Ice-melting and snow-heating cable and braiding method of its core

Abstract

A snow-melting heating cable and its core braiding method are disclosed, comprising a heat-conducting layer, a heat-insulating layer, and an insulating layer. The insulating layer includes an upper insulating layer and a lower insulating layer. The heat-conducting layer is wrapped with the upper insulating layer, the heat-insulating layer is wrapped with the lower insulating layer, and the insulating layer is wrapped with an outer sheath. An arc-shaped clamping plate is fixedly installed in the middle of the inner wall of the outer sheath. The internal gap of the outer sheath is filled with a filling layer. A steel mesh armor layer is wrapped around the outer sheath, and a steel tape armor layer is nested outside the steel mesh armor layer. A limiting block is fixed at the middle position of the top of the cable and is embedded in a fixing component. The cable design in this invention is reasonable, can directionally transfer cable heat, and the breakage of local heating fibers does not affect heat conduction.

Description

Technical Field

[0001] This invention belongs to the technical field of heating cables, specifically relating to a snow-melting heating cable and a braiding method for its core. Background Technology

[0002] Winter roads are prone to snow and ice accumulation, severely impacting traffic flow and driving safety. This can easily lead to traffic accidents, causing losses to people's lives and the national economy. Heated snow-melting cables offer advantages such as safety, durability, environmental friendliness, energy efficiency, convenient control, and the ability to operate normally in special environments. Using heated cables for snow and ice melting provides guaranteed heat, making it a safe and reliable method. However, traditional heated snow-melting cables have the following drawbacks that limit their practical application:

[0003] 1. Traditional ice and snow melting heating cables use a single heating wire process, which has a large bending radius, small bending angle, stress concentration, and is prone to breakage. Once a break occurs, the entire line will be paralyzed.

[0004] 2. Traditional ice-melting heating cables lack flexibility. During construction, they are difficult to bend or prone to breakage due to excessive bending. Furthermore, the allowable bending radius is small, which cannot meet the actual road conditions of engineering applications and may easily lead to safety hazards during installation.

[0005] 3. Traditional ice and snow melting heating cables have huge heat loss. When the heating cable is working, the energy utilization rate is low, the heating unit is prone to damage, and the cable will diffuse energy in all directions during the heating process, resulting in insufficient heating area and a large amount of heat loss.

[0006] 4. The armoring process of Chuanrong Ice and Snow Heating Cable is relatively simple. If only steel mesh armor is used, the cable strength is insufficient; if only steel tape armor is used, the cable flexibility is insufficient and it is difficult to bend. Summary of the Invention

[0007] The purpose of this invention is to provide a snow-melting heating cable and a braiding method for its core, which effectively improves the cable's temperature resistance and mechanical load resistance, enhances the ease of construction, increases the cable's flexibility and bending radius, further improves the cable's safety, and reduces heat loss.

[0008] To achieve the above objectives, the present invention provides the following technical solution:

[0009] A snow-melting heating cable includes a heat-conducting layer (1), a heat-insulating layer (2), and an insulation layer (3), characterized in that: the insulation layer (3) includes an upper insulation layer (31) and a lower insulation layer (32), the heat-conducting layer (1) is wrapped with the upper insulation layer (31), the heat-insulating layer (2) is wrapped with the lower insulation layer (32), the insulation layer (3) is wrapped with an outer sheath (5), an arc-shaped clamping plate (8) is fixedly provided in the middle of the inner wall of the outer sheath (5), the internal gap of the outer sheath (5) is a filling layer (4), the outer sheath (5) is wrapped with a steel mesh armor layer (6), the steel mesh armor layer (6) is nested with a steel strip armor layer (7), and a limiting block (9) is fixed at the middle position of the top of the cable, the limiting block (9) is embedded in the fixing component (10).

[0010] Preferably, the heat-conducting layer (1) is composed of two heat-conducting wire cores arranged side by side, the heat insulation layer (2) is composed of two heat-insulating wire cores arranged side by side, and the heat insulation layer (2) is located directly below the heat-conducting layer (1).

