A cable incorporating micro electrical signal conductors

Abstract

The utility model aims at providing a kind of integrated micro electric signal conductor's cable, realize the integration of multiple signal lines, can effectively suppress common mode interference, fully meet the use requirement under the complex electric field environment of power cable inside, realize safe, reliable and efficient signal transmission, solve the problems of many cable quantity in prior art, large space occupation and easy to be interfered with electromagnetic interference.The utility model includes cable core, the outer layer of cable core is cover layer, the cable core includes several electric power conductor and several signal conductor, the signal conductor is embedded in the gap between the electric power conductor, the outer layer of electric power conductor is crosslinked polyethylene structure, the signal conductor includes N pairs of twisted pair wire, each pair of twisted pair wire includes two twisted enameled wire, the outer layer of signal conductor is wound with polyamide imide film.The utility model is applied to the technical field of power cable.

Description

Technical Field

[0001] This invention relates to the technical field of power cables, and in particular to a cable with an integrated miniature electrical signal conductor. Background Technology

[0002] In power monitoring systems, the transmission of signals from current / voltage transformers presents numerous drawbacks. Firstly, in traditional methods, current / voltage transformers and communication signals typically require independent cabling. For example, in a typical power monitoring scenario, a single power cable transmitting the main current often requires 12 signal lines to transmit related monitoring signals, significantly increasing the number of cables, thus complicating the installation process and raising subsequent maintenance costs considerably.

[0003] On the other hand, conventional independent signal lines have a relatively large outer diameter, with a cross-sectional area typically ≥0.5mm², occupying a significant amount of space and making them difficult to embed within power cables, thus failing to meet the space-efficient requirements of modern power systems. Furthermore, if signal lines and power lines are designed separately, the signal lines are highly susceptible to electromagnetic interference generated by the power lines.

[0004] However, Chinese patents such as CN116246833A disclose a signal line for use in power line carrier systems, and CN108242280A disclose a physically foamed insulated data signal line structure. These structures, which separate the signal line from the power line, are susceptible to electromagnetic interference, thus affecting the stability of signal transmission and severely restricting the efficiency and reliability of signal transmission in power monitoring systems.

[0005] Therefore, it is necessary to provide a cable that integrates miniature electrical signal conductors to achieve the integration of multiple signal lines, effectively suppress common-mode interference, fully meet the usage requirements of the complex electric field environment inside the power cable, realize safe, reliable and efficient signal transmission, and solve the problems of large number of cables, large space occupation and susceptibility to electromagnetic interference in the existing technology. Utility Model Content

[0006] The technical problem to be solved by this utility model is to overcome the shortcomings of the prior art and provide a cable that integrates miniature electrical signal conductors, realizes the integration of multiple signal lines, can effectively suppress common-mode interference, fully meet the usage requirements of the complex electric field environment inside the power cable, realize safe, reliable and efficient signal transmission, and solve the problems of large number of cables, large space occupation and susceptibility to electromagnetic interference in the prior art.

[0007] The technical solution adopted by this utility model is as follows: This utility model includes a cable core, the outer layer of which is an outer jacket. The cable core includes several electrical conductors and several signal conductors. The signal conductors are twisted together and embedded in the gaps between the electrical conductors. The outer layer of the electrical conductors is a cross-linked polyethylene structure. The signal conductors include N pairs of twisted wires. Each pair of twisted wires includes two twisted enameled wires. All twisted wires can also be twisted together to further enhance the signal anti-interference capability. The outer layer of the signal conductors is wrapped with a polyamide-imide film.

[0008] As can be seen from the above scheme, this application, as a high-density embedded miniature signal conductor structure, integrates multiple current-type signal lines inside the cable. The enameled wire is embedded in the gap of the outer edge of the power conductor to ensure a spacing of ≥0.5mm, thereby ensuring the stability and safety of signal transmission. By optimizing the selection of wire materials and insulation design, within the limited space of a three-phase cable, the magnetic fields generated by the three-phase cables cancel each other out, resulting in a smaller internal magnetic field. This achieves safe, reliable, and efficient signal transmission, solving the problems of numerous cables, large space occupation, and susceptibility to electromagnetic interference in existing technologies.

