivers outstanding mechanical performance: it withstands more than 10 000 cyclic bending tests and more than 10,000 cyclic flexion tests, while meeting the tensile strength requirements of ≥ 200 N for the main cable and ≥ 50 N for the branch cables. These properties enable the cable to satisfy the service requirements under repeated bending, flexing and tensile loads induced by high-frequency motion in underwater environments. The developed technology provides a high-performance and high-reliability cable solution for underwater equipment, marine vessels and offshore engineering applications.

       

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