Segmented functionalization-based soft and hard combined cable and manufacturing method thereof

Abstract

The invention provides a soft and hard combined cable based on segmented functionalization and a manufacturing method thereof, and relates to the technical field of cable design. The cable is provided with a conductor, an insulating layer and a sheath from inside to outside. A lining layer and an armor layer are arranged between the insulating layer and the sheath from inside to outside in a set length range, and the end part of the armor layer is provided with a conical buffer part of which the large end faces the armor layer; and the outer side of the buffer part is coated with a fixing layer. According to the invention, a single structure mode of'full-soft 'or'full-hard' of a traditional cable is broken through, and soft and hard segment partition customization is realized on a single cable. The cable uses the conductor with high flexibility and low hardness, so that the cable is easy to bend and convenient to lay and install; and the armor layer is additionally arranged in the area susceptible to mechanical damage, so that the cable is not easy to damage.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cable design, in particular to a soft and hard combined cable based on segmented functionalization and a manufacturing method thereof. BACKGROUND

[0002] In the process of cable laying, a whole cable needs to be used to avoid the use of joints to connect two cables. The existing cables include flexible cables and armored cables and various structures. The flexible cable has high flexibility and is easy to install in complex environments, but it is difficult to meet the requirements of mechanical damage resistance, and such a cable uses a soft conductor, which has the disadvantages of complex production process and single wire breakage under impact. Although the armored hard structure cable can protect the cable, the cable has poor flexibility and a large laying radius, and is not easy to install in complex environments.

[0003] In the current installation and use process of the cable, when a cable needs to be laid in a variable laying environment, the cable needs to meet the contradictory requirements of flexible laying requirements (such as narrow space of corners) and mechanical damage resistance (such as passageways). At this time, neither the flexible cable nor the armored cable can meet the requirements. SUMMARY

[0004] In view of the deficiencies of the prior art, the purpose of the present application is to provide a soft and hard combined cable based on segmented functionalization and a manufacturing method thereof. In the outer side of the continuous conductor, the armored layer is arranged in a set range to become a hard segment, and the position without the armored layer becomes a soft segment. A transition soft pad is arranged between the hard segment and the soft segment, and a sheath is arranged on the outermost side, so that one cable meets the requirements of different positions in the laying environment.

[0005] In order to achieve the above-mentioned purpose, the present application is realized by the following technical scheme: In a first aspect, a soft and hard combined cable based on segmented functionalization is provided. From the inside to the outside, the cable is provided with a conductor, an insulation layer and a sheath. There is a gap between the insulation layer and the sheath. In the gap, an inner liner layer and an armored layer are arranged in a set length range along the length direction of the cable. The end part of the inner liner layer and the armored layer is provided with a conical buffer part, and the large end of the conical buffer part faces the inner liner layer and the armored layer. The outer side of the buffer part is covered with a fixed layer.

[0006] In a second aspect, a preparation method of the soft and hard combined cable based on segmented functionalization is provided. The method comprises the following steps: S1, covering the outer side of the conductor with an insulation layer, and covering the inner liner layer and the armored layer in a set length range; S2, covering the end part of the armored layer with a buffer part, and covering the outer side of the buffer part with a fixed layer to obtain a cable without a sheath; S3, preparing a sheath on the outer side of the cable without a sheath by extrusion to obtain a soft and hard combined cable based on segmented functionalization.

[0007] The beneficial effects of the present application are as follows: The present application breaks through the traditional single structure mode of "all-soft" or "all-hard" cable, and realizes soft and hard segment partition customization on a single cable. The cable uses a conductor with high flexibility and low hardness, which makes it easy to bend and convenient to install. The armored layer is added in the area susceptible to mechanical damage, so that the cable is not easily damaged. In this way, the cable is easy to bend in places without armored layer, and has strong damage resistance in places with armored layer. According to the actual installation environment, the cable is designed and customized, and one cable can meet the use requirements of multiple installation scenarios. Moreover, the armored layer is only added in the area that needs protection, which can significantly reduce the material cost and the product weight. BRIEF DESCRIPTION OF DRAWINGS

[0008] The accompanying drawings, which form a part of this specification, are included to provide a further understanding of the application and are incorporated in and constitute a part of this specification. The embodiments of the application, and their

[0009] Figure 1 It is a structure schematic diagram of the soft and hard combined cable based on segmented functionalization in embodiment 1; wherein, 1, conductor; 2, insulation layer; 3, inner liner layer; 4, armored layer; 5, buffer part; 6, fixing layer; 7, outer sheath.