[0009] In a preferred embodiment, a cable filling layer is provided between the power conductor, the signal conductor and the outer jacket, and the cable filling layer is filled with cotton or hemp rope.

[0010] A preferred embodiment is that the diameter of the enameled wire is 0.1-0.3 mm.

[0011] In a preferred embodiment, the insulating layer of the signal conductor is a polyamide-imide varnish with a thickness of 3-5 μm.

[0012] In a preferred embodiment, the outer layer of the electrical conductor is a cross-linked polyethylene structure, which serves as the insulating layer of the electrical conductor, and the thickness of the insulating layer is 0.6-1.2 mm.

[0013] A preferred embodiment is that the outer layer is a halogen-free flame-retardant polyolefin structure, and the thickness of the outer layer is 1.0-1.8 mm. Attached Figure Description

[0014] Figure 1 This is the first structural diagram of this utility model;

[0015] Figure 2 This is a structural diagram of the signal conductor;

[0016] Figure 3 This is the second structural diagram of the present invention;

[0017] Figure 4This is the third structural diagram of this utility model;

[0018] Figure 5 This is the fourth structural diagram of this utility model. Detailed Implementation

[0019] like Figures 1 to 5 As shown, in this embodiment, the present invention includes a cable core, the outer layer of which is an outer jacket 1. The cable core includes a plurality of power conductors 2 and a plurality of signal conductors 3. The signal conductors 3 are twisted and embedded in the gaps between the power conductors 2. The outer layer of the power conductors 2 is a cross-linked polyethylene structure 4. The signal conductors 3 include N pairs of twisted wires, each pair of twisted wires including two twisted enameled wires 5. The outer layer of the signal conductors 3 is wound with a polyamide-imide film 6.

[0020] The power conductor 2 serves as the power transmission layer, with 1-4 circular annealed copper conductors arranged in the center of the cable. The cross-sectional area ranges from 1.5 to 240 mm², and it mainly undertakes the transmission of the main current, providing stable power transmission for the power system.

[0021] The enameled wire 5 is mainly used for transmitting electrical signals. In order to effectively suppress common-mode interference, the wires are twisted into pairs with a twist pitch of 5mm. The enameled wire 5 is embedded in the gap of the power conductor 2, and the spacing is ≥0.5mm to ensure the stability and safety of signal transmission.

[0022] The polyamide-imide film 6 serves as the fixing layer for the signal conductor 3. The polyamide-imide film 6 is used to wrap the signal conductor 3. The film has a thickness of 0.06 mm, a dielectric strength of ≥2.5 kV, and a temperature resistance of 300 degrees Celsius, providing good insulation performance.

[0023] like Figures 1 to 2 As shown, in this embodiment, a cable filling layer 7 is provided between the power conductor 2, the signal conductor 3 and the outer jacket layer 1, and the cable filling layer 7 is filled with cotton and hemp rope.

[0024] In this embodiment, the diameter of the enameled wire 5 is 0.1-0.3 mm.

[0025] In this embodiment, the insulating layer of the signal conductor 3 is a polyamide-imide varnish, and the thickness of the polyamide-imide varnish is 3-5 μm.

[0026] In this embodiment, the outer layer of the power conductor 2 is a cross-linked polyethylene structure 4, which serves as the insulating layer of the power conductor 2. The thickness of the insulating layer is 0.6-1.2 mm. Using cross-linked polyethylene as the insulating material for the power conductor, with its thickness selected within the range of 0.6-1.2 mm according to actual needs, effectively isolates the power conductor from the outside environment, ensuring safe power transmission.

