Anti-embrittlement high-elasticity low-temperature-resistant cable for energy storage system

Abstract

The invention relates to the technical field of cables, discloses an anti-embrittlement high-elasticity low-temperature-resistant cable for an energy storage system, and aims at solving the problems that a traditional integrated cable protection sleeve is prone to embrittlement at low temperature and prone to breakage due to stress superposition of a bending part. The protection layer is formed by arranging first supporting assemblies and flexible assemblies at intervals, second supporting assemblies are coaxially and fixedly connected outside the flexible assemblies, the second supporting assemblies and the first supporting assemblies are in clearance fit, when the cable is bent, the adjacent first supporting assemblies extrude the flexible assemblies, and overall bending is achieved through deformation of the flexible assemblies; meanwhile, the first supporting assembly and the second supporting assembly are matched so that the bending amplitude of a single position can be limited, the stress of deformation can be equally divided by the multiple flexible assemblies, the scheme achieves complementation of compression resistance, abrasion resistance and low-temperature flexibility, stress can be dispersed, the low-temperature brittle failure risk can be reduced, and the structural integrity and the service life of the cable in a severe environment are guaranteed.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a highly elastic, low-temperature energy storage system cable that is resistant to embrittlement. Background Technology

[0002] Cables are electrical devices consisting of mutually insulated conductors and an outer insulating protective layer, used to transmit electrical energy, electrical signals, or to convert electromagnetic energy. Energy storage system cables need to be resistant to low temperatures because energy storage systems are often deployed in cold regions or outdoors. Low temperatures can easily cause the insulation layer of ordinary cables to harden, become brittle, or even crack, thereby damaging the insulation performance, interrupting the system's charging and discharging process, and potentially causing safety accidents in severe cases. Therefore, low-temperature resistance is a necessary condition to ensure stable and safe operation across the entire temperature range.

[0003] Most existing cable protective sleeves adopt an integrated structural design. The main materials of the integrated protective sleeve, such as rubber and polyvinyl chloride, are prone to embrittlement at low temperatures, resulting in a significant decrease in material toughness and a marked reduction in crack resistance. Simultaneously, the protective sleeve at the cable bend must withstand the combined effects of two stresses: the cold contraction stress caused by low temperatures and the localized tensile stress generated during cable bending. These two stresses intensify each other, making the bend a weak area of ​​stress concentration. When the combined stress exceeds the tolerance limit of the embrittled material, the integrated protective sleeve is highly susceptible to cracking or even breakage at the bend, causing it to lose its mechanical and insulating protection functions for the cable's internal conductors and insulation layers. This can not only lead to cable short circuits and leakage faults but also shorten the cable's service life, posing a serious threat to the stable operation of power transmission or signal transmission systems. Summary of the Invention

[0004] The technical problem to be solved by the present invention is that the existing cable protective sleeve with integrated structure has the disadvantage that the main material is prone to embrittlement at low temperature, and the bending part will be subjected to the superposition of cold shrinkage stress and bending tensile stress, which will make the part prone to breakage, thereby losing the protective function and threatening the stable operation of the system. To this end, we propose a high elasticity low temperature energy storage system cable that is embrittlement resistant.

[0005] To achieve the above objectives, this application adopts the following technical solution: a high-elasticity, low-temperature energy storage system cable with anti-embrittlement properties, comprising: a conductor and a cable protective layer, wherein the cable protective layer includes a first support component and a flexible component, the first support component and the flexible component being spaced apart, the inner diameter and outer diameter of the first support component and the flexible component being the same, a second support component being coaxially disposed outside the flexible component, the second support component and the flexible component being fixedly connected, the width of the second support component being greater than that of the flexible component, the two sides of the second support component extending to the outside of the first support component, and the second support component and the first support component being clearance-fitted; when the cable is bent, the adjacent first support components located at the bending part of the cable press against each other to form the flexible component, and the bending displacement is compensated by the deformation of the flexible component, thereby achieving the overall flexible bending of the cable.