[0011] Preferably, the heat-conducting wire core is made of composite braided metal fibers and reinforcing fibers, wherein the metal fibers are alloy heating wires and the reinforcing fibers are aramid fibers.

[0012] Preferably, the heat-insulating core is woven from heat-insulating fibers and reinforcing fibers, wherein the heat-insulating fibers are asbestos fibers and the reinforcing fibers are aramid fibers.

[0013] Preferably, the filling layer (4) includes an upper filling layer (41) and a lower filling layer (42). The upper filling layer (41) is made of thermally conductive putty at the junction with the upper insulating layer (31), and the lower filling layer (42) is made of thermally insulating putty at the junction with the lower insulating layer (32).

[0014] Preferably, the insulating layer (3) is made of EP rubber material; the outer sheath (5) is made of high-strength polyester material.

[0015] Preferably, the arc-shaped clamp (8) is provided with two semi-arc anti-slip rubber pads (81) on the side near the cable, and the arc-shaped clamp (8) is fixed on the outer sheath (5) on the side away from the cable.

[0016] Preferably, the fixing component (10) includes a fixing plate (101), and a limiting groove (102) is fixed at the top center of the fixing plate (101). The fixing plate (101) is semi-circular in shape.

[0017] A method for braiding the core of a snow-melting heating cable mainly includes the following steps:

[0018] S1. Raw material selection: Select reinforcing fibers and four functional fibers for later use;

[0019] S2, Baseline Weaving: Keep the reinforcing fiber in a straight line. Divide the four functional fibers into two groups and place them on both sides of the reinforcing fiber. Start weaving from the same starting point. The two groups of functional fibers intertwine and wrap around the reinforcing fiber at the same pitch. Each pair of functional fibers creates a node after one turn of wrapping. The nodes are alternately located on both sides of the reinforcing fiber. When the four functional fibers are woven together, the nodes on both sides can appear at the same time. After the above weaving is completed, a set of winding baseline is formed.

[0020] S3. Core forming: Take n sets of identical winding baselines (n is an even number and n≥2), match the protruding node part of one set of winding baselines with the non-protruding node part of another set of winding baselines, and then extrude and form the core.

[0021] S4. Insulation Extrusion: After the extruded wire core is wrapped with an insulation layer, insulation is extruded to form the cable core.

[0022] Preferably, the functional fiber is either a metal fiber or a heat-insulating fiber, and the core made by winding the metal fiber is a heat-conducting core, while the core made by winding the heat-insulating fiber is a heat-insulating core.

[0023] Compared with the prior art, the present invention provides a snow-melting heating cable and a braiding method for its core, which has the following beneficial effects:

[0024] 1. In this invention, the heat-conducting wire core is made of four metal fibers and one aramid fiber, which are then braided together to form a set of winding baselines. Multiple sets of winding baselines are then combined and extruded to ensure the stability of the wire core structure. The metal fibers will form nodes with each other. If a local fiber breaks, the current will pass through other metal fibers at the node, ensuring the normal operation of the cable and thus not affecting the overall heating of the cable.

[0025] 2. In this invention, reinforcing fibers are incorporated into both the heat-conducting core and the heat-insulating core, and the cores are braided using the same pitch, so that the overall flexibility of the cable can be kept uniform, thereby increasing the bending radius of the cable and enhancing its flexibility. This allows the cable to adapt to the complex environment in actual construction during the laying process.

[0026] 3. The cable in this invention adopts an upper heat-conducting and lower heat-insulating structure. The upper layer is made of a mixture of metal fiber and aramid fiber, and the lower layer is made of a mixture of heat-insulating fiber and aramid fiber. This not only enhances the flexibility of the cable, but also enables directional heat transfer and reduces heat loss. This solves the problems of huge heat loss, low energy utilization, and uneven heating area of ​​traditional heating cables.

