Aluminum alloy cable

Abstract

The application belongs to the field of cables, and particularly relates to an aluminum alloy cable. The aluminum alloy cable specifically comprises a sheath layer, a core wire and a protection structure layer. The protection structure layer is a double-layer structure composed of an inner protection layer and an outer protection layer. The inner protection layer comprises a main body part and a rib part. The main body part is in a hollow tubular shape and tightly covers the outer surface of the core wire. The rib part is uniformly distributed on the outer surface of the main body part. The outer protection layer comprises a main body part and an arch structure. The main body part is in a hollow tubular shape and covers the outer side of the inner protection layer. The arch structure is arranged corresponding to the inner protection layer and is arranged on the inner surface of the main body part. The rib part and the arch structure are in abutment. The aluminum alloy cable retains the original lightweight feature. The outer protection layer and the inner protection layer are arranged in cooperation to form the protection structure layer, and the compression resistance and the torsion resistance of the cable are strengthened.

Description

Technical Field

[0001] This invention belongs to the field of cables, and particularly relates to an aluminum alloy cable. Background Technology

[0002] Aluminum alloy cables are a new type of power cable invented using AA8030 series aluminum alloy material as the conductor and advanced technologies such as special compaction and annealing treatment. They are a low-cost alternative to traditional oxygen-free copper power cables, and compared to pure aluminum cables, their performance in various aspects is improved, meeting the standards for use under most conditions.

[0003] Currently, aluminum alloy cables suffer from certain structural and performance defects. This is primarily due to the high-voltage transmission characteristics of these cables, which limit the use of most metal-based compressive strength components. This makes it difficult to effectively incorporate such structures within the cable, resulting in susceptibility to pressure and torsional damage. Furthermore, compared to conventional pure copper cables, the conductivity of aluminum alloy cables is more prone to rapid decline when the internal conductive wires deform. Therefore, effectively improving the structural strength of aluminum alloy cables is an important research direction. Summary of the Invention

[0004] To address the issues of insufficient structural strength in existing aluminum alloy cables and the inapplicability of traditional processes for enhancing cable resistance to extrusion deformation, this invention provides a shaped aluminum alloy cable.

[0005] The main objective of this invention is:

[0006] I. Maintain the relatively lightweight characteristics of the overall aluminum alloy cable;

[0007] Second, it can effectively improve the cable's resistance to pressure and deformation.

[0008] To achieve the above objectives, the present invention adopts the following technical solution.

[0009] An aluminum alloy cable, specifically comprising:

[0010] Sheath layer, core wire and protective structural layer;

[0011] The protective structure layer circumferentially covers the outer surface of the core wire, and the sheath layer further circumferentially covers the outer surface of the protective structure layer;

[0012] The protective structure layer is a two-layer structure consisting of an inner protective layer and an outer protective layer;

[0013] The inner protective layer includes a main body and ribs. The main body is a hollow tube that fits tightly to the outer surface of the core wire, while the ribs are evenly distributed circumferentially on the outer surface of the main body. In the radial cross-section of the cable, the ribs are arc-shaped, with one end connected to the outer surface of the inner body and are evenly distributed and arranged in a rotationally symmetrical manner.

[0014] The outer protective layer includes a main body and arched structures. The main body is a hollow tube structure that covers the radially outer side of the inner protective layer and is tightly attached to the inner surface of the sheath layer. The number of arched structures is equal to the number of ribs in the inner protective layer, and the two are set in a one-to-one correspondence. The arched structures are located on the inner surface of the main body. On the radial cross-section of the cable, the arched structures arch inward at an angle.

[0015] The ribs and arched structures abut against each other.

[0016] As a preferred option

[0017] The ribs of the inner protective layer are all twisted in the same circumferential direction.

[0018] As a preferred option

[0019] The included angles between the main body of the outer protective layer and the arched structure are acute and obtuse angles, respectively.

[0020] The rib ends of the inner protective layer abut against the acute angle between the arched structure and the outer body, so that the ribs of the inner and outer protective layers and the arched structure can cooperate and be fixed together.

[0021] As a preferred option

[0022] The protective structure layer is also equipped with rigid tension ropes.