[0006] Preferably, the first support component includes a first rigid support ring, the outer wall of the first rigid support ring is provided with an outer plane, two sets of first limiting inclined surfaces are symmetrically provided on the sides of the outer plane, and a first rounded corner is provided at the connection between the outer plane and the first limiting inclined surface.

[0007] Preferably, the first rigid support ring has two sets of extrusion vertical edges symmetrically arranged on its sides, which are used to extrude the flexible component when the cable is bent.

[0008] Preferably, the flexible component includes a flexible deformation ring, the outer wall of which is provided with a connecting plane, and two sets of arc-shaped transition edges are symmetrically arranged on the sides of the connecting plane.

[0009] Preferably, the flexible deformation ring has two sets of deformation edges symmetrically arranged on its sides, and the deformation edges are fixedly connected to the extrusion vertical edges.

[0010] Preferably, the second support component includes a second rigid ring, the inner wall of which is provided with an inner plane, and the inner plane is fixedly connected to the connecting plane.

[0011] Preferably, two sets of second limiting inclined surfaces are symmetrically arranged on the sides of the inner plane, and the angle between the second limiting inclined surface and the inner plane is equal to the angle between the extrusion vertical edge and the outer plane.

[0012] Preferably, a second rounded corner is provided between the inner plane and the second limiting inclined plane, and the second rounded corner is aligned with the first rounded corner.

[0013] Preferably, when the cable is bent, the first limiting inclined surface on the outer side of the cable bend abuts against the inner plane, while the outer plane on the inner side of the cable bend abuts against the second limiting inclined surface, thereby limiting the bending amplitude of the cable at a certain position.

[0014] Preferably, the conductor is wrapped with an insulating layer, the insulating layer is covered with a wrapping layer, a filler layer is filled between the insulating layer and the wrapping layer, and an armor layer is covered with the wrapping layer. The armor layer is coaxially disposed inside the cable protection layer.

[0015] The technical effects and advantages of this invention are as follows: This invention achieves complementary performance through a protective sleeve structure with alternating first and flexible components. The first support component meets the pressure and wear resistance requirements of the cable foundation, while the flexible component provides sufficient bending allowance and maintains toughness at low temperatures, dispersing and absorbing stress, effectively reducing the risk of low-temperature fracture. The second support component not only protects the flexible component, which has weaker wear and pressure resistance, preventing it from directly bearing external force damage, but also does not hinder the cable's flexible bending through a gap fit with the first support component. Simultaneously, the cooperation between the first and second support components precisely limits the bending amplitude at a single location on the cable, allowing multiple flexible components to share the bending deformation and distribute the stress evenly, preventing excessive deformation and fracture of a single flexible component. Furthermore, under the constraint of the second support component, the flexible component disperses stress through compression deformation on both sides, further reducing the risk of low-temperature brittle fracture. Ultimately, this ensures the structural integrity and service life of the cable under harsh environments such as low temperatures and repeated bending, effectively solving the technical problem of traditional cable protective sleeves failing to simultaneously achieve flexibility and pressure and wear resistance at low temperatures. Attached Figure Description

[0016] The disclosure of this invention is illustrated with reference to the accompanying drawings. It should be understood that the drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings, the same reference numerals are used to refer to the same parts: Figure 1 This is a schematic cross-sectional view of the overall structure of the present invention; Figure 2 This is a three-dimensional structural diagram of the entire invention; Figure 3 This is a schematic cross-sectional view of the overall structure of the present invention; Figure 4 This is a cross-sectional structural diagram of the cable protective sleeve portion of the present invention; Figure 5 This is a schematic diagram of the structure of the first support component, the flexible component, and the second support component when the cable of the present invention is in a bent state; Figure 6 This is a three-dimensional structural diagram of the first support component of the present invention; Figure 7 This is a three-dimensional structural diagram of the flexible component portion of the present invention; Figure 8 This is a cross-sectional structural diagram of the second support component of the present invention.

