Photovoltaic cable with long service life

Abstract

The invention relates to the technical field of cables, and discloses a long-life photovoltaic cable which comprises a conductor, an insulating layer arranged outside the conductor and a sheath layer arranged outside the insulating layer, the conductor is formed by stranded tinned copper wires, the surface of each copper wire is covered with a layer of tin, and the sheath layer is arranged outside the insulating layer. Both the insulating layer and the sheath layer adopt a flame-retardant halogen-free polyolefin material with at least temperature resistance as a base material, the content of carbon black in the sheath layer is greater than%, and the materials of the insulating layer and the sheath layer are subjected to an irradiation crosslinking processing procedure. The invention aims to provide the long-life photovoltaic cable which is temperature-resistant, aging-resistant, acid and alkali-resistant, flame-retardant and excellent in ultraviolet-proof performance.

Description

Technical Field

[0001] The invention relates to the technical field of cables, in particular to a long-life photovoltaic cable. Background Art

[0002] With the increasing attention paid to renewable energy around the world, solar power generation is an important part of clean energy, among which photovoltaic power generation will occupy a significant share with its unique advantages. The realization of this grand goal is inseparable from the solid support of photovoltaic cables with excellent performance and long service life. Photovoltaic cables are key components in solar power generation systems, and their quality is directly related to the operating efficiency and stability of the entire system. Therefore, in order to meet this huge and continuously growing market demand, we must increase our R&D efforts, continuously innovate technology, and strive to develop more efficient, durable and environmentally friendly photovoltaic cable products. This is not only a strong boost to my country's photovoltaic industry, but also an important contribution to the global renewable energy industry.

[0003] Traditional photovoltaic cables have a series of significant deficiencies in terms of temperature resistance, aging resistance, acid and alkali resistance, flame retardancy, and UV resistance. These defects have largely limited the overall performance and reliability of the photovoltaic system. Specifically, the temperature resistance of traditional cables is limited, and they are often unable to withstand high temperature environments under extreme weather conditions, resulting in accelerated aging of cable materials and performance degradation. At the same time, their aging resistance is poor. Long-term exposure to outdoor environments will cause the cable surface to crack and harden, which in turn affects the electrical performance and mechanical strength of the cable. In addition, traditional cables also have shortcomings in acid and alkali resistance. They are not able to resist acid and alkali corrosion environments, which can easily lead to damage to the cable insulation layer and cause safety hazards. In terms of flame retardancy, some traditional cables have a low flame retardancy level. Once a fire or other unexpected situation occurs, the fire is likely to spread along the cable, increasing the risk of accidents. Finally, traditional cables also have obvious defects in UV resistance. Long-term exposure to ultraviolet rays will cause the cable surface to age and discolor, seriously affecting the service life of the cable. Summary of the invention

[0004] The purpose of the present invention is to provide a long-life photovoltaic cable with excellent temperature resistance, aging resistance, acid and alkali resistance, flame retardancy and UV protection performance, and to propose a long-life photovoltaic cable.

[0005] The technical solution of the present invention to solve the above technical problems is as follows:

[0006] A long-life photovoltaic cable comprises a conductor, an insulating layer arranged outside the conductor and a sheath layer arranged outside the insulating layer, wherein the conductor is composed of twisted tinned copper wires, the surface of the copper wires is covered with a layer of tin, the insulating layer and the sheath layer are both made of flame-retardant halogen-free polyolefin material with a temperature resistance greater than 150 degrees as a base material, the carbon black content in the sheath layer should be greater than 4%, and the materials of the insulating layer and the sheath layer are both processed by a radiation cross-linking process.

[0007] Based on the above technical solution, the present invention can also be improved as follows.

[0008] Furthermore, the cable also includes at least one functional layer arranged on the insulation layer or the sheath layer.

[0009] Furthermore, the functional layer is one or more of a shielding layer, a waterproof layer, a flame retardant layer, a heat insulating layer, an anti-ultraviolet layer, and a reinforcing fiber layer.

[0010] Furthermore, the functional layer is a shielding layer, which is arranged between the insulation layer and the sheath layer of the cable, wherein the shielding layer is composed of a copper mesh, an aluminum mesh or a stainless steel mesh or a conductive polymer material.

[0011] Furthermore, the functional layer is a waterproof layer, which is arranged outside the sheath layer, wherein the waterproof layer is made of a waterproof polymer or rubber material.