[0010] Figure 2 It is a shape schematic diagram of the butyl rubber self-adhesive tape in embodiment 1; wherein, (A) is a front view, and (B) is a side view. DETAILED DESCRIPTION

[0011] It should be noted that the following detailed description is exemplary in nature and is intended to provide further description of the application. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs.

[0012] It should be noted that the terms used herein are only intended to describe specific embodiments and are not intended to limit exemplary embodiments according to the present application. As used herein, the singular form is intended to include the plural form unless the context clearly indicates otherwise, and it should also be understood that when the terms "comprise" and / or "include" are used in this specification, they mean that there is a feature, step, operation, device, component and / or combination thereof.

[0013] The embodiment of one or more of the present application provides a soft and hard combined cable based on segmented functionalization, which is provided from inside to outside with a conductor, an insulation layer and a sheath; there is a gap between the insulation layer and the sheath, and within the gap along the length direction of the cable, an inner liner layer and an armor layer are provided from inside to outside, the end of the inner liner layer and the armor layer is provided with a tapered buffer, and the large end of the tapered buffer is towards the inner liner layer and the armor layer; the outside of the buffer is covered with a fixing layer.

[0014] Through the above structure, the cable is divided into a soft segment and a hard segment: the soft segment is not provided with the armor layer, has a small laying radius, and is suitable for narrow spaces (such as corners) that need to be bent; the hard segment is provided with the armor layer, has good protection effect, has a large laying radius, and is suitable for passages and other spaces. The same continuous conductor is used in the soft segment and the hard segment, and the outside is covered with a continuous sheath, which can meet the requirements of conduction and safety.

[0015] For example, the conductor is a 5th soft copper conductor or a 2nd twisted copper conductor with low rebound properties after special processing, the conductor properties meet the provisions of the existing standard GB / T 3956, is easy to bend, and meets the bending requirements and conduction performance requirements in the laying scene.

[0016] When the cable is a multi-core structure, a plurality of cable cores covered with an insulation layer are twisted into a cable, and a tape, an inner liner layer and an armor layer are sequentially provided from inside to outside in the gap between the cable cores and the sheath; wherein the tape is used to fix the relative positions of the plurality of cable cores.

[0017] Optionally, an electromagnetic shielding layer is arranged between the inner liner layer and the insulation layer to meet the relevant technical requirements of electromagnetic shielding.

[0018] Optionally, the material of the buffer includes one or more of butyl rubber, foamed polyethylene and thermoplastic polyurethane, which has good material elasticity, good compatibility with cable insulation, sheath and other materials, and a temperature resistance level that meets the operation requirements of the cable; the material of the buffer is connected to the internal structure in the form of adhesion, which is convenient to process.

[0019] Optionally, the taper angle of the buffer is 15-20°, the buffer layer fills the height difference between the hard segment and the soft segment and the right angle gap formed thereby, forms a transition zone with elasticity and modulus gradient, greatly reduces the structural stiffness mutation, and also eliminates the cracking points and internal pores caused by "suspension" or incomplete filling during sheath extrusion.

[0020] Optionally, the fixing layer covers the buffer and extends a set length on the surface of the armor layer and the insulation layer exposed at both ends of the buffer, which can integrate the end of the armor layer, the buffer layer and the insulation inner liner layer into a whole, enhance the structural rigidity and stability of the transition zone, and provide a flat and stable base surface for subsequent sheath extrusion.

[0021] The embodiment of one or more of the present application provides the preparation method of the above-mentioned soft and hard combined cable based on segmented functionalization, comprising the steps of: S1, coating an insulating layer outside the conductor, coating an inner liner layer and an armor layer within a set length range; S2, coating a buffer portion at the end of the armor layer, and coating a fixing layer outside the buffer portion to obtain a sheathless cable; S3, preparing a sheath outside the sheathless cable by extrusion to obtain a soft and hard combined cable based on segmented functionalization.

[0022] In the above process, the continuous conductor is processed into a cable including a soft segment and a hard segment, which can meet the requirements of variable laying environments, the buffer portion is arranged between the hard segment and the soft segment, and the fixing layer is coated outside the buffer portion, which can effectively prevent the armor layer from separating and improve the quality of subsequent sheath extrusion.

[0023] Optionally, in S1, the conductor is annealed after being stranded, for example, the second type of copper conductor in accordance with GB / T 3956-2008 is used, and after being stranded, the conductor is heated to 350-450℃ in an inert atmosphere for annealing to improve flexibility (i.e., the second type of stranded copper conductor with low rebound property); or for example, the fifth type of copper conductor in accordance with GB / T 3956-2008 is used.