[0017] Legend: 1. First support component; 2. Flexible component; 3. Second support component; 4. Conductor; 5. Insulating layer; 6. Filling layer; 7. Wrapping layer; 8. Armoring layer; 101. First rigid support ring; 102. Outer plane; 103. First limiting slope; 104. Extruded vertical edge; 105. First rounded corner edge; 201. Flexible deformation ring; 202. Connecting plane; 203. Arc-shaped transition edge; 204. Deformation edge; 301. Second rigid ring; 302. Inner plane; 303. Second limiting slope; 304. Second rounded corner edge. Detailed Implementation

[0018] It is readily understood that, based on the technical solution of this invention, those skilled in the art can propose various interchangeable structural methods and implementations without altering the essential spirit of the invention. Therefore, the following detailed embodiments and accompanying drawings are merely illustrative examples of the technical solution of this invention and should not be considered as the entirety of the invention or as limitations or restrictions on the technical solution of this invention.

[0019] The protective sheaths of cables commonly use polymer materials such as rubber and plastics. At low temperatures, the molecular chain mobility weakens, causing the material to change from flexible to rigid. This results in a significant decrease in elasticity and toughness and a marked increase in brittleness. When subjected to external stresses such as the cable's own weight, wind force, and vibration, the brittle protective sheath cannot absorb stress through deformation, eventually leading to cracks or even breakage. Furthermore, some cables that have already been laid and shaped may no longer require repeated bending in low-temperature environments. However, the bending points of the cables already in a bent state have generated continuous internal stress. Low temperatures cause the sheath material to drastically decrease in toughness and increase in brittleness. At this point, the material can no longer buffer the stress from bending through deformation, and the stress at the bending points will further concentrate, eventually exceeding the material's tolerance limit and causing breakage.

[0020] Existing cable protective sheaths are typically integrated, and the core of the outermost protective sheath is limited by the functional requirements of abrasion resistance and pressure resistance. High-flexibility materials, such as some silicone rubbers and low-density polyethylene, often have looser molecular structures or more branches to achieve flexibility at low temperatures. While this structure improves flexibility, it leads to a decrease in material hardness, surface strength, and resistance to deformation. This makes them vulnerable to damage from ground friction and heavy object compression during laying and use, and they cannot withstand long-term deformation under external forces. Therefore, high-flexibility materials cannot be directly used for the outermost protective sheath due to performance mismatch. The primary task of cable protective sheaths is to protect the internal cable core from physical damage. Therefore, materials with higher hardness and denser structures, such as high-density polyethylene and cross-linked polyethylene, must be prioritized. While these materials meet the core requirements of abrasion resistance and pressure resistance, their low-temperature toughness is poor, making them prone to embrittlement at low temperatures. This causes the cable's bending points to be subjected to tensile stress and low-temperature shrinkage, leading to breakage and affecting the cable's service life. To address the problem of the inability to simultaneously achieve both flexibility and pressure and abrasion resistance in cables at low temperatures, this application proposes the following improvements.

[0021] Reference Figure 1 , Figure 2 and Figure 3 As shown, the present invention provides a technical solution: a high-elasticity, low-temperature energy storage system cable with anti-brittleness, comprising: a conductor 4 and a cable protective layer, an insulation layer 5 wrapped around the conductor 4, a wrapping layer 7 sleeved around the insulation layer 5, a filler layer 6 filling the space between the insulation layer 5 and the wrapping layer 7, an armor layer 8 sleeved around the wrapping layer 7, and the armor layer 8 being coaxially disposed inside the cable protective layer.