[0012] Furthermore, the functional layer is a flame retardant layer, which is arranged at any position of the cable to improve the flame retardant performance of the cable, wherein the flame retardant layer is made of a flame retardant polymer material.

[0013] Furthermore, the functional layer is a heat-insulating layer, which is arranged at a location inside the cable that requires heat insulation to reduce heat transfer, wherein the heat-insulating layer is made of heat-insulating materials such as ceramic fiber or aerogel.

[0014] Furthermore, the functional layer is an anti-ultraviolet layer, which is arranged on the outer layer of the cable to protect the cable from damage by ultraviolet radiation, wherein the anti-ultraviolet layer is composed of ultraviolet absorbent or reflective material.

[0015] Furthermore, the functional layer is a reinforcing fiber layer, which is arranged at the position inside the cable that needs to be reinforced to improve the mechanical strength and wear resistance of the cable, wherein the reinforcing fiber layer is made of high-strength materials such as glass fiber or aramid fiber.

[0016] Furthermore, the conductor and the insulating layer, the insulating layer and the sheath layer, the insulating layer and the functional layer, and the sheath layer and the functional layer are all connected in a tightly fitting manner.

[0017] Compared with the prior art, the technical solution of this application has the following beneficial technical effects:

[0018] The conductor of the present invention is composed of twisted tinned copper wires, and its external insulation layer and sheath layer are both made of flame-retardant halogen-free polyolefin material with a temperature resistance of at least degrees as the base material. This design enables the cable to maintain stable performance in extremely high temperature environments, effectively avoiding the problems of accelerated material aging and performance degradation caused by high temperature. Secondly, the flame-retardant halogen-free polyolefin material used in the insulation layer and sheath layer itself has good aging resistance. In addition, after being treated with radiation cross-linking processing steps, the molecular structure stability of the material is further enhanced, making the cable less likely to crack or harden under long-term outdoor exposure, thereby ensuring the electrical performance and mechanical strength of the cable. In terms of acid and alkali resistance, the materials used in the insulation layer and sheath layer of the long-life photovoltaic cable have strong resistance to acid and alkali corrosion environments. This feature The property enables the cable to maintain the integrity of the insulation layer in an acid-base corrosive environment, avoiding the safety hazards caused by damage to the insulation layer. In terms of flame retardant performance, the flame retardant halogen-free polyolefin material used in the insulation layer and the sheath layer itself has a high flame retardant grade. In addition, after irradiation cross-linking processing, the flame retardant performance of the material has been further improved, which makes the cable not easy to burn in accidental situations such as fire, and even if it burns, it will not produce toxic smoke, thereby reducing the risk of accidents. Finally, in terms of UV protection, the carbon black content in the sheath layer is greater than 4%. This design enables the cable surface to effectively absorb and reflect ultraviolet rays, avoiding aging and discoloration of the cable surface caused by long-term ultraviolet radiation. This not only extends the service life of the cable, but also ensures the appearance of the cable during long-term use. BRIEF DESCRIPTION OF THE DRAWINGS

[0019] Figure 1 This is a schematic diagram of the connection structure of a long-life photovoltaic cable of the present invention;

[0020] Figure 2 This is a schematic diagram of the connection structure of another long-life photovoltaic cable of the present invention.

[0021] In the figure: 1. conductor; 2. insulation layer; 3. sheath layer; 4. functional layer. DETAILED DESCRIPTION

[0022] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0023] Combination Figure 1-Figure 2As shown, a long-life photovoltaic cable of the present invention comprises a conductor 1, an insulating layer 2 arranged outside the conductor 1, and a sheath layer 3 arranged outside the insulating layer 2, wherein the conductor 1 is composed of twisted tinned copper wires, the surface of the copper wires is covered with a layer of tin, the insulating layer 2 and the sheath layer 3 both use a flame-retardant halogen-free polyolefin material with a temperature resistance greater than 150 degrees as a base material, the carbon black content in the sheath layer 3 should be greater than 4%, and the materials of the insulating layer 2 and the sheath layer 3 are both processed by a radiation cross-linking process.