[0027] 4. The armor layer of the cable in this invention adopts a composite structure of steel mesh and steel strip, which not only enhances the strength of the cable but also ensures its flexibility. Furthermore, the number of steel strips can be increased or decreased according to different engineering applications to adapt to the flexibility required by the cable under different conditions, and different types of cables can be flexibly selected for laying. Attached Figure Description

[0028] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings:

[0029] Figure 1 This is a structural diagram of the heating cable in this invention.

[0030] Figure 2 This is a cross-sectional view of the heating cable in this invention.

[0031] Figure 3 This is a schematic diagram of the winding baseline structure of the wire core in this invention.

[0032] Figure 4 This is a schematic diagram of the fit between the winding baselines in this invention.

[0033] Figure 5 This is a schematic diagram of the overall structure of the wire core in this invention.

[0034] Figure 6 This is a schematic diagram of the arc-shaped card plate in the present invention.

[0035] Figure 7 This is a schematic diagram of the arc-shaped clamp plate fixing the cable core in this invention.

[0036] Figure 8 This is a schematic diagram of the structure of the fixing component in this invention.

[0037] Figure 9 This is a schematic diagram of the structure of the fixing component for fixing the cable in this invention.

[0038] Figure 10 This is a schematic diagram of the steel mesh armor layer in this invention.

[0039] Figure 11 This is a schematic diagram of the composite armor layer structure of steel mesh and steel strip in this invention. Figure 1

[0040] Figure 12 This is a schematic diagram of the composite armor layer structure of steel mesh and steel strip in this invention. Figure 2

[0041] In the diagram: 1. Thermal conductive layer; 2. Thermal insulation layer; 3. Insulating layer; 4. Filling layer; 5. Outer sheath; 6. Steel mesh armor layer; 7. Steel strip armor layer; 8. Arc-shaped clamping plate; 9. Limiting block; 10. Fixing plate; 41. Upper filling layer; 42. Lower filling layer; 81. Anti-slip rubber pad; 10. Fixing component; 101. Fixing plate; 102. Limiting groove.

[0042] In the diagram, Ⅰ represents reinforcing fiber; Ⅱ represents functional fiber; and a represents the distance between two adjacent nodes during the weaving process. Detailed Implementation

[0043] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0044] Example 1

[0045] Reference Figure 3 ,4,5:

[0046] 1. Braiding method of heat-conducting wire core:

[0047] S1. Select a single aramid fiber as the reinforcing fiber and four metal fibers as the functional fibers for later use (the diameter of the aramid fiber is 0.01 mm, and the diameter of the metal fiber is 0.12 mm).

[0048] S2. Keep the aramid fiber in a straight line. Divide the four metal fibers into two groups and place them on both sides of the aramid fiber. Start weaving from the same starting point. The two groups of metal fibers intertwine and wrap around the aramid fiber at the same pitch. Each pair of metal fibers creates a node after one turn of wrapping. The nodes are alternately located on both sides of the aramid fiber. When the four metal fibers are woven together, the nodes on both sides can appear at the same time. After the above weaving is completed, a set of wrapping baselines is formed.

[0049] S3. Take four identical winding baselines, and match the protruding node part of one winding baseline with the non-protruding node part of another winding baseline. Repeat the same process for the other two sets, and then extrude them to form a heat-conducting wire core.

[0050] S4. After the extruded wire core is wrapped with an insulation layer, the insulation is extruded.

[0051] 2. Braiding method of the heat insulation wire core:

[0052] S1. Select a single aramid fiber as the reinforcing fiber and four asbestos fibers as the functional fibers for later use (the diameter of the aramid fiber is 0.01 mm, and the diameter of the asbestos fiber is 0.12 mm).

[0053] S2. Keep the aramid fiber in a straight line. Divide the four asbestos fibers into two groups and place them on both sides of the aramid fiber. Start weaving from the same starting point. The two groups of asbestos fibers intertwine and wrap around the aramid fiber at the same pitch. Each pair of asbestos fibers creates a node after one round of wrapping. The nodes are alternately located on both sides of the aramid fiber. When the four asbestos fibers are woven together, the nodes on both sides can appear at the same time. After the above weaving is completed, a set of wrapping baselines is formed.

