Phase change energy storage and thermochromism cable overheating protection structure

Abstract

The invention discloses a phase change energy storage and thermochromism cable overheat protection structure, which belongs to the technical field of cables, and comprises a conductor and a sheath layer, the sheath layer is arranged on the outer side of the conductor, a gradient phase change layer is arranged between the conductor and the sheath layer, the gradient phase change layer is made of paraffin / expanded graphite composite phase change material and coats the outer surface of the conductor, and the outer surface of the gradient phase change layer is coated with a thermochromism layer. The gradient phase change layer can absorb overload heat; the sheath layer comprises a base material, a thermochromic pigment and butyl stearate, the thermochromic pigment takes the base material as a matrix, and the color of the sheath layer is changed along with the change of the temperature. According to the invention, the gradient phase change layer is arranged between the conductor and the sheath layer, so that when a traditional cable is overloaded, the temperature of the conductor rises quickly, the protection response of a circuit breaker and the like lags behind, and the temperature rise cannot be inhibited at the initial stage of abnormal temperature. The gradient phase change layer is arranged to absorb heat, 30% of overload heat can be absorbed, peak temperature rise of the conductor is reduced, the temperature rise rate is reduced, the temperature rise process is obviously delayed, and the hysteresis defect of action of the circuit breaker is overcome.

Description

TECHNICAL FIELD

[0001] The present application relates to a phase change energy storage and heat-induced color change cable overheating protection structure, belonging to the technical field of cables. BACKGROUND

[0002] Cables are needed in most devices, and traditional cables can only transfer electrical energy and prevent other objects from causing short circuits. It is not convenient to observe the specific operation of the cable on the market. Cable overload or overheating protection mainly relies on external circuit breakers, thermistors or electronic temperature sensor modules. The circuit breaker and thermistor usually cut off the circuit to prevent the fault from continuing to develop, which cannot give visual early warning at the initial stage of temperature anomaly; intelligent cables need to embed electronic temperature measurement chips and signal lines in the cable sheath to collect and transmit temperature data in real time, which can give early warning, but the cost is high, the structure is complex, and additional waterproof and moisture-proof design and continuous power supply are required, which has greater reliability and maintenance difficulty.

[0003] Therefore, it is necessary to design a phase change energy storage and heat-induced color change cable overheating protection structure to solve the problems of traditional cables, such as delayed alarm response, lack of intuitive early warning, and high power consumption cost. SUMMARY

[0004] The technical problem to be solved by the present application is to provide a phase change energy storage and heat-induced color change cable overheating protection structure, which solves the problems of traditional cables, such as delayed alarm response, lack of intuitive early warning, and high power consumption cost.

[0005] The technical problem to be solved by the present application is solved by the following technical solution: a phase change energy storage and heat-induced color change cable overheating protection structure, comprising a conductor and a sheath layer, The outer side of the conductor is provided with the sheath layer, Characterized in that: A gradient phase change layer is arranged between the conductor and the sheath layer, the gradient phase change layer adopts paraffin / expanded graphite composite phase change material, is coated on the outer surface of the conductor, and can absorb overload heat; The sheath layer comprises a base material, a heat-induced color change pigment, and butyl stearate, the heat-induced color change pigment takes the base material as a matrix, the butyl stearate is mixed in the base material, and the color of the sheath layer changes with temperature.

[0006] Preferably, the gradient phase change layer is extruded and coated on the outer side of the conductor, and the thickness of the gradient phase change layer is 1.2-1.7mm.

[0007] Preferably, the thickness of the sheath layer is 1.8-2.5mm, and an axial shallow groove is pressed on the surface of the sheath layer.

[0008] Preferably, the sheath layer includes two color changes.

[0009] Preferably, the sheath layer is one color at less than 45 DEG C, a gradual color of two colors at 45 DEG C-60 DEG C, and another color at greater than 60 DEG C.

[0010] Preferably, the conductor is made of tinned copper stranded wire.

[0011] Preferably, the base material is made of TPE, and the butyl stearate is arranged in the form of a capsule in the base material.

[0012] The beneficial effects of the present application are: Through the present application, the gradient phase change layer is arranged between the conductor and the sheath layer, the conductor of the traditional cable is rapidly heated when overloaded, the protection response of the circuit breaker lags, and the temperature rise cannot be inhibited in the initial stage of temperature anomaly. By setting the gradient phase change layer to absorb heat, 30% of the overload heat can be absorbed, the peak temperature rise of the conductor is reduced, the temperature rise rate is reduced, the temperature rise process is significantly delayed, and the lag defect of the circuit breaker action is compensated.