[0024] In a preferred embodiment, the present invention can be further configured as follows: the cable also includes at least one functional layer 4 arranged on the insulating layer 2 or the sheath layer 3. The introduction of the functional layer 4 can further enhance the temperature resistance of the cable. By selecting materials with higher temperature resistance grades as the functional layer, the stability and service life of the cable in a high temperature environment can be effectively improved, and the problems of accelerated material aging and performance degradation caused by insufficient temperature resistance of traditional cables can be avoided. Secondly, the functional layer 4 can also improve the aging resistance of the cable. In an outdoor environment, the cable is exposed to natural factors such as sunlight, wind and rain for a long time, and the surface is prone to cracking and hardening, which in turn affects the electrical properties and mechanical strength of the cable. By arranging the functional layer 4 on the insulating layer 2 or the sheath layer 3, materials with excellent aging resistance can be selected, thereby effectively extending the service life of the cable. In terms of acid and alkali resistance, the functional layer 4 can also play an important role. By selecting materials with strong resistance to acid and alkali corrosion environment as the functional layer, the cable can be protected from acid and alkali corrosion, and damage to the insulation layer and potential safety hazards can be avoided. In addition, the functional layer 4 can also improve the flame retardant properties of the cable. In unexpected situations such as fire, the flame retardant level of traditional cables is low, and the fire is easy to spread along the cable, increasing the risk of accidents. By arranging a functional layer 4 with flame retardant properties on the insulation layer 2 or the sheath layer 3, the spread of the fire can be effectively prevented and the risk of accidents can be reduced. Finally, the introduction of the functional layer 4 can also enhance the cable's ability to resist ultraviolet rays. By arranging a functional layer 4 containing special anti-ultraviolet additives on the sheath layer 3, the cable's ability to resist ultraviolet rays can be further enhanced, and the cable surface can be prevented from aging and discoloring due to long-term exposure to ultraviolet rays, thereby extending the service life of the cable.

[0025] In a preferred embodiment of the present invention, the functional layer 4 can be further configured as follows: the functional layer 4 is one or more of a shielding layer, a waterproof layer, a flame retardant layer, a heat insulating layer, an anti-ultraviolet layer, and a reinforcing fiber layer. When the functional layer 4 is used as a shielding layer, it can effectively prevent electromagnetic interference and signal leakage, and improve the electromagnetic compatibility of the cable, which is very important for the stable transmission of signals in the photovoltaic system. Secondly, when the functional layer 4 is a waterproof layer, it can significantly improve the waterproof performance of the cable, prevent moisture from invading the interior of the cable, and cause problems such as reduced insulation performance or short circuits. This is particularly important for photovoltaic cables installed outdoors. Furthermore, when the flame retardant layer is used as the functional layer 4, it can significantly improve the flame retardant performance of the cable, preventing the fire from spreading. The spread of fire and the risk of fire are extremely important for the safe operation of photovoltaic systems. In addition, the thermal insulation layer as the functional layer 4 can effectively reduce the heat transfer of the cable in a high temperature environment and protect the internal structure of the cable from the influence of high temperature, thereby improving the temperature resistance and service life of the cable. When the anti-ultraviolet layer is used as the functional layer 4, it can significantly enhance the cable's resistance to ultraviolet rays, prevent the cable surface from aging and discoloring due to long-term exposure to ultraviolet rays, and extend the service life of the cable. Finally, the reinforcing fiber layer as the functional layer 4 can significantly improve the mechanical strength and tensile properties of the cable, enhance the durability and reliability of the cable, which is particularly important for photovoltaic cables that need to withstand greater tension and pressure.

[0026] In a preferred embodiment of the present invention, the functional layer 4 is a shielding layer, which is arranged between the insulating layer 2 and the sheath layer 3 of the cable, wherein the shielding layer is composed of a copper mesh, an aluminum mesh, a stainless steel mesh or a conductive polymer material. A shielding layer 4 is added between the insulating layer 2 and the sheath layer 3 of the cable, and the shielding layer is composed of a copper mesh, an aluminum mesh, a stainless steel mesh or a conductive polymer material. These materials have good conductivity and shielding effectiveness, and can effectively prevent the propagation of electromagnetic interference and radio frequency interference. The setting of the shielding layer significantly improves the electromagnetic compatibility of the cable, reduces the electromagnetic radiation generated by the cable during the transmission of electric energy, and also reduces the interference of the external electromagnetic field on the internal signal of the cable, thereby improving the stability and transmission efficiency of the signal, which is very important for the accurate transmission of signals in the photovoltaic system and the stable operation of the system. The shielding layer is arranged between the insulating layer 2 and the sheath layer 3, which not only ensures good contact between the shielding layer and the internal conductor of the cable, but also avoids direct exposure of the shielding layer to the external environment, thereby extending the service life of the shielding layer and the overall reliability of the cable. At the same time, this design is also convenient for the manufacture and installation of the cable, reducing the production cost and construction difficulty.