[0023] As a preferred option

[0024] The rigid pull rope is set on the radial inner side of the rib of the inner protective layer, and a rigid pull rope is provided for each rib.

[0025] As a preferred option

[0026] The outer protective layer has a filling groove in its arched structure.

[0027] The filling groove is filled with filler material.

[0028] As a preferred option

[0029] The filler is an insulating silicone ball.

[0030] As a preferred option

[0031] The core wire is composed of several conductive wires wrapped in a bundle tube. The conductive wires are aluminum alloy conductive wires and are used to realize power transmission and / or electrical signal transmission. The inner surface of the bundle tube is also provided with an insulating shielding layer.

[0032] The beneficial effects of this invention are:

[0033] The aluminum alloy cable of this invention retains its original lightweight characteristics, and constructs a protective structure layer by setting up a coordinated outer protective layer and an inner protective layer structure, which work together to enhance the cable's compressive strength and torsional strength. Attached Figure Description

[0034] Figure 1 This is a schematic diagram of the structure of the present invention;

[0035] Figure 2 This is a schematic diagram of the force guiding the cable under pressure deformation according to the present invention;

[0036] Figure 3 This is a schematic diagram of the cable of the present invention subjected to torsional deformation force;

[0037] Figure 4 A schematic diagram of the compressive deformation guiding force when a rigid tension rope is provided for the cable of the present invention.

[0038] In the picture:

[0039] 100 Sheath layer, 200 Core wire, 201 Bundle tube, 202 Insulation shielding layer, 203 Conductive wire, 300 Protective structure layer, 301 Inner protective layer, 3011 Inner body, 3012 Rib, 30121 End, 302 Outer protective layer, 3021 Outer body, 3022 Arched structure, 30221 Filling groove, 30222 Acute angle, 30223 Filler material, 303 Rigid pull rope. Detailed Implementation

[0040] The present invention will be further described clearly and in detail below with reference to specific embodiments and the accompanying drawings. Those skilled in the art will be able to implement the present invention based on these descriptions. Furthermore, the embodiments of the present invention described below are generally only some, not all, of the embodiments of the present invention. Therefore, all other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the scope of protection of the present invention.

[0041] In the description of this invention, it should be understood that the terms "thickness," "upper," "lower," "horizontal," "top," "bottom," "inner," "outer," "circumferential," etc., indicating orientation or positional relationships, are based on the orientation or positional relationships shown in the accompanying drawings and are only for the convenience of describing the invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of the invention. In the description of this invention, "a plurality of" means at least two, such as two, three, etc., unless otherwise explicitly specified, and "several" means one or more.

[0042] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection, an electrical connection, or a connection that allows communication between them; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0043] Unless otherwise specified, all raw materials used in the embodiments of the present invention are commercially available or obtainable by those skilled in the art; unless otherwise specified, all methods used in the embodiments of the present invention are methods mastered by those skilled in the art.

[0044] Example

[0045] One such Figure 1 The aluminum alloy cable shown specifically includes:

[0046] Sheath layer 100, core wire 200 and protective structure layer 300;

[0047] The core wire 200 is composed of a bundle tube 201 covering a plurality of conductive wires 203. The conductive wires 203 are aluminum alloy conductive wires 203, used to realize power transmission and / or electrical signal transmission. The inner surface of the bundle tube 201 is also provided with an insulating shielding layer 202.

[0048] The protective structure layer 300 circumferentially covers the outer surface of the core wire 200, and the sheath layer 100 further circumferentially covers the outer surface of the protective structure layer 300.

[0049] The protective structure layer 300 is a double-layer structure consisting of an inner protective layer 301 and an outer protective layer 302;

[0050] The inner protective layer 301 includes a main body and ribs 3012. For ease of explanation and differentiation, the main body of the inner protective layer 301 is described as an inner body 3011 in the embodiment. The inner body 3011 is a hollow tube that fits tightly against and covers the outer surface of the core wire 200. The ribs 3012 are evenly distributed circumferentially on the outer surface of the inner body 3011. In the radial cross-section of the cable, the ribs 3012 are arc-shaped, with one end connected to the outer surface of the inner body 3011 and are evenly distributed and rotationally symmetrical. All the ribs 3012 are twisted in the same circumferential direction. This structure gives it good elastic deformation capability and can effectively buffer deformation when the cable is subjected to compressive force.

