Prefabricated fused stress cone and manufacturing process

Abstract

The present invention relates to high-voltage power cable connection accessories, and discloses a prefabricated fused stress cone and a manufacturing process. It can be prefabricated in advance, can be cross-linked with the cable to form an integral body, effectively eliminates the micro-air gaps between the stress cone and the cable insulation layer and prevents polarization, and effectively improves the electrical performance stability and power transmission safety during cable power transmission. The present invention includes the following steps: manufacturing a stress control body, manufacturing a stress control body in a conical shape; manufacturing a fused stress cone, placing the stress control body in a first composite mold, injecting non-crosslinked polyethylene raw material into the first composite mold, the non-crosslinked polyethylene raw material passes through the stress control body, through heating and extrusion, the non-crosslinked polyethylene raw material forms a stress cone insulator, after cooling, the stress control body is sleeved on the outer wall of the stress cone insulator, and the stress control body and the stress cone insulator are melt-grafted and cross-linked to combine, forming a fused stress cone with an integral welding structure.

Description

Technical Field

[0001] The present invention relates to high-voltage power cable connection accessories, in particular to a prefabricated fused stress cone and a manufacturing process thereof. Background Art

[0002] A high-voltage power cable is a power device used for high-voltage electric energy transmission, and is mostly applied to long-distance and large-length power transmission and distribution. In actual application of high-voltage cables, the electric field is concentrated at the cable terminal position. The uniform distribution of this electric field and the realization of stable electrical performance are completed by the cable terminal stress cone. Therefore, an accessory - a cable terminal plug-and-play connector is required at the high-voltage cable terminal, which can make the electric field constant, dispersed and homogenized, so that the concentrated field strength can be restored to the normal electrical operation state.

[0003] Currently, the plug-and-play connectors of cable terminals generally adopt a rubber prefabricated design. This design utilizes the excellent elasticity of the rubber stress cone to enable it to closely fit on the insulating layer of the cable. However, since heat is generated during the long-term continuous current-carrying operation of the cable, this thermal effect will cause the insulating layer of the cable to gradually soften. With the continuous clamping action of the rubber stress cone on the cable, the diameter of the cable insulating layer will shrink, and at the same time, the interfacial pressure between the rubber and the insulating layer will also be weakened accordingly; at the same time, the microscopic interface between the stress cone insulation and the cable insulation is polarized under the action of high electric field strength and thermal field, ultimately resulting in a decrease in the maximum breakdown electric field strength that the cable can withstand.

[0004] In the existing cable plug-and-play connector structure, during the long-term operation of the cable, the stress cone insulation and the cable insulation are in a high-field sensitive area with a movable interface. This interface is affected by the dual action of the electric field and the thermal field. This action causes polarization of the tiny air gaps between the stress cone and the cable inside the connector and the trace moisture and impurities on the interface. The polarization effect will cause distortion of the interface electric field between the stress cone and the cable insulating layer in the high electric field strength area, thereby increasing the risk of surface discharge and leading to breakdown of the insulating layer. Moreover, the plug-and-play connector of the cable terminal needs to be prefabricated in advance, which should be convenient for transportation and storage, and can be directly and quickly fused with the high-voltage cable terminal on site to completely eliminate the electrical hidden dangers of the micro-air gap interface. Summary of the Invention

[0005] The present invention aims to solve at least one of the technical problems existing in the prior art. For this purpose, the present invention provides a prefabricated fused stress cone and a manufacturing process thereof, which can be prefabricated in advance, can be cross-linked with the cable to form an integral body, effectively eliminate the micro-air gap between the stress cone and the cable insulating layer and prevent polarization, and effectively improve the electrical performance stability and power transmission safety during cable power transmission.

[0006] In a first aspect, a manufacturing process of a prefabricated fused stress cone according to an embodiment of the present invention includes the following steps:

[0007] Fabricate a stress control body, and fabricate the stress control body in a conical shape;

[0008] Fabricate a fused stress cone. Place the stress control body in a first composite mold, and inject a non-crosslinked polyethylene raw material into the first composite mold. The non-crosslinked polyethylene raw material passes through the stress control body. Through heating and extrusion, the non-crosslinked polyethylene raw material forms a stress cone insulator. After cooling, the stress control body is sleeved on the outer wall of the stress cone insulator, and the stress control body and the stress cone insulator are melt grafted and crosslinked to form a fused stress cone with an integral welded structure.

