A multi-core flexible cable for smart energy and its preparation method

Abstract

The present invention provides a multi-core flexible cable for smart energy and a preparation method thereof, comprising a cable core, a shielding layer, an inner sheath, a reinforcement layer, and an outer sheath, arranged sequentially from the inside to the outside. The cable core comprises a plum blossom-shaped skeleton and a plurality of control wire core groups arranged outside the plum blossom-shaped skeleton, and a filler is arranged within the plum blossom-shaped skeleton. The multi-core flexible cable for smart energy and a preparation method thereof provided by the present invention have the following characteristics: the plum blossom-shaped skeleton separates the plurality of control wire core groups, thereby improving the roundness of the multi-core flexible cable and reducing the loss of current transmission between wire groups; the control wire core groups are arranged in five equal parts, thereby increasing the structural stability of the multi-core flexible cable during use, while reducing signal attenuation and friction between wire groups; the filling core in the center of the plum blossom-shaped skeleton adopts a reinforced core structure, which improves the tensile strength and flexibility of the filling, prolongs the service life of the cable; the shielding layer ensures the electrical continuity of the multi-core flexible cable when it moves back and forth, and has multiple functions such as good oil resistance, wear resistance, and low temperature resistance.

Description

Technical Field

[0001] The present invention belongs to the technical field of flexible cables, and specifically relates to a multi-core flexible cable for smart energy and a preparation method thereof. Background Art

[0002] With the rapid development of domestic automation, the requirements for the signal transmission effect and flexibility of cables are becoming higher and higher. Not only are there higher requirements for the service life and product performance of cables, but there are also higher requirements for the appearance quality of cables. The current existing flexible cables cannot meet market demand.

[0003] Therefore, it is necessary to design a novel multi-core flexible cable and its production process to solve the above problems. Summary of the Invention

[0004] In order to solve the problems in the prior art, the purpose of the present invention is to provide a multi-core flexible cable for smart energy and a preparation method thereof.

[0005] In order to achieve the above-mentioned purpose and the above-mentioned technical effect, the technical solution adopted by the present invention is:

[0006] A multi-core flexible cable for smart energy includes a cable core, a shielding layer, an inner sheath, a reinforcement layer and an outer sheath arranged in sequence from the inside to the outside. The cable core includes a plum blossom-shaped skeleton and several groups of control wire core groups arranged outside the plum blossom-shaped skeleton. A filler is arranged inside the plum blossom-shaped skeleton.

[0007] Furthermore, the filling piece includes a central filling core arranged at the center position inside the plum blossom-shaped skeleton and plum blossom-shaped leaf fillings arranged in the five plum blossom-shaped leaves inside the plum blossom-shaped skeleton, and the central filling core and the plum blossom-shaped leaf fillings are not connected.

[0008] Furthermore, there are five control core groups, each of which includes a polyimide film and two twisted control cores wrapped inside the polyimide film. A control core group is set in the gap between the outer peripheries of each two adjacent plum blossom leaves of the plum blossom skeleton.

[0009] Furthermore, the control core includes a core conductor and an insulating layer covering the outside of the core conductor. The core conductor is a stranded conductor formed by twisting a plurality of Category 5e tinned copper wires. The thickness of the insulating layer is 0.3-1.0 mm.

[0010] Furthermore, the twisting pitch of the two twisted control cores in each control core group is 60-80 mm.

[0011] Furthermore, the shielding layer includes a double-sided spread aluminum foil layer arranged on the outside of the cable core and a tinned copper wire braided layer arranged on the outside of the double-sided spread aluminum foil layer, and several groups of tinned drainage wires are arranged between the double-sided spread aluminum foil layer and the tinned copper wire braided layer, and the tinned drainage wires are in contact with the metal surface of the metal strip of the double-sided spread aluminum foil layer.

[0012] Furthermore, the double-sided winged aluminum foil layer is made of a metal strip with a thickness of 0.045-0.05 mm and a width of 20-25 mm. The overlap rate of the metal strip is 25-30%, completely covering the control wire core group.

[0013] Furthermore, there are five groups of tinned drain wires which are evenly distributed in five equal parts between the double-sided aluminum foil layer and the tinned copper wire braided layer. The tinned drain wires are formed by twisting several tinned copper wires with a twisting pitch of 18-22 mm.