[0051] The outer protective layer 302 includes a main body and arched structures 3022. For ease of explanation and distinction, the main body of the outer protective layer 302 is described in this embodiment as an outer main body 3021. The outer main body 3021 is a hollow tubular structure that covers the radially outer side of the inner protective layer 301 and is tightly fitted to the inner surface of the sheath layer 100. The number of arched structures 3022 is equal to the number of ribs 3012 in the inner protective layer 301, and they are arranged in a one-to-one correspondence. The arched structures 3022 are located on the inner surface of the outer main body 3021, in the radial cross-section of the cable. The arched structure 3022 arches inward at an angle. Because it arches in an angle, the angles between it and the outer body 3021 are an acute angle 30222 and an obtuse angle, respectively. The end 30121 of the rib 3012 of the inner protective layer 301 abuts against the acute angle 30222 between the arched structure 3022 and the outer body 3021, so that the ribs 3012 of the inner protective layer 301 and the outer protective layer 302 and the arched structure 3022 can cooperate and be fixed together, improving the structural stability of both and producing a better cooperation effect.

[0052] With the cooperation of the aforementioned protective structure layer 300, the aluminum alloy cable of this invention can effectively solve the problem of insufficient compressive strength of existing aluminum alloy cables. As a low-cost alternative to oxygen-free copper cables, aluminum alloy cables have good conductivity, but their mechanical properties are significantly lower than those of oxygen-free copper cables. This is because, due to the inherent properties of the alloy conductive wire 203 in the aluminum alloy cable, its conductivity will rapidly decline after being subjected to deformation damage such as torsion and compression. Conventionally, cables are not as fragile as optical cables and do not require numerous protective structures. Furthermore, the high-voltage power transmission of cables does not allow for the use of conventional metal protective structures, which could easily create greater safety hazards. Even with multiple layers of insulation protection, the high density of metal protective structures would weaken the lightweight advantage of aluminum alloy cables, thus negating the fundamental purpose. Therefore, this invention uses a special insulating elastic rubber to prepare the protective structure layer 300. Through the cooperation of the inner protective layer 301 and the outer protective layer 302, as... Figure 2As shown, when the cable is subjected to an external radial force, the sheath layer 100 is transmitted inward along the outer protective layer 302 and the inner protective layer 301. During this process, due to the structural characteristics of the inner protective layer 301 and the outer protective layer 302, the ribs 3012 of the inner protective layer 301 will gradually approach the inner body 3011 and tend to "fit". Furthermore, the acute angle 30222 formed by the end 30121 of the ribs 3012 and the outer body 3021 and the arched structure 3022 will push the outer protective layer 302 to form a certain degree of torsion. Thus, the bending deformation of the ribs 3012 and the torsion of the outer protective layer 302, as well as the shrinkage deformation caused by the torsion, achieve the effect of buffering the external force, so that the external force is significantly weakened during the transmission process. On the other hand, the displacement of the arched structure 3022 caused by the torsion of the outer protective layer 302 will also compress the ribs 3012 and increase their deformation, thereby achieving a better buffering effect.

[0053] On the other hand, torsion damage is also one of the main forms of damage to aluminum alloy cables. Regarding torsion damage, as mentioned above, when... Figure 1 When the outer protective layer 302 shown is subjected to a clockwise torsional force, it will produce a similar effect to that produced when subjected to a radial external force. Figure 2 The deformation buffering effect shown is as follows: when the cable is subjected to the opposite counterclockwise torsional force, the special structural cooperation formed by the protective structural layer 300 in the cable of this invention will, as... Figure 3 As shown, the arched structure 3022 of the outer protective layer 302 pushes the ribs 3012 of the inner protective layer 301 outward, producing a deformation in the opposite arc direction. However, the ribs 3012 are restricted by the outer body 3021, thus producing a hardening effect, transforming from a flexible protective layer 300 into a rigid protective layer, thereby suppressing torsion and forming a torsion protection effect on the cable.