[0054] S3. Take four identical winding baselines, and match the protruding node part of one winding baseline with the non-protruding node part of another winding baseline. Repeat the same process for the other two sets, and then extrude them to form a heat-insulating wire core.

[0055] S4. After the extruded wire core is wrapped with an insulation layer, the insulation is extruded.

[0056] Example 2

[0057] Reference Figure 1 , 2 and Figure 6-12 This embodiment is basically the same as Embodiment 1. A snow-melting heating cable includes a heat-conducting layer 1, a heat-insulating layer 2, and an insulating layer 3. The insulating layer 3 includes an upper insulating layer 31 and a lower insulating layer 32. The heat-conducting layer 1 is wrapped with the upper insulating layer 31, the heat-insulating layer 2 is wrapped with the lower insulating layer 32, and the insulating layer 3 is wrapped with an outer sheath 5. An arc-shaped clamping plate 8 is fixedly installed in the middle of the inner wall of the outer sheath 5. The internal gap of the outer sheath 5 is filled with a filling layer 4. The outer sheath 5 is wrapped with a steel mesh armor layer 6, and a steel strip armor layer 7 is nested outside the steel mesh armor layer 6. A limiting block 9 is fixed at the middle position of the top of the cable and is embedded in the fixing component 10.

[0058] The heat-conducting layer 1 is composed of two sets of heat-conducting wire cores as described in Example 1 above, and the heat-insulating layer 2 is composed of two sets of heat-insulating wire cores as described in Example 1 above.

[0059] The insulation layer is made of EP rubber material. The filler layer 4 includes an upper filler layer 41 and a lower filler layer 42. The upper filler layer 41 is thermally conductive putty, and the lower filler layer 42 is thermally insulating putty. The outer sheath 5 is made of high-strength polyester material.

[0060] Example 3

[0061] Reference Figure 1 , 210, 11, 12. This embodiment is basically the same as the first embodiment. The outer sheath 5 is wrapped with a steel mesh armor layer 6, and the steel mesh armor layer 6 is nested with a steel strip armor layer 7.

[0062] Depending on the specific engineering requirements, different numbers of steel strips should be selected. For example, when laying on roads with high traffic volume, cables with more steel strips should be selected, such as heating cables with 6 layers of steel strips, with each layer spaced 1m apart, to enhance the load-bearing capacity of the heating cable. If laid on pipes for insulation, heating cables without steel strips can be selected to enhance the flexibility of the heating cable.

[0063] Example 4

[0064] Reference Figure 2 , 6 7. This embodiment is basically the same as the first embodiment. Two semi-circular anti-slip rubber pads 81 are provided on the inner side of the arc-shaped card plate 8 near the cable. The side of the arc-shaped card plate 8 away from the cable is fixed on the outer sheath 5.

[0065] After the heat-conducting layer 1 and the heat-insulating layer 2 of the heating cable are braided, the top two strands are the heat-conducting layer 1 and the bottom two strands are the heat-insulating layer 2. The arc-shaped clamping plates 8 are clamped to the separating surfaces of the heat-conducting layer 1 and the heat-insulating layer 2 from both sides. The anti-slip rubber pads of the arc-shaped clamping plates 8 are in close contact with the heat-conducting layer 1 and the heat-insulating layer 2 to prevent the heat-conducting layer 1 and the heat-insulating layer 2 from rotating and thus failing to achieve directional heat conduction. The interval between the arc-shaped clamping plates 8 is 3m.

[0066] Example 5

[0067] Reference Figure 2 , 8 9. This embodiment is basically the same as the first embodiment. A limiting block 9 is fixed at the middle position of the top of the cable. The fixing component 10 includes a fixing plate 101. A limiting groove 102 is fixed at the middle of the top of the fixing plate 101. The fixing plate 101 is semi-circular in shape.

[0068] The heating cable is laid in the road surface, and the limiting block 9 in the middle of its top is embedded in the limiting groove 102 of the fixing component 10. The fixing component 10 is fixedly buried in the road surface, and one fixing component 10 is set every 3m to fix the heating cable as a whole so that it does not rotate.