[0014] Furthermore, the braiding angle of the tinned copper wire braided layer in contact with the tinned drain wire is 40-50°, and the braiding density is not less than 85%.

[0015] Furthermore, the reinforcement layer is a braided layer woven with high-strength Kevlar fiber, with a braiding angle of 40-50° and a braiding density of 50-55%.

[0016] Furthermore, the outer protective layer is made of nitrile polyvinyl chloride material with a thickness of 1.5-2.4 mm.

[0017] The present invention discloses a method for preparing a multi-core flexible cable for smart energy, comprising the following steps:

[0018] S1: Make the control wire core and plum blossom-shaped frame. The conductor of the control wire core is made of Category 5e tinned copper wire stranded wire;

[0019] S2: Extrude an insulation layer outside the conductor of the control core using an extrusion method;

[0020] S3: Twisting the control wire cores with the extruded insulation layer in pairs, with a twisting pitch of 60-80 mm, and wrapping the two twisted control wire cores with a polyimide film to form a control wire core group;

[0021] S4: The control wire core groups obtained in step S3 are evenly arranged outside the five plum blossom-shaped leaves formed by the plum blossom-shaped skeleton to form a uniform distribution state. The central filling core at the center of the plum blossom-shaped skeleton is filled with high-strength Kevlar fiber, and the plum blossom-shaped leaves are filled with reinforced cotton thread to finally form a cable core;

[0022] S5: Setting a shielding layer on the outside of the cable core: Setting a double-sided winged aluminum foil layer on the outside of the cable core, weaving a tinned copper wire braided layer outside the double-sided winged aluminum foil layer, and distributing five groups of tinned drain wires equally between the double-sided winged aluminum foil layer and the tinned copper wire braided layer. The tinned drain wires are in contact with the metal surface of the metal tape of the double-sided winged aluminum foil layer to form a shielding layer;

[0023] S6: Extruding an inner sheath on the outside of the shielding layer;

[0024] S7: Braiding reinforcement layer on the inner sheath;

[0025] S8: Extruding an outer protective layer outside the reinforcement layer. The outer protective layer adopts an extrusion type to increase the adhesion with the reinforcement layer and the inner protective layer. Compared with the prior art, the beneficial effects of the present invention are:

[0026] (1) The polyimide film is coated on the control wire core to form a control wire core group, which is arranged in the outer gap of the plum blossom-shaped skeleton. The plum blossom-shaped skeleton separates the five control wire core groups, which not only improves the roundness of the multi-core flexible cable, but also reduces the loss of current transmission between the wire groups; the control wire core groups are evenly arranged in five equal parts, which increases the structural stability of the multi-core flexible cable during use and reduces the friction between the wire groups. At the same time, the center filling core of the plum blossom-shaped skeleton adopts a reinforced core structure, which improves the tensile strength of the filling and extends the service life of the multi-core flexible cable;

[0027] (2) The control wire core group is made of two pairs of twisted control wire cores, with different twist pitches, and the twist pitch is controlled at 60-80mm. The twisted control wire core is wrapped with a layer of polyimide film to increase the sliding property between the wire group and the filling;

[0028] (3) The central filling core in the middle of the plum blossom-shaped frame is filled with high-strength Kevlar fiber, and the plum blossom-shaped leaves in the five plum blossom-shaped leaves of the plum blossom-shaped frame are filled with reinforced cotton thread, thereby improving the filling softness and increasing the tensile strength of the plum blossom-shaped frame;

[0029] (4) The shielding layer is composed of a double-sided winged aluminum foil layer, a tinned drain wire and a tinned copper wire braid layer, which increases the anti-interference ability of the shielding layer and ensures the electrical continuity of the cable when it moves back and forth.