[0054] Furthermore,

[0055] The protective structure layer 300 of the present invention is further provided with a rigid pull rope 303. The rigid pull rope 303 is disposed on the radial inner side of the rib 3012 of the inner protective layer 301. A rigid pull rope 303 is provided for each rib 3012. Specifically, the rigid pull rope 303 used in this embodiment is a nylon fiber rope. The rigid pull rope 303 can further enhance the cable's resistance to pressure and torsion.

[0056] Firstly, because the rigid pull rope 303 can act as a stress-bearing point, when subjected to radial force or inward compressive force generated by the contraction of the protective structure layer 300 due to cable torsion, the rigid pull rope 303, due to its rigidity, can serve as a stress-bearing point located on the outside of the core wire 200, and to a certain extent, block the radial inward transmission of force. Secondly, the rigid pull rope 303, in conjunction with the inner protective layer 301 of the present invention, can also... Figure 4 As shown, this alters the deformation trend of the inner protective layer 301 under stress and compression to a certain extent;

[0057] like Figure 2 When the rigid tension rope 303 is not present, the rib 3012 undergoes elastic deformation in a "compliant" manner to absorb external forces and form a buffer. However, when the rigid tension rope 303 is present, the rib 3012 of the inner protective layer 301 will change its elastic deformation tendency. Figure 4 As shown, it will not completely conform to the outer surface of the inner body 3011 of the inner protective layer 301, but will increase the curvature to form a larger bending deformation, increase the elastic deformation range, thereby absorbing more external force and forming a better buffering effect.

[0058] In addition, the outer protective layer 302 has a filling groove 30221 in its arched structure 3022. The filling groove 30221 is filled with a filler material 30223. The filler material 30223 can be common fillers such as flame-retardant filler rope used in common cables, or it can be filled with elastic microspheres, such as common insulating silicone microspheres, in accordance with the structural features of the present invention. This will further enable the arched structure 3022 to more effectively achieve deformation and increase the elastic modulus, thereby achieving the absorption of more external forces and buffering.

Claims

1. An aluminum alloy cable, characterized in that, Specifically, it includes: Sheath layer, core wire and protective structural layer; The protective structure layer circumferentially covers the outer surface of the core wire, and the sheath layer further circumferentially covers the outer surface of the protective structure layer; The protective structure layer is a two-layer structure consisting of an inner protective layer and an outer protective layer; The inner protective layer includes an inner main body and ribs. The inner main body is a hollow tube that fits tightly to the outer surface of the core wire, while the ribs are evenly distributed circumferentially on the outer surface of the inner main body. In the radial cross-section of the cable, the ribs are arc-shaped, with one end connected to the outer surface of the inner main body and are evenly distributed and arranged in a rotationally symmetrical manner. The outer protective layer includes an outer main body and an arched structure. The outer main body is a hollow tube structure that covers the radially outer side of the inner protective layer and is tightly attached to the inner surface of the sheath layer. The number of arched structures is equal to the number of ribs in the inner protective layer, and the two are set in a one-to-one correspondence. The arched structure is located on the inner surface of the outer main body. On the radial cross section of the cable, the arched structure arches obliquely inward. The ribs and the arched structure abut against each other. The included angles between the outer main body of the outer protective layer and the arched structure are acute and obtuse angles, respectively. The rib end of the inner protective layer abuts against the acute angle between the arched structure and the outer main body, so that the ribs of the inner and outer protective layers and the arched structure can cooperate and be fixed together. The protective structure layer is also equipped with rigid pull ropes; The rigid pull rope is set on the radial inner side of the rib of the inner protective layer, and a rigid pull rope is provided for each rib.

2. The aluminum alloy cable according to claim 1, characterized in that, The ribs of the inner protective layer are all twisted in the same circumferential direction.

3. The aluminum alloy cable according to claim 1, characterized in that, The outer protective layer has a filling groove in its arched structure. The filling groove is filled with filler material.

4. The aluminum alloy cable according to claim 3, characterized in that, The filler is an insulating silicone ball.

5. The aluminum alloy cable according to any one of claims 1 to 4, characterized in that, The core wire is composed of several conductive wires wrapped in a bundle tube. The conductive wires are aluminum alloy conductive wires and are used to realize power transmission and / or electrical signal transmission. The inner surface of the bundle tube is also provided with an insulating shielding layer.

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