[0027] In a preferred embodiment, the present invention can be further configured as follows: the functional layer 4 is a waterproof layer, and the waterproof layer is arranged on the outside of the sheath layer 3, wherein the waterproof layer is composed of a waterproof polymer or a rubber material. The arrangement of the waterproof layer significantly improves the waterproof performance of the cable. The waterproof layer composed of a waterproof polymer or a rubber material has excellent waterproof sealing and weather resistance, can effectively block the intrusion of external moisture, and protect the internal structure and insulating materials of the cable from moisture erosion, thereby extending the service life of the cable. The waterproof layer is arranged on the outside of the sheath layer 3, which not only ensures the close fit between the waterproof layer and the cable, but also avoids the aging, cracking and other problems that may be caused by direct exposure of the waterproof layer to the external environment. At the same time, this design is also convenient for the installation and maintenance of the cable, and reduces the construction difficulty and cost. The role of the waterproof layer in the photovoltaic system is particularly prominent. For example, in coastal areas or areas with abundant rain, photovoltaic cables often need to pass through humid environments. At this time, the presence of the waterproof layer is particularly important. It can not only prevent moisture from invading the interior of the cable, but also effectively resist the erosion of corrosive substances such as salt spray, acids and alkalis, and protect the cable from damage by environmental factors.

[0028] In a preferred embodiment of the present invention, the functional layer 4 can be further configured as follows: the functional layer 4 is a flame retardant layer, and the flame retardant layer is arranged at any position of the cable to improve the flame retardant performance of the cable, wherein the flame retardant layer is composed of a flame retardant polymer material, and the arrangement of the flame retardant layer significantly improves the fire resistance level of the cable, and in extreme cases such as fire, the flame retardant layer can quickly form a protective layer, isolate oxygen and heat, slow down the burning speed of the cable, and even achieve self-extinguishing, thereby winning precious time for personnel evacuation and fire fighting and rescue. This feature is crucial to improving the safety and reliability of photovoltaic systems, especially in photovoltaic power stations in densely populated areas or near important facilities. The flame retardant layer can be arranged at any position of the cable, such as between the insulating layer 2 and the sheath layer 3, outside the sheath layer 3, or other key positions inside the cable to ensure that the entire system is protected when a fire occurs. It can maintain high flame retardant properties. In addition, the flame retardant layer is composed of flame retardant polymer materials. These materials not only have excellent flame retardant properties, but also have good mechanical properties and weather resistance, which can ensure that the cable maintains stable performance during long-term use. At the same time, the setting of the flame retardant layer will not have a negative impact on the electrical performance of the cable, thereby ensuring the normal operation of the photovoltaic system. In terms of specific applications, the role of the flame retardant layer in the photovoltaic system is mainly reflected in improving the overall safety of the system. For example, in the cable laying of photovoltaic power stations, the reasonable setting of the flame retardant layer can effectively reduce the risk of fire caused by cable burning, and protect the key equipment and personnel safety of the photovoltaic system. In addition, in special environments, such as high temperature, humidity or corrosive environments, the flame retardant layer can also provide additional protection and extend the service life of the cable.