[0024] Optionally, in S1, the inner liner layer is prepared by extrusion or wrapping, which is used to isolate the armor layer from the internal structure and prevent the internal structure from being damaged during the preparation process of the armor layer; the material of the armor layer is armor steel belt, and the thickness of the armor layer meets the corresponding standard requirements of the product, which is used to protect the internal conductor; for a single-core cable, the inner liner layer is extruded or wrapped outside the insulating layer; for a multi-core cable, after the insulating layer is prepared, the multiple insulated cable cores are stranded into a cable, and the inner liner layer is prepared outside by wrapping after being fixed by a wrapping belt.

[0025] Optionally, in S2, the end of the armor layer is coated with the large end of the wedge-shaped elastic material, and the insulating layer not covered by the armor layer is coated with the small end of the wedge-shaped elastic material, so that multiple wedge-shaped elastic materials form a conical buffer portion around the conductor; the end of the armor layer is coated, which can effectively absorb and buffer the shear stress and peeling stress concentrated at the end of the armor layer when the cable is bent, prevent these stresses from directly acting on the sheath to cause cracking, and prevent the inner liner layer and the armor layer from separating due to stress.

[0026] Optionally, in S2, the coverage area of ​​the fixing layer in the cable length direction is larger than that of the buffer section, and the coverage area extends 20-30cm beyond the buffer section at both ends; for the armor layer, a radial constraint force can be applied to the end of the armor steel strip, directly preventing the end of the steel strip from "lifting" or "opening" due to elasticity or external force, and firmly pressing it onto the inner lining layer and the buffer strip; for the conical buffer section, it can be tightly bound in a predetermined position, protecting the soft buffer strip surface from being scratched or contaminated before sheath extrusion, and also preventing it from shifting, deforming or falling off during the subsequent sheath extrusion process.

[0027] The present invention will be further described below with reference to the embodiments.

[0028] Example 1 A type of rigid-flexible cable based on segmented functionality, such as Figure 1 As shown, from the inside out, there are: conductor 1, insulation layer 2, and sheath 7; there is a gap between insulation layer 2 and sheath 7, and within a set length range along the cable length direction of the gap, there are inner lining layer 3 and armor layer 4 arranged from the inside out, and a conical buffer part 5 is provided at the end of inner lining layer 3 and armor layer 4, with the large end of the conical part 5 facing inner lining layer 3 and armor layer 4; a fixing layer 6 is covered on the outside of the buffer part.

[0029] Conductor 1 is a stranded copper conductor, which is a low-rebound conductor and easy to bend.

[0030] The inner lining layer 3 is made of a wear-resistant polymer material and is used to isolate the armor layer 4 from the insulation layer 2, preventing damage to the internal structure during the preparation of the armor layer.

[0031] The material of the buffer part 5 is butyl rubber, specifically butyl rubber self-adhesive tape, that is, the connection method between the buffer part and the internal structure is adhesive.

[0032] The cone angle of the buffer section 5 is 15°, which allows for a smooth transition between the hard and soft sections of the cable.

[0033] The fixing layer 6 is made of non-woven polyester fiber tape, which covers the buffer part 5, and the armor layer 4 and the insulation layer 2 are 20cm long beyond both ends of the buffer part 5.

[0034] The method for manufacturing a segmented, functionally-based rigid-flex cable according to this embodiment includes the following steps: S0. The overall structure of the cable is designed according to the actual on-site construction environment requirements. An armor layer is designed for the length range of the cable that needs protection, and no armor layer is designed for other locations. S1. Using the second type of copper conductor conforming to GB / T 3956—2008, the conductor is stranded and then annealed at 400°C in an inert atmosphere to meet the flexibility requirements; an insulating layer 2 is spirally wound around the outside of the conductor or an extruded insulating layer 2 is used to prepare an inner liner 3 by extrusion within a set length range; then an armored steel strip is spirally wound to form an armored layer 4. S2, Process the butyl rubber self-adhesive tape as follows: Figure 2 The wedge-shaped strips shown, multiple wedge-shaped strips as follows Figure 2 The roots are connected as shown in (A) for easy operation; Figure 2 The notch in the upper left corner of (B) is used to wrap the armor layer, so that the outer surface of the buffer part 5 can be smoothly transitioned; after the armor steel tape is wrapped and the end point is fixed, construction is immediately carried out at the cross section at the end of the armor layer 4. The thickest end of the wedge-shaped butyl rubber self-adhesive tape is tightly and without wrinkles wrapped around the end of the armor layer 4 and covers the set range of the armor layer 4, ensuring that the wedge strip completely covers the sharp edge and end point of the armor steel tape; after the wedge strip is flattened, it is attached to the insulation layer along the length of the cable, ensuring that the wedge strip smoothly transitions to the insulation layer of the soft section, and is firmly attached by its self-adhesion to obtain the conical buffer part 5. The fixing layer 6 is spirally wrapped around the outside of the buffer part 5 along the circumference of the cable, so that the fixing layer 6 completely covers the buffer part 5 and the armor layer 4 and insulation layer 2 within the 20cm range exposed at both ends of the buffer part 5, to obtain the unsheathed cable; S3. A sheath 7 is prepared on the outside of the unsheathed cable by extrusion to obtain a flexible and rigid combined cable based on segmented functionality.