[0013] Through the present application, the thermochromic material is arranged in the sheath layer, in the traditional cable, the circuit breaker or the thermal element cannot provide intuitive and early temperature warning, the intelligent temperature measurement scheme has high cost and needs external power supply and signal line, by arranging the thermochromic material in the sheath layer, without external power supply, the sheath layer gradually changes from blue to white when the temperature reaches 45-60 DEG C, and the sheath layer is completely white within 5 min; the on-site staff can visually judge whether the cable is at risk of overload.

[0014] Through the present application, the heat dissipation groove is arranged on the outside of the sheath layer, the sheath heat dissipation efficiency is reduced after the cable overheats, the heat is difficult to release quickly, and local overtemperature accumulation is prone to occur, by arranging the heat dissipation groove, the convection surface area of the cable surface can be increased, the heat dissipation efficiency of the cable can be improved, the heat release can be accelerated, and the temperature rise accumulation under continuous overload can be reduced. The conductor is made of multiple tinned copper wires, the resistance at high frequency is reduced, the overall bending life of the cable is improved, and the mechanical durability is improved. BRIEF DESCRIPTION OF DRAWINGS

[0015] Fig. 1 The figure is a structural schematic diagram of the present application.

[0016] Fig. 2 The figure is a temperature rise test diagram of the present application.

[0017] In the figure: 1-conductor, 2-gradient phase change layer, 3-sheath layer. DETAILED DESCRIPTION

[0018] In order to make the technical means, creative features, objectives and effects of the present invention easier to understand, the present invention is further described below in conjunction with specific embodiments. Example

[0019] like Figs. 1-2 As shown, a phase change energy storage and thermochromic cable overheat protection structure includes a conductor 1 and a sheath layer 3. The sheath layer 3 is arranged on the outside of the conductor.

[0020] A gradient phase change layer 2 is provided between the conductor 1 and the sheath layer 3 , and the gradient phase change layer 2 is coated on the outside of the conductor 1 .

[0021] Conductor 1 is made of multiple strands of tinned copper wire. In this embodiment, conductor 1 is 50 mm² tinned copper stranded wire with a tin coating thickness of 5-10 μm. As the current-carrying core of the cable, conductor 1 ensures stable output with a maximum current carrying capacity exceeding 200 A. The tin coating reduces high-frequency resistance, resists oxidation, and improves contact performance.

[0022] Compared to traditional bare copper wire, the tin layer increases skin depth at high frequencies of 1-10 MHz, reducing AC resistance by 5%–8% at 10 MHz. The surface contact resistance is ≤0.5 mΩ·cm², significantly better than the approximately 10 mΩ·cm² of oxidized bare copper. The stranded structure combined with the tin coating ensures a flex life of >500,000 cycles and an elongation at break of >15%. The stranded structure and the tin coating applied to the surface of conductor 1 ensure a flex life of >500,000 cycles and an elongation at break of >15% over long-term use.

[0023] A gradient phase change layer 2 is positioned outside the conductor 1. In this embodiment, the thickness of this layer ranges from 1.2 to 1.7 mm. It is made of a paraffin wax / expanded graphite composite phase change material, with paraffin wax comprising 60% and expanded graphite comprising 40%. This layer is extruded and coated onto the outer surface of the conductor 1 to absorb excess heat. The cross-section of the layer closely matches the conductor 1, with no discernible stepping.

[0024] The gradient phase change layer 2 can conduct heat and absorb phase change heat when the cable temperature reaches a phase change point of about 60°C.

[0025] A sheath layer 3 is provided on the outside of the gradient phase change layer 2. In this embodiment, when the temperature of the cable changes, the color of the sheath layer 3 can also change. The sheath layer 3 has two colors and can form a gradient color within a certain temperature range.

[0026] In the embodiment, the sheath layer 3 comprises a substrate, a thermochromic pigment, and butyl stearate. The thermochromic pigment is mixed in the substrate, and the butyl stearate is mixed in the substrate in the form of capsules. The sheath layer 3 changes color with temperature change.

[0027] The substrate is TPE, and the butyl stearate is mixed in the substrate in the form of capsules. The thermochromic pigment accounts for 5% of the sheath layer 3, and the butyl stearate in the form of capsules accounts for 10% of the sheath layer 3. The thermochromic pigment has different colors at different temperatures, and the butyl stearate can adjust the temperature change temperature and improve the dispersibility. The thickness of the sheath layer 3 is 2.0 mm.