[0029] In a preferred embodiment of the present invention, the functional layer 4 can be further configured as follows: the functional layer 4 is a heat-insulating layer, and the heat-insulating layer is arranged at the position inside the cable that needs heat insulation to reduce heat transfer, wherein the heat-insulating layer is composed of heat-insulating materials such as ceramic fiber or aerogel. The setting of the heat-insulating layer improves the temperature resistance level of the cable. In a high-temperature environment, the heat-insulating layer can effectively isolate the external heat from invading the inside of the cable, maintain the stability of the temperature inside the cable, and ensure that the cable can still work normally under high-temperature conditions. This feature is particularly important for the application of photovoltaic cables in high-temperature areas such as deserts and tropical areas, and can significantly improve the stability and reliability of the photovoltaic system. In the photovoltaic system, the heat-insulating layer can be arranged at the position inside the cable that needs heat insulation, such as between the conductor and the insulating layer, between the insulating layer and the sheath layer, or at the cable joint, to reduce the heat transfer in these positions and improve the overall heat insulation performance of the cable. In addition, the heat-insulating layer is It is made of high-efficiency thermal insulation materials such as ceramic fiber or aerogel. These materials have excellent thermal insulation properties and chemical stability, and can maintain stable performance in harsh environments such as high temperature, high pressure, and corrosion. At the same time, these materials also have good mechanical strength and anti-aging properties, which can ensure that the thermal insulation layer does not fall off or deform during long-term use, and maintain a stable thermal insulation effect. In terms of specific applications, the role of the thermal insulation layer in the photovoltaic system is mainly reflected in improving the thermal stability and operating efficiency of the system. For example, in the cable laying of photovoltaic power stations, by reasonably setting the thermal insulation layer, the temperature of the cable in a high temperature environment can be effectively reduced, the power loss caused by the temperature increase can be reduced, and the power generation efficiency of the photovoltaic system can be improved. In addition, in special environments, such as high temperature, strong radiation or corrosive environments, the thermal insulation layer can also provide additional protection to ensure the normal operation of the cable under these extreme conditions.

[0030] In a preferred embodiment of the present invention, the functional layer 4 is an anti-ultraviolet layer, which is arranged on the outer layer of the cable to protect the cable from damage by ultraviolet radiation, wherein the anti-ultraviolet layer is composed of ultraviolet absorbent or reflective material, and the provision of the anti-ultraviolet layer improves the outdoor service life of the cable. In outdoor environment, ultraviolet radiation is one of the main reasons for the aging of cable materials. The anti-ultraviolet layer effectively reduces the destructive effect of ultraviolet rays on cable materials by absorbing or reflecting ultraviolet rays, slows down the aging rate of the cable, and thus prolongs the service life of the cable, which is crucial for the long-term stable operation of photovoltaic cables outdoors, and helps to reduce maintenance costs and replacement frequency. The anti-ultraviolet layer can be arranged on the outer layer of the cable, that is, on the sheath layer 3 or combined with it, to protect the cable from damage by ultraviolet radiation. This design is not only suitable for the production of new cables, but also can be used to upgrade existing cables to improve their anti-ultraviolet performance. In addition, the anti-ultraviolet layer is composed of ultraviolet absorbent Or reflective material, these materials have excellent UV resistance and chemical stability, UV absorbers can absorb UV rays and convert them into harmless heat energy, while reflectors can reflect UV rays back to reduce their direct effect on cable materials, these materials not only have high-efficiency UV resistance, but also have good weather resistance and aging resistance, which can ensure that the UV resistance layer maintains stable performance during long-term use. In terms of specific applications, the role of the UV resistance layer in the photovoltaic system is mainly reflected in protecting the cable from damage by UV radiation. For example, in areas with strong UV radiation such as deserts and plateaus, photovoltaic cables are susceptible to aging due to UV rays. By adding an anti-UV layer, the destructive effect of UV rays on the cable can be effectively reduced, and the long-term stability of the cable performance can be maintained, thereby improving the overall reliability and operation efficiency of the photovoltaic system. In addition, in salt fog and humid environments such as coastal areas, the anti-UV layer can provide additional protection and enhance the weather resistance and aging resistance of the cable.