[0030] (5) The inner sheath is made of 80A hardness elastomer material, which improves the wear between the reinforcement layer and the shielding layer and improves the flexibility of the cable;

[0031] (6) The reinforcement layer is woven with high-strength Kevlar fiber with a weaving angle of 40-50° and a weaving density of 50% to 55%, which improves the cable's tensile strength and flexibility;

[0032] (7) The outer protective layer is made of nitrile polyvinyl chloride material, which has the characteristics of oil resistance, wear resistance, and low temperature resistance. The outer protective layer is soft and has a smooth surface. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a structural schematic diagram of the present invention;

[0034] Among them, 1. Cable core; 1-1. Plum blossom-shaped skeleton; 1-1-1. Center filling core; 1-1-2. Plum blossom-shaped leaf filling; 1-2. Control wire core; 1-3. Polyimide film; 2. Shielding layer; 2-1. Double-sided winged aluminum foil layer; 2-2. Tinned drain wire; 2-3. Tinned copper wire braided layer; 3. Inner sheath; 4. Reinforcement layer; 5. Outer sheath. DETAILED DESCRIPTION

[0035] The embodiments of the present invention are described in detail below so that the advantages and features of the present invention can be more easily understood by those skilled in the art, thereby making a clearer and more precise definition of the protection scope of the present invention.

[0036] like Figure 1 As shown, a multi-core flexible cable for smart energy includes a cable core 1, a shielding layer 2, an inner sheath 3, a reinforcement layer 4 and an outer sheath 5 arranged in sequence from the inside to the outside. The cable core 1 includes a plum blossom-shaped skeleton 1-1 and several groups of control wire core groups arranged outside the plum blossom-shaped skeleton 1-1. Fillers are arranged in the plum blossom-shaped skeleton 1-1. The fillers include a central filling core 1-1-1 arranged at the center position inside the plum blossom-shaped skeleton 1-1 and plum blossom-shaped leaf fillings 1-1-2 arranged in five plum blossom-shaped leaves inside the plum blossom-shaped skeleton 1-1.

[0037] There is a gap between the central filling core 1-1-1 and the plum blossom-shaped leaf filling 1-1-2, and they are not connected. Considering that the center is subjected to relatively large force when the cable is bent for a long time, the central filling core 1-1-1 is filled with high-strength Kevlar fiber, and the plum blossom-shaped leaf filling 1-1-2 is filled with reinforced cotton thread. The plum blossom-shaped leaf filling 1-1-2 is designed to be in the shape of a plum blossom leaf when extruded, giving a certain supporting force, thereby improving the filling softness and increasing the tensile strength of the plum blossom skeleton 1-1.

[0038] There are five groups of control core groups, each of which includes a polyimide film 1-3 and two twisted control cores 1-2 wrapped inside the polyimide film 1-3. A group of control core groups is arranged in the outer gap of the plum blossom leaves of each adjacent two plum blossom-shaped skeletons 1-1. The twisting pitch of the two twisted control cores 1-2 in each group of control core groups is 60-80mm, and the twisting pitch is different. After twisting, the polyimide film 1-3 is wrapped around the control core group to increase the sliding between the wire group and the filling.

[0039] The control core 1-2 includes a core conductor and an insulating layer wrapped around the outside of the core conductor. The core conductor is a twisted conductor made of several Category 5e tinned copper wires. It is a high-precision material with anti-oxidation and signal attenuation reduction functions to ensure more stable electrical performance. The thickness of the insulating layer is 0.3-1.0mm, preferably 0.5mm, and is extruded to the outside of the core conductor.

[0040] The shielding layer 2 includes a double-sided winged aluminum foil layer 2-1 arranged on the outside of the cable core 1 and a tinned copper wire braided layer 2-3 arranged on the outside of the double-sided winged aluminum foil layer 2-1. Several groups of tinned drain wires 2-2 are arranged between the double-sided winged aluminum foil layer 2-1 and the tinned copper wire braided layer 2-3. The tinned drain wires 2-2 are in contact with the metal surface of the metal strip of the double-sided winged aluminum foil layer 2-1, which increases the anti-interference ability of the shielding layer 2 and ensures the electrical continuity of the cable when it moves back and forth.

[0041] The double-sided winged aluminum foil layer 2-1 is made of a metal strip with a thickness of 0.045-0.05mm and a width of 20-25mm. The metal overlap rate of the metal strip is 25-30%, which completely covers the control wire core group, has good shielding effect, is light weight and is soft.