[0035] Example 2 A segmented functional flexible-rigid hybrid cable differs from Embodiment 1 in that it is a multi-core cable, the conductor uses the fifth type of soft copper conductor conforming to GB / T 3956—2008, and the buffer part is made of foamed polyethylene.

[0036] In this embodiment, multiple insulated cable cores are twisted into a cable, and then the relative positions of the multiple cable cores are fixed with a wrapping tape. An inner lining layer is prepared on the outside of the wrapping tape by wrapping, and an armor layer and a sheath are sequentially arranged on the outside of the inner lining layer.

[0037] Example 3 A segmented functionalized rigid-flex cable differs from Embodiment 1 in that an electromagnetic shielding layer is provided between the insulation layer and the inner lining layer to provide electromagnetic shielding.

[0038] The above are merely preferred embodiments of this application and are not intended to limit this application. Various modifications and variations can be made to this application by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A hybrid cable based on segmented functionalization, characterized in that, From inside to outside, a conductor, an insulation layer and a sheath are arranged; a gap exists between the insulation layer and the sheath; within a set length range along the cable length direction, an inner liner layer and an armor layer are arranged from inside to outside; the end of the inner liner layer and the armor layer is provided with a tapered buffer part; the large end of the tapered buffer part faces the inner liner layer and the armor layer; and the buffer part is covered with a fixing layer.

2. The segmented functionalized hybrid cable of claim 1, wherein, The conductor is a twisted conductor made of copper material; and the armor layer is made of armor steel belt.

3. The segmented functionalized hybrid cable of claim 1, wherein, An electromagnetic shielding layer is arranged between the inner liner layer and the insulation layer. Alternatively, the material of the buffer part comprises one or more of butyl rubber, foamed polyethylene and thermoplastic polyurethane. Alternatively, the taper angle of the buffer part is 15-20°.

4. The segmented functionalized hybrid cable of claim 1, wherein, The soft and hard combined cable is a multi-core structure; a plurality of cable cores covered with an insulation layer are twisted into a cable; and a tape, the inner liner layer and the armor layer are arranged in the gap between the cable and the sheath from inside to outside.

5. The segmented functionalized hybrid cable of claim 1, wherein, The fixing layer covers the buffer part and extends a set length on the surface of the armor layer and the insulation layer exposed at both ends of the buffer part.

6. A method of manufacturing a segmented functionalized hybrid cable according to any one of claims 1 to 5, characterized in that, The method comprises the steps of: S1, covering the conductor with an insulation layer and covering the inner liner layer and the armor layer within a set length range; S2, covering the end of the armor layer with a buffer part and covering the buffer part with a fixing layer to obtain a sheathless cable; S3, preparing a sheath on the sheathless cable by extrusion to obtain a soft and hard combined cable based on segmented functionalization.

7. The method of claim 6, wherein the method further comprises the step of: 5 applying a layer of adhesive to the outer surface of the cable core. 10 In S1, the conductor is annealed after being twisted.

8. The method for manufacturing a segmented, functionally-based rigid-flex cable as described in claim 6, characterized in that, In S1, the inner liner layer is prepared by extrusion or wrapping.

9. The method for manufacturing a segmented, functionally-based rigid-flex cable as described in claim 6, characterized in that, In S2, a tapered buffer part is formed by surrounding the insulation layer with a wedge-shaped elastic material; the large end of the tapered buffer part is covered and bonded to the end of the armor layer; and the small end is bonded to the insulation layer not covered by the armor layer.

10. The method of claim 6, wherein the method of manufacturing a flexible rigid hybrid cable based on segmented functionalization is characterized by, In S2, the covering range of the fixing layer in the cable length direction is greater than the buffer part, and the two ends of the covering range each exceed the buffer part by 20-30 cm.

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