[0031] In a preferred embodiment of the present invention, the functional layer 4 is a reinforcing fiber layer, which is arranged at the position inside the cable that needs to be reinforced to improve the mechanical strength and wear resistance of the cable, wherein the reinforcing fiber layer is composed of high-strength materials such as glass fiber or aramid fiber. The arrangement of the reinforcing fiber layer improves the mechanical strength of the cable. During transportation, installation and use, the cable may be subjected to various external forces such as tension, pressure, bending, etc. The reinforcing fiber layer is composed of high-strength materials such as glass fiber or aramid fiber. These materials have excellent tensile strength and compressive strength and can effectively resist external force damage. The cable structure is strong and durable, which can resist the bad effect and maintain the integrity and stability of the cable structure. This feature is particularly important for the application of photovoltaic cables in complex environments, such as mountains, deserts, oceans and other harsh terrains, as well as occasions that require frequent movement or bending, such as wind power generation, solar tracking systems, etc. In photovoltaic systems, the reinforced fiber layer can be set in the parts that need to be strengthened inside the cable, such as between the conductor and the insulation layer, between the insulation layer and the sheath layer, or in the bends, joints and other vulnerable parts of the cable, so as to improve the mechanical strength and wear resistance of these parts. This design is not only suitable for the production of new cables, but also can be used to upgrade and improve the existing cables. Its overall performance, in addition, the reinforced fiber layer is made of high-strength materials such as glass fiber or aramid fiber, these materials not only have excellent mechanical properties, but also have good weather resistance and corrosion resistance. In outdoor environments, these materials can resist the erosion of natural factors such as wind, rain, sun, salt spray, etc., and maintain the long-term stability and reliability of the cable. At the same time, these materials also have good insulation properties and thermal stability, and will not have a negative impact on the electrical properties of the cable. In terms of specific applications, the role of the reinforced fiber layer in the photovoltaic system is mainly reflected in improving the mechanical strength and wear resistance of the cable. For example, in mountain photovoltaic power stations In the field of power transmission, cables need to cross rugged terrain and are easily subjected to friction and extrusion by external forces. By adding a reinforced fiber layer, the cable's wear and extrusion resistance can be effectively improved, and the internal structure of the cable can be protected from damage. In marine photovoltaic power stations, cables need to withstand the impact of waves and the erosion of salt spray. The reinforced fiber layer can resist the destructive effects of these harsh environments and maintain the long-term stability and reliability of the cable. In addition, in wind power generation and solar tracking systems, cables need to move and bend frequently. The reinforced fiber layer can improve the flexibility and fatigue resistance of the cable, ensuring the normal operation of the cable in these dynamic environments.

[0032] In a preferred embodiment, the present invention can be further configured as follows: the conductor 1 and the insulating layer 2, the insulating layer 2 and the sheath layer 3, the insulating layer 2 and the functional layer 4, and the sheath layer 3 and the functional layer 4 are all connected in a tightly fitting manner, and the layers inside the cable are all connected in a tightly fitting manner. This design significantly improves the overall performance and reliability of the cable. The tightly fitting connection method can effectively prevent the penetration of external factors such as moisture and air, reduce the stress inside the cable caused by environmental changes, and improve the mechanical strength and durability of the cable. In addition, the tight fit can also ensure that the cable reduces energy loss when transmitting electrical energy and improves transmission efficiency. The tightly fitting connection method significantly improves the waterproof performance of the cable. In outdoor environments, photovoltaic cables are easily affected by moisture such as rain and humidity, which leads to a decrease in insulation performance. Through tight fitting, a layer with An effective waterproof barrier can effectively prevent the penetration of moisture and keep the inside of the cable dry, thereby extending the service life of the cable. The tight-fitting connection method enhances the mechanical strength and durability of the cable. During the use of the cable, it may be affected by various external forces such as mechanical vibration and temperature changes. The tight-fitting design enables the various layers to work together better to resist the destructive effects of external forces and reduce the damage to the cable caused by external forces. At the same time, the tight fit can also reduce the thermal stress generated by the cable when the temperature changes, and improve the heat resistance and cold resistance of the cable. The tight-fitting connection method also helps to improve the electrical performance of the cable. When transmitting electrical energy, the tightly fitting cable can reduce the loss of energy during the transmission process and improve the transmission efficiency. At the same time, the tight fit can also ensure the stability of the electrical connection between the layers inside the cable and reduce electrical failures caused by poor contact.

[0033] A long-life photovoltaic cable mainly includes a conductor 1, an insulating layer 2 arranged outside the conductor 1, and a sheath layer 3 arranged outside the insulating layer 2. The conductor 1 is composed of twisted tinned copper wires, and the surface of the copper wires is covered with a layer of tin. This design not only improves the conductivity of the conductor, but also the tin layer on the surface of the copper wires can effectively prevent the copper wires from oxidizing, thereby extending the service life of the cable. The insulating layer 2 and the sheath layer 3 both use a flame-retardant halogen-free polyolefin material with a temperature resistance of at least 150 degrees as a substrate. This material not only has excellent temperature resistance and can remain stable under high temperature conditions, but also has outstanding aging resistance, acid and alkali resistance and flame retardancy. In particular, the carbon black content in the sheath layer 3 is greater than 4%, which makes the cable have a good UV protection function and further enhances the outdoor use performance of the cable. In terms of connection method, the conductor 1, the insulating layer 2 and the sheath layer 3 are connected together in a tightly fitting manner. Specifically, first, the twisted tinned copper wire conductor 1 is pretreated, such as decontamination and degreasing, to ensure good bonding between it and the insulating layer 2. Then, a layer of liquid or semi-solid insulating material is coated on the outer surface of the conductor 1, and an insulating layer 2 is formed after curing. Similarly, a layer of liquid or semi-solid sheath material is coated on the outer surface of the insulating layer 2, and a sheath layer 3 is formed after curing. In this process, an extruder and other equipment can be used for coating to ensure that the layers are tightly combined without gaps. In addition, the materials of the insulating layer 2 and the sheath layer 3 are both subjected to irradiation cross-linking processing before coating. This is to irradiate the molecular polymers in the insulation and sheath with high-energy particle rays to form a cross-linked structure between their molecular chains, thereby enhancing the stability and durability of the material. Compared with other warm water and chemical cross-linking, irradiation cross-linking avoids the instability of the material under high temperature conditions and after contact with water, and further improves the service life of the cable. In summary, the long-life photovoltaic cable achieves the characteristics of aging resistance, acid and alkali resistance, flame retardancy, UV resistance and long service life through its unique structural design, high-quality material selection, and sophisticated processing methods, providing a strong guarantee for the stable operation of the solar power generation system.