[0042] There are five groups of tinned drain wires 2-2, evenly distributed between the double-sided winged aluminum foil layer 2-1 and the tinned copper wire braid layer 2-3. The tinned drain wires 2-2 are made of several tinned copper wires with a diameter of 0.190-0.195mm, twisted together with a twist pitch of 18-22mm. The tinned drain wires 2-2 are preferably made of sixteen tinned copper wires with a diameter of 0.190-0.195mm, twisted together. They contact the metal surface of the metal strip of the double-sided winged aluminum foil layer 2-1 to ensure electrical continuity of the shielding layer 2.

[0043] The tinned copper wire braided layer 2-3 is woven from several tinned copper wires with a diameter of 0.145-0.15 mm. The braiding angle of the tinned copper wire braided layer 2-3 in contact with the tinned drain wire 2-2 is 40-50°, and the braiding density is not less than 85%, which further improves the best shielding effect of the entire spectrum and ensures excellent mechanical strength and low DC impedance characteristics.

[0044] The inner sheath 3 is made of an elastomeric material with a hardness of 80A, which improves the wear between the reinforcement layer 4 and the shielding layer 2 and improves the flexibility of the cable.

[0045] The reinforcement layer 4 is a braided layer made of high-strength Kevlar fiber with a braiding angle of 40-50° and a braiding density of 50-55%, which improves the tensile strength of the cable and enhances the flexibility of the cable.

[0046] The outer protective layer 5 is made of nitrile polyvinyl chloride material, which has the characteristics of oil resistance, wear resistance, and low temperature resistance. The outer protective layer is soft and has a smooth surface. The thickness is 1.5-2.4 mm, preferably 1.8 mm, and is extruded to the outside of the reinforcement layer 4.

[0047] A method for preparing a multi-core flexible cable for smart energy, comprising the following steps:

[0048] S1: Manufacture control cores 1-2 and plum blossom-shaped frame 1-1. The conductors of control cores 1-2 are made of Category 5e tinned copper wire strands. The conductors of control cores 1-2 are made of high-precision materials that are resistant to oxidation and reduce signal attenuation, ensuring more stable electrical performance.

[0049] S2: Extrude an insulation layer outside the conductor of the control core 1-2, using an extrusion method;

[0050] S3: Twist the control wire cores of the extruded insulation layer in pairs, with the twisting pitch controlled at 60-80 mm. Wrap the two twisted control wire cores 1-2 with polyimide films 1-3 to form a control wire core group, thereby increasing the sliding property between the wire group and the filling.

[0051] S4: The control wire core groups obtained in step S3 are evenly arranged outside the five plum blossom-shaped leaves formed by the plum blossom-shaped skeleton 1-1 to form a uniform distribution state. The central filling core 1-1-1 at the central position of the plum blossom-shaped skeleton 1-1 is filled with high-strength Kevlar fiber, and the plum blossom-shaped leaf filling 1-1-2 is filled with reinforced cotton thread, and finally the cable core 1 is formed;

[0052] S5: Shielding layer 2 is provided on the outside of cable core 1; specifically, double-sided winged aluminum foil layer 2-1 is provided on the outside of cable core 1, tinned copper wire braided layer 2-3 is woven outside double-sided winged aluminum foil layer 2-1, five groups of tinned drain wires 2-2 are evenly distributed between double-sided winged aluminum foil layer 2-1 and tinned copper wire braided layer 2-3, and tinned drain wires 2-2 are in contact with the metal surface of the metal tape of double-sided winged aluminum foil layer 2-1 to form shielding layer 2;

[0053] S6: Extruding the inner protective layer 3 on the outer side of the shielding layer 2;

[0054] S7: Weaving a reinforcement layer 4 on the inner sheath 3;

[0055] S8: Extruding an outer protective layer 5 on the outside of the reinforcement layer 4. The outer protective layer 5 adopts an extrusion type, which increases the adhesion with the reinforcement layer 4 and the inner protective layer 3 and improves the tensile strength of the protective layer surface.

[0056] Parts not specifically described in the present invention may adopt existing technologies and will not be described in detail here.

[0057] The above descriptions are merely embodiments of the present invention and are not intended to limit the patent scope of the present invention. Any equivalent structure or equivalent process transformation made using the contents of the present invention specification, or directly or indirectly applied in other related technical fields, are also included in the patent protection scope of the present invention.