[0022] Please see Figure 1 and Figure 4 As shown, the cable protective layer includes a first support component 1 and a flexible component 2, which are spaced apart. The inner and outer diameters of both components are identical. This staggered protective sleeve structure provides complementary advantages in enhancing cable flexibility and low-temperature fracture resistance. The first support component 1 maintains the overall structural strength of the protective sleeve, meeting the basic requirements for pressure resistance and abrasion resistance. The flexible component 2 provides sufficient bending allowance for the cable, improving overall flexibility. Furthermore, the flexible component 2 can be made of low-density polyethylene, maintaining a certain degree of toughness at low temperatures and buffering stress during bending. Even if the first support component 1 becomes brittle in a low-temperature environment, the staggered flexible rings can disperse and absorb external stress, preventing stress concentration at a single point and subsequent breakage. Simultaneously, the presence of the flexible component 2 allows the cable to retain a certain degree of bending capacity at low temperatures, effectively reducing the risk of low-temperature breakage.

[0023] Please see Figure 4 , Figure 5 As shown, although the flexible component 2 has good flexibility, its wear resistance and pressure resistance are not strong. Therefore, a second support component 3 is coaxially arranged outside the flexible component 2. The second support component 3 is fixedly connected to the flexible component 2. The width of the second support component 3 is greater than that of the flexible component 2. The second support component 3 covers the outside of the flexible component 2, which can protect the flexible component 2 and prevent the flexible component 2 from directly bearing external pressure and friction. The two sides of the second support component 3 extend to the outside of the first support component 1, and the second support component 3 and the first support component 1 are fitted with a gap. The outer walls of the first rigid support ring 101 are provided with first limiting inclined surfaces 103 on both sides, and the inner walls of the second rigid ring 301 are provided with second limiting inclined surfaces 303 on both sides. This can provide a certain space for the rotational misalignment between the first support component 1 and the second support component 3. Therefore, the arrangement of the second support component 3 will not hinder the flexible bending of the cable.

[0024] Grooves are formed between each of the second support components 3, so that the outermost layer of the cable protective sleeve has a structure with several protrusions and grooves spaced apart. The concave and convex shape can increase the friction of the outer layer. In low-temperature environments, when the operator's hands are stiff or wearing gloves, it can prevent the cable from slipping during installation and wiring, thereby improving construction efficiency. Moreover, when installing the cable, the grooves can enhance the clamping force of the cable ties, preventing the cable from shifting in vibrating environments such as energy storage chambers. On the other hand, this uneven surface structure can enhance heat dissipation capacity. By increasing the contact area with air, it can improve the heat dissipation efficiency during high current transmission, reduce the cable operating temperature, avoid high temperature accelerating material aging, and adapt to high-power energy storage scenarios.

[0025] Please see Figure 6 As shown, the first rigid support ring 101 has two sets of extrusion vertical edges 104 symmetrically arranged on its sides. The extrusion vertical edges 104 are used to extrude the flexible component 2 when the cable is bent. When the cable is bent, the adjacent first support components 1 located at the bending part of the cable extrude the flexible component 2 between them. The bending displacement is compensated by the deformation of the flexible component 2, thereby realizing the overall flexible bending of the cable. Furthermore, since the flexible component 2 is provided with a second support component 3, the flexible deformation ring 20 is constrained by the blocking and limiting effect of the second support component 3. 1. It will not arch upwards. The compression of the vertical edges 104 on both sides causes the deformation edges 204 on both sides of the flexible deformation ring 201 to tilt inwards and deform. This not only retains the mobility required for cable bending, but also maintains the stability of the overall flexible component 2. The compressive stress is transmitted to its interior through the deformation edges 204 on both sides, which facilitates more precise stress distribution. Compared with the traditional corrugated pipe structure for bending, it can prevent stress concentration at the crest of the upward arch of the corrugated pipe. Especially in low temperature environments, it is easier to further reduce the risk of embrittlement and fracture of the protective sleeve.