[0069] It should be noted that, in this document, relational terms such as first and second, etc., are used only to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the terms "comprises," "comprising," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that includes a list of elements includes not only those elements but also other elements not explicitly listed, or elements inherent to such process, method, article, or apparatus.

[0070] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A snow-melting heating cable, comprising a heat-conducting layer (1), a heat-insulating layer (2), and an insulating layer (3), characterized in that: The insulation layer (3) includes an upper insulation layer (31) and a lower insulation layer (32). The heat-conducting layer (1) is wrapped with the upper insulation layer (31). The heat insulation layer (2) is wrapped with the lower insulation layer (32). The insulation layer (3) is wrapped with an outer sheath (5). An arc-shaped card plate (8) is fixedly installed in the middle of the inner wall of the outer sheath (5). The internal gap of the outer sheath (5) is a filling layer (4). The outer sheath (5) is wrapped with a steel mesh armor layer (6). A steel strip armor layer (7) is nested outside the steel mesh armor layer (6). A limit block (9) is fixed at the middle position of the top of the cable. The limit block (9) is embedded in the fixing component (10). The heat-conducting layer (1) is composed of two heat-conducting wire cores arranged side by side, and the heat insulation layer (2) is composed of two heat-insulating wire cores arranged side by side, with the heat insulation layer (2) located directly below the heat-conducting layer (1); The filling layer (4) includes an upper filling layer (41) and a lower filling layer (42). The upper filling layer (41) is in contact with the upper insulating layer (31) and is composed of thermally conductive putty. The lower filling layer (42) is in contact with the lower insulating layer (32) and is composed of thermally insulating putty. The arc-shaped clamp (8) has two semi-arc anti-slip rubber pads (81) on the side near the cable, and the arc-shaped clamp (8) is fixed on the outer sheath (5) on the side away from the cable. The fixing component (10) includes a fixing plate (101), and a limiting groove (102) is fixed at the top center of the fixing plate (101). The fixing plate (101) is semi-circular in shape. The braiding method of the heat-conducting or heat-insulating core of the ice-melting heating cable mainly includes the following steps: S1. Raw material selection: Select reinforcing fibers and four functional fibers for later use; S2. Baseline Weaving: The reinforcing fiber is kept straight. The four functional fibers are divided into two groups and located on both sides of the reinforcing fiber. Weaving starts from the same point. The two groups of functional fibers intertwine and wind on the reinforcing fiber at the same pitch. Each pair of functional fibers creates a node after one turn of winding. The nodes are alternately located on both sides of the reinforcing fiber. When the four functional fibers are woven together, the nodes on both sides can appear simultaneously. After the above weaving is completed, a winding baseline is formed. The functional fiber is any one of metal fiber or heat insulation fiber. The core made by winding metal fiber is the heat-conducting core, and the core made by winding heat insulation fiber is the heat-insulating core. S3. Core forming: Take n sets of the same winding baseline, where n is an even number and n≥2. After the protruding node part of one set of winding baselines is matched with the non-protruding node part of another set of winding baselines, they are extruded and formed to form a heat-conducting core or a heat-insulating core. S4. Insulation Extrusion: After the extruded heat-conducting or heat-insulating wire core is wrapped with an insulation layer, insulation is extruded to form a cable core.

2. The ice-melting heating cable according to claim 1, characterized in that: The heat-conducting wire core is made of composite braided metal fibers and reinforcing fibers, wherein the metal fibers are alloy heating wires and the reinforcing fibers are aramid fibers.

3. The ice-melting heating cable according to claim 1, characterized in that: The heat-insulating core is woven from heat-insulating fibers and reinforcing fibers. The heat-insulating fibers are asbestos fibers, and the reinforcing fibers are aramid fibers.

4. The ice-melting heating cable according to claim 1, characterized in that: The insulating layer (3) is made of EP rubber material; the outer sheath (5) is made of high-strength polyester material.

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