[0028] In the embodiment, the thermochromic material is a mixture of crystal violet lactone and bisphenol A. The thermochromic material is blue in a low-temperature environment.

[0029] The surface of the sheath layer 3 is provided with a heat dissipation groove, which is arranged along the axial direction of the cable. The heat dissipation groove is made on the surface of the sheath layer 3 by pressing, and shallow grooves are pressed along the axial direction of the cable. In the embodiment, a plurality of heat dissipation grooves are provided, the depth of the heat dissipation groove is 0.2 mm, the width is 1.0 mm, and the interval between the heat dissipation grooves is 3 mm. The heat dissipation groove can increase the surface area of the sheath layer 3, strengthen air convection, and improve the heat dissipation efficiency of the sheath layer 3.

[0030] The sheath layer 3 includes two color changes. In the embodiment, the color of the sheath layer 3 is white, blue, and blue-white gradient. The color of the sheath layer 3 is blue when the temperature is less than 45℃, the color is blue-white gradient when the temperature is 45℃-60℃, and the color of the sheath layer 3 is white when the temperature of the sheath layer 3 is greater than 60℃.

[0031] The gradient phase change layer 2 and the sheath layer 3 are arranged outside the conductor 1 by extrusion coating. No secondary processing such as gluing, threading, and winding is provided at the connection between each layer to ensure the close fit between each layer. Through the cooperation of the conductor 1, the gradient phase change layer 2, and the sheath layer 3, when the cable is overloaded, the temperature of the conductor 1 rises, the gradient phase change layer 2 absorbs heat and delays heat conduction to the sheath layer 3, the temperature of the sheath layer 3 gradually rises, and rises to 45℃, then gradually changes from blue to white, and completely changes to white when the temperature reaches 60℃. The on-site staff can visually judge the approximate temperature of the cable to confirm whether the cable is at risk of overheating and take measures such as power off and load reduction.

[0032] In the embodiment, when the current is overloaded to 220A, the sheath can change from blue to white within 5 minutes, and the temperature rise rate is reduced by 40% compared with the traditional cable.

[0033] The above shows and describes the basic principles, main features and advantages of the present application. Those skilled in the art should understand that the present application is not limited to the above-mentioned embodiments, and various changes and improvements can be made to the present application without departing from the spirit and scope of the present application, and such changes and improvements all fall within the scope of the present application. The scope of protection of the present application is defined by the appended claims and their equivalents.

Claims

1. A phase change energy storage and thermochromic cable overheat protection structure, including Conductor, sheath, The outer side of the conductor is provided with the sheath layer, Its characteristics are: A gradient phase change layer is provided between the conductor and the sheath layer. The gradient phase change layer is made of a paraffin wax / expanded graphite composite phase change material and is coated on the outer surface of the conductor. The gradient phase change layer can absorb overload heat. The sheath layer comprises a substrate, a thermochromic pigment, and butyl stearate. The thermochromic pigment uses the substrate as a matrix, and the butyl stearate is mixed in the substrate. The color of the sheath layer changes with temperature.

2. The cable overheat protection structure with phase change energy storage and thermochromic properties according to claim 1, characterized in that: The gradient phase change layer is extruded and coated on the outside of the conductor, and the thickness of the gradient phase change layer is 1.2-1.7 mm.

3. The cable overheat protection structure with phase change energy storage and thermochromic properties according to claim 1, characterized in that: The thickness of the sheath layer is within a range of 1.8-2.5 mm, and axial shallow grooves are pressed on the surface of the sheath layer.

4. The cable overheat protection structure with phase change energy storage and thermochromic properties according to claim 1, characterized in that: The jacket layer includes two color variations.

5. The cable overheat protection structure with phase change energy storage and thermochromic properties according to claim 4, characterized in that: The sheath layer is one color when the temperature is less than 45°C, is a gradient color of two colors when the temperature is between 45°C and 60°C, and is another color when the temperature is greater than 60°C.

6. The cable overheat protection structure with phase change energy storage and thermochromic properties according to claim 1, characterized in that: The conductor is made of tinned copper stranded wire.

7. The cable overheat protection structure with phase change energy storage and thermochromic properties according to claim 1, characterized in that: The substrate is TPE, and the butyl stearate is arranged in the substrate in the form of capsules.

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