[0026] Please see Figure 6 , Figure 7and Figure 8 As shown, the first support component 1 includes a first rigid support ring 101. The outer wall of the first rigid support ring 101 is provided with an outer plane 102. Two sets of first limiting inclined surfaces 103 are symmetrically arranged on the sides of the outer plane 102. The flexible component 2 includes a flexible deformation ring 201. The outer wall of the flexible deformation ring 201 is provided with a connecting plane 202. Two sets of arc-shaped transition edges 203 are symmetrically arranged on the sides of the connecting plane 202. Two sets of deformation edges 203 are symmetrically arranged on the sides of the flexible deformation ring 201. 04, and the deformed edge 204 is fixedly connected to the extrusion vertical edge 104. The second support component 3 includes a second rigid ring 301. The inner wall of the second rigid ring 301 is provided with an inner plane 302. The inner plane 302 is fixedly connected to the connecting plane 202. Two sets of second limiting inclined surfaces 303 are symmetrically arranged on the sides of the inner plane 302. The angle between the second limiting inclined surface 303 and the inner plane 302 is equal to the angle between the extrusion vertical edge 104 and the outer plane 102.

[0027] When the cable is bent, the first limiting inclined surface 103 on the outer side of the cable bend abuts against the inner plane 302, while the outer plane 102 on the inner side of the cable bend abuts against the second limiting inclined surface 303. This limits the bending amplitude of the cable at a certain position. During the cable bending process, adjacent first support components 1 tilt and approach each other. The first limiting inclined surface 103 of the first support component 1 located on the outer side of the cable bend will tightly abut against the inner plane 302 of the component in the second support component 3. At the same time, the outer plane 102 of the first support component 1 located on the inner side of the bend will also just abut against the second limiting inclined surface 303 of the component in the second support component 3. This coordination prevents the first support component 1 and the second support component 3 from rotating and misaligning relative to each other, thus precisely limiting the degree of bending at a single location of the cable. Compared to the potential for localized excessive bending in traditional structures, this design allows the overall bending action of the cable to be borne and deformed by multiple flexible components 2. Each flexible component 2 will evenly distribute all the deformation stress required for the cable bending, effectively preventing excessive deformation of a single flexible component 2 due to excessive stress, thereby reducing the risk of it breaking due to exceeding its own tolerance limit. This ensures the structural integrity and service life of the cable under harsh environments such as repeated bending or low temperatures.

[0028] A first rounded corner 105 is provided at the connection between the outer plane 102 and the first limiting inclined surface 103, and a second rounded corner 304 is provided between the inner plane 302 and the second limiting inclined surface 303. The second rounded corner 304 is aligned with the first rounded corner 105. The first rounded corner 105 and the second rounded corner 304 are used to make the flexible component 2 and the second support component 3 rotate and shift more smoothly.

[0029] Working principle: When the cable is in a straight state, the second support component 3 is located outside the flexible component 2, shielding the flexible component 2. The second support component 3 and the first support component 1 work together to protect the cable, improving the cable's compressive strength and abrasion resistance. The flexible component 2 is relatively soft and has good elasticity. When the cable is bent, the adjacent first support component 1 at the bending point squeezes the flexible component 2, causing the flexible component 2 to deform. Furthermore, since the first rigid support ring 101 has first limiting inclined surfaces 103 on both sides of its outer wall, and the second rigid ring 301 has second limiting inclined surfaces 303 on both sides of its inner wall, the rotation between the first support component 1 and the second support component 3 can be facilitated. The staggered arrangement provides a certain amount of space, thus enabling the cable to bend flexibly. During bending, the first support component 1 is in an inclined state, and the first limiting inclined surface 103 in the first support component 1 located outside the cable bending part abuts against the inner plane 302. At the same time, the outer plane 102 located inside the cable bending part also abuts against the second limiting inclined surface 303 in the second support component 3. The first support component 1 and the second support component 3 can no longer rotate and stagger, thereby limiting the degree of bending of the cable at a single position. The bending of the cable is achieved by the joint deformation of multiple flexible components 2. Each flexible component 2 equally distributes the deformation stress required for the cable bending, preventing the flexible component 2 at a certain position from being excessively deformed and breaking.