Claims

1. A method for preparing a multi-core flexible cable for smart energy, characterized in that: The multi-core flexible cable for smart energy includes a cable core, a shielding layer, an inner sheath, a reinforcement layer, and an outer sheath arranged in sequence from the inside to the outside. The cable core includes a plum blossom-shaped skeleton and a plurality of control wire core groups arranged outside the plum blossom-shaped skeleton. A filler is arranged inside the plum blossom-shaped skeleton. The filling piece includes a central filling core arranged at the center of the plum blossom frame and plum blossom-shaped leaf fillings arranged in five plum blossom-shaped leaves inside the plum blossom frame; There is a gap between the central filling core and the plum blossom-shaped leaf filling, and they are not connected. The central filling core is made of high-strength Kevlar fiber, and the plum blossom-shaped leaf filling is made of reinforced cotton thread. The plum blossom-shaped leaf filling is to form a plum blossom leaf shape during extrusion, providing a certain support force, thereby improving the filling softness and increasing the tensile strength of the plum blossom-shaped skeleton; There are five control core groups in total. One control core group is set in the gap between the outer peripheries of each two adjacent plum blossom-shaped leaves of the plum blossom-shaped skeleton. Each control core group includes a polyimide film and two twisted control cores coated inside the polyimide film. The control core group is made of two pairs of twisted control cores. The twisting pitch is different and the twisting pitch is controlled at 60-80mm. The control core includes a core conductor and an insulating layer coated on the outside of the core conductor. The core conductor is a stranded conductor formed by twisting a plurality of Category 5e tinned copper wires. The thickness of the insulating layer is 0.3-1.0mm. The shielding layer includes a double-sided winged aluminum foil layer arranged outside the cable core and a tinned copper wire braided layer arranged outside the double-sided winged aluminum foil layer, and a plurality of groups of tinned drain wires are arranged between the double-sided winged aluminum foil layer and the tinned copper wire braided layer, and the tinned drain wires are in contact with the metal surface of the metal strip of the double-sided winged aluminum foil layer; The double-sided winged aluminum foil layer is made of a metal strip with a thickness of 0.045-0.05mm and a width of 20-25mm. The overlap rate of the metal strip is 25-30%, completely covering the control wire core group. There are five groups of tinned drain wires, which are evenly distributed between the double-sided winged aluminum foil layer and the tinned copper wire braided layer. The tinned drain wires are made of several tinned copper wires twisted together, with a twist pitch of 18-22mm. The braiding angle of the tinned copper wire braided layer in contact with the tinned drain wire is 40-50°, and the braiding density is not less than 85%; The reinforcement layer is a braided layer made of high-strength Kevlar fiber, with a braiding angle of 40-50° and a braiding density of 50-55%. The thickness of the outer sheath is 1.5-2.4 mm. The preparation method comprises the following steps: S1: Make the control wire core and plum blossom-shaped frame. The conductor of the control wire core is made of Category 5e tinned copper wire stranded wire; S2: Extrude an insulation layer outside the conductor of the control core using an extrusion method; S3: Twisting the control wire cores with the extruded insulation layer in pairs, with a twisting pitch of 60-80 mm, and wrapping the two twisted control wire cores with a polyimide film to form a control wire core group; S4: The control wire core groups obtained in step S3 are evenly arranged outside the five plum blossom-shaped leaves formed by the plum blossom-shaped skeleton to form a uniform distribution state. The central filling core at the center of the plum blossom-shaped skeleton is filled with high-strength Kevlar fiber, and the plum blossom-shaped leaves are filled with reinforced cotton thread to finally form a cable core; S5: A double-sided winged aluminum foil layer is provided on the outside of the cable core. A tinned copper wire braid layer is woven outside the double-sided winged aluminum foil layer. Five groups of tinned drain wires are evenly distributed between the double-sided winged aluminum foil layer and the tinned copper wire braid layer. The tinned drain wires are in contact with the metal surface of the metal tape of the double-sided winged aluminum foil layer to form a shielding layer. S6: Extruding an inner sheath on the outside of the shielding layer; S7: Braiding reinforcement layer on the inner sheath; S8: An outer protective layer is extruded outside the reinforcement layer. The outer protective layer adopts an extrusion type to increase the adhesion with the reinforcement layer and the inner protective layer.

Images