[0034] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0035] Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions and variations may be made to the embodiments without departing from the principles and spirit of the present invention, and that the scope of the present invention is defined by the appended claims and their equivalents.

Claims

1. A long-life photovoltaic cable, characterized in that: The invention comprises a conductor (1), an insulating layer (2) arranged outside the conductor (1), and a sheath layer (3) arranged outside the insulating layer (2), wherein the conductor (1) is composed of twisted tinned copper wires, the surface of the copper wires is covered with a layer of tin, the insulating layer (2) and the sheath layer (3) are both made of a flame-retardant halogen-free polyolefin material with a temperature resistance of more than 150 degrees as a base material, the carbon black content in the sheath layer (3) should be more than 4%, and the materials of the insulating layer (2) and the sheath layer (3) are both processed by a radiation cross-linking process.

2. A long-life photovoltaic cable according to claim 1, characterized in that: The cable further comprises at least one functional layer (4) arranged on the insulating layer (2) or the sheath layer (3).

3. A long-life photovoltaic cable according to claim 2, characterized in that: The functional layer (4) is one or more of a shielding layer, a waterproof layer, a flame retardant layer, a heat insulating layer, an anti-ultraviolet layer, and a reinforcing fiber layer.

4. A long-life photovoltaic cable according to claim 3, characterized in that: The functional layer (4) is a shielding layer, which is arranged between the insulation layer (2) and the sheath layer (3) of the cable, wherein the shielding layer is made of a copper mesh, an aluminum mesh or a stainless steel mesh or a conductive polymer material.

5. A long-life photovoltaic cable according to claim 3, characterized in that: The functional layer (4) is a waterproof layer, which is arranged outside the sheath layer (3), wherein the waterproof layer is made of a waterproof polymer or rubber material.

6. A long-life photovoltaic cable according to claim 3, characterized in that: The functional layer (4) is a flame retardant layer, which is arranged at any position of the cable to improve the flame retardant performance of the cable, wherein the flame retardant layer is made of a flame retardant polymer material.

7. A long-life photovoltaic cable according to claim 3, characterized in that: The functional layer (4) is a heat-insulating layer, which is arranged at a location inside the cable that requires heat insulation to reduce heat transfer, wherein the heat-insulating layer is made of heat-insulating materials such as ceramic fibers or aerogels.

8. A long-life photovoltaic cable according to claim 3, characterized in that: The functional layer (4) is an anti-ultraviolet layer, which is arranged on the outer layer of the cable to protect the cable from damage caused by ultraviolet radiation, wherein the anti-ultraviolet layer is composed of ultraviolet absorbent or reflective material.

9. A long-life photovoltaic cable according to claim 3, characterized in that: The functional layer (4) is a reinforcing fiber layer, which is arranged at a location inside the cable that needs to be reinforced to improve the mechanical strength and wear resistance of the cable, wherein the reinforcing fiber layer is made of high-strength materials such as glass fiber or aramid fiber.

10. A long-life photovoltaic cable according to any one of claims 3 to 9, characterized in that: The conductor (1) and the insulating layer (2), the insulating layer (2) and the sheath layer (3), the insulating layer (2) and the functional layer (4), and the sheath layer (3) and the functional layer (4) are all connected in a tightly fitting manner.

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