[0030] The technical scope of this invention is not limited to the content described above. Those skilled in the art can make various modifications and variations to the above embodiments without departing from the technical concept of this invention, and all such modifications and variations should fall within the protection scope of this invention.

Claims

1. A brittle fracture resistant, high flexibility, low temperature resistant, energy storage system cable, characterized by, The cable protection layer comprises a first support assembly and a flexible assembly, the first support assembly and the flexible assembly are arranged at intervals, the inner diameter of the first support assembly and the flexible assembly is uniform, and the outer diameter of the first support assembly and the flexible assembly is uniform, the outer part of the flexible assembly is coaxially provided with a second support assembly, the second support assembly and the flexible assembly are fixedly connected, the width of the second support assembly is greater than that of the flexible assembly, the two sides of the second support assembly extend to the outside of the first support assembly, and the second support assembly and the first support assembly are gap-fitted; when the cable bending is in a bent state, the adjacent first support assemblies at the cable bending part extrude the flexible assembly therebetween, the bending displacement is compensated through the deformation of the flexible assembly, and then the flexible bending of the whole cable is realized.

2. The anti-crisping, high-elasticity, low-temperature-resistant, energy- storage system cable of claim 1, wherein: The first support assembly comprises a first hard support ring, an outer wall of the first hard support ring is provided with an outer flat surface, two groups of first limiting inclined surfaces are symmetrically arranged on the side of the outer flat surface, and a first rounded corner is arranged at the connection between the outer flat surface and the first limiting inclined surface.

3. The anti-crisping, high-elasticity, low-temperature-resistant, energy- storage system cable of claim 2, wherein: Two groups of extrusion vertical edges are symmetrically arranged on the side of the first hard support ring, and the extrusion vertical edges are used for extruding the flexible assembly when the cable is bent.

4. The anti-crisping, high elasticity, low temperature resistant, energy storage system cable of claim 1, wherein: The flexible assembly comprises a flexible deformation ring, an outer wall of the flexible deformation ring is provided with a connecting flat surface, and two groups of arc-shaped transition edges are symmetrically arranged on the side of the connecting flat surface.

5. The anti-crisping, high elasticity, low temperature resistant, energy storage system cable of claim 4, wherein: Two groups of deformation edges are symmetrically arranged on the side of the flexible deformation ring, and the deformation edges are fixedly connected with the extrusion vertical edges.

6. The anti-crisping, high elasticity, low temperature resistant, energy storage system cable of claim 1, wherein: The second support assembly comprises a second hard ring, an inner wall of the second hard ring is provided with an inner flat surface, and the inner flat surface is fixedly connected with the connecting flat surface.

7. The anti-crisping, high elasticity, low temperature resistant, energy storage system cable of claim 6, wherein: Two groups of second limiting inclined surfaces are symmetrically arranged on the side of the inner flat surface, and the included angle between the second limiting inclined surfaces and the inner flat surface is equal to the included angle between the extrusion vertical edges and the outer flat surface.

8. The anti-crisping, high elasticity, low temperature resistant, energy storage system cable of claim 6, wherein: A second rounded corner is arranged between the inner flat surface and the second limiting inclined surface, and the second rounded corner is aligned with the first rounded corner.

9. The anti-crisping, high elasticity, low temperature resistant, energy storage system cable of claim 2, wherein: When the cable bending is in a bent state, the first limiting inclined surface on the outside of the cable bending part abuts against the inner flat surface, and the outer flat surface on the inside of the cable bending part abuts against the second limiting inclined surface, so as to limit the bending amplitude of the cable at a certain position.

10. The anti-crisping, high elasticity, low temperature resistant, energy storage system cable of claim 1, wherein: An insulating layer is wrapped outside the conductor, a wrapping layer is sleeved outside the insulating layer, a filling layer is filled between the insulating layer and the wrapping layer, an armor layer is sleeved outside the wrapping layer, and the armor layer is coaxially arranged inside the cable protection layer.

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