[0027] In this embodiment, the outer jacket 1 is a halogen-free flame-retardant polyolefin structure, and the thickness of the outer jacket 1 is 1.0-1.8mm. The outer jacket 1 is made of halogen-free flame-retardant polyolefin material with an oxygen index ≥30 and a thickness between 1.0 and 1.8mm, which has good flame-retardant properties and can improve the fire safety performance of the cable while ensuring its normal use.

[0028] In this embodiment, the power conductor 2 is a 4×6mm² copper conductor with a voltage rating of 450 / 750V; the signal line is a 10×0.15mm enameled wire, of which 6 wires are used to transmit 50mA current transformer signals; the outer sheath is made of gray halogen-free flame-retardant polyolefin, and the cable outer diameter is 8.2mm.

[0029] The manufacturing process is as follows: First, the power conductor 2 is stranded, and then an XLPE insulation layer is extruded onto the stranded conductor, which is the cross-linked polyethylene structure 4; Second, the 3 pairs of twisted wires and 6 enameled wires 5 are stranded again, and the polyamide-imide film 6 is used for insulation and fixation, and then the 6 enameled wires 5 are fixed in the gaps of the power conductor 2; Finally, an outer sheath is extruded, and after cooling treatment, the finished cable is formed.

[0030] In this embodiment, in order to be suitable for industrial environments that use a large number of frequency converters, medium frequency furnaces and other equipment that generate harmonics, as an improvement to this solution, a 0.06mm copper or aluminum shielding layer is added to the outer layer of the signal line and neutral line, which is also within the protection scope of this utility model.

[0031] In this embodiment, the signal line can be embedded in various AC and DC voltage level cables of 12V-220KV, including high, medium, and low voltage cables. The manufacturing method of the cable itself remains unchanged, and the signal line is manufactured according to the method described in this solution, which is also within the protection scope of this utility model.

[0032] Table 1 is a parameter table for the enameled wire:

[0033]

[0034] Table 1

[0035] Table 2 shows the test performance results of this utility model:

[0036]

[0037] Table 2

[0038] Although the embodiments of this utility model are described with reference to actual solutions, they do not constitute a limitation on the meaning of this utility model. For those skilled in the art, modifications to the implementation schemes and combinations with other schemes based on this specification are obvious.

Claims

1. A cable integrating a miniature electrical signal conductor, comprising a cable core, characterized in that: The outer layer of the cable core is an outer jacket (1). The cable core includes several power conductors (2) and several signal conductors (3). The signal conductors (3) are twisted and embedded in the gaps between the power conductors (2). The outer layer of the power conductors (2) is a cross-linked polyethylene structure (4). The signal conductors (3) include N pairs of twisted wires. Each pair of twisted wires includes two twisted enameled wires (5). The outer layer of the signal conductors (3) is wrapped with a polyamide-imide film (6).

2. The cable with integrated miniature electrical signal conductor according to claim 1, characterized in that: A cable filling layer (7) is provided between the power conductor (2), the signal conductor (3) and the outer jacket (1), and the cable filling layer (7) is filled with cotton and hemp rope.

3. The cable with integrated miniature electrical signal conductor according to claim 1, characterized in that: The diameter of the enameled wire (5) is 0.1 - 0.3 mm.

4. The cable with integrated miniature electrical signal conductor according to claim 1, characterized in that: The insulating layer of the signal conductor (3) is a polyamide-imide varnish with a thickness of 3-5 μm.

5. The cable with integrated miniature electrical signal conductor according to claim 1, characterized in that: The cross-linked polyethylene structure (4) serves as the insulating layer of the electrical conductor (2), and the thickness of the insulating layer is 0.6-1.2 mm.

6. The cable with integrated miniature electrical signal conductor according to claim 1, characterized in that: The outer layer (1) is a halogen-free flame-retardant polyolefin structure, and the thickness of the outer layer (1) is 1.0-1.8 mm.

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