[0009] Second aspect, a manufacturing process for a prefabricated fused stress cone according to an embodiment of the present invention includes the following steps:

[0010] Fabricate a stress control body, and fabricate the stress control body in a conical shape;

[0011] Fabricate a stress cone insulator. The stress cone insulator is made of a non-crosslinked polyethylene raw material, and both ends of the stress cone insulator extend outward along the axis direction of the stress cone insulator.

[0012] Fabricate a fused stress cone. Sleeve the stress control body on the outer wall of the stress cone insulator, and synchronously place them in a first composite mold. Through heating and extrusion, the stress control body and the stress cone insulator are melt grafted and crosslinked to form a fused stress cone with an integral welded structure.

[0013] Third aspect, a manufacturing process for a prefabricated fused stress cone according to an embodiment of the present invention includes the following steps:

[0014] Fabricate a stress cone insulator. The stress cone insulator is made of a non-crosslinked polyethylene raw material, and both ends of the stress cone insulator extend outward along the axis direction of the stress cone insulator. The stress cone insulator has a connection hole for sleeving a cable. The connection hole extends along the axis of the stress cone insulator and penetrates through the stress cone insulator.

[0015] On-site welding and installation. Sleeve the stress cone insulator on the cable, and the inner wall of the stress cone insulator is sequentially attached to the insulation layer and the insulation shielding layer of the cable. Place the stress cone insulator and the cable in a third composite mold. Through heating, the stress cone insulator and the insulation layer of the cable are melt grafted and crosslinked to form an integral welded structure.

[0016] Fabricate a stress control body, and fabricate the stress control body in a conical shape;

[0017] Manufacture a fused stress cone, sleave the stress control body on the outer wall of the stress cone insulator, and synchronously place the stress control body, the stress cone insulator, and the cable in a second composite mold. Through heating and extrusion, the stress control body and the stress cone insulator are melt-grafted and crosslinked together to form a fused stress cone with an integral welded structure.

[0018] Fourthly, a prefabricated fused stress cone according to an embodiment of the present invention includes a stress cone insulator and a stress control body; the stress cone insulator is made of non-crosslinked polyethylene raw material, and the stress cone insulator is used for sleaving a cable; the stress control body is sleaved on the outer wall of the stress cone insulator, and the stress control body and the stress cone insulator are melt-grafted and crosslinked together to form an integral welded structure.

[0019] The embodiment of the present invention has at least the following beneficial effects: The stress cone insulator made of non-crosslinked polyethylene raw material can not only achieve composite crosslinking with the stress control body through heating and extrusion, but also because the stress cone insulator is made of non-crosslinked polyethylene raw material, the characteristics of this material enable it to combine and crosslink with crosslinked polyethylene, that is, the stress cone insulator can be combined and crosslinked with the insulating layer of the cable through the method of melt grafting to form a seamless integral fused structure. This combination method enables the fusion interface between two different materials to reach a grafting combination state without air gaps and interfaces, thereby ensuring that the stress cone insulator and the insulating layer of the cable can be completely fused to form a unified whole. During the power transmission operation of the cable, the situation of electric field distortion and breakdown caused by microscopic air gaps in the insulation structure can be eliminated or avoided, effectively improving the safety and reliability of cable power transmission; in addition, prefabricating the fused stress cone or the stress cone insulator and the stress control body in advance not only simplifies the steps and difficulties of on-site welding installation, but also facilitates transportation and storage. The power transmission site can store the required fused stress cones or stress cone insulators and stress control bodies in advance, which is convenient for replacement and on-site welding installation at any time, effectively improving the convenience and reliability.

[0020] The additional aspects and advantages of the present invention will be partially given in the following description, partially become obvious from the following description, or be understood through the practice of the present invention. Description of the Drawings

[0021] The above and / or additional aspects and advantages of the present invention will become obvious and easy to understand from the description of the embodiments in conjunction with the following drawings, where:

[0022] Figure 1 It is a schematic structural diagram of a fused stress cone manufactured by using the manufacturing process of the first embodiment of the present invention;

[0023] Figure 2 is Figure 1 a cross-sectional view showing the structure;

[0024] Figure 3 is Figure 1 a schematic exploded view showing the structure;

[0025] Figure 4 is Figure 3 a cross-sectional view showing the structure;

[0026] Figure 5 is Figure 3 a plan cross-sectional view showing the structure;

[0027] Figure 6 is Figure 3 a cross-sectional view showing the structure from another angle;

[0028] Figure 7 a schematic structural view of the cable installed by applying the embodiments of the present invention;

[0029] Figure 8 a schematic view of the state after the fusion stress cone of the embodiment of the present invention is installed on the cable;

[0030] Figure 9 a schematic comparison view of the structures of four different fusion stress cones made by applying the manufacturing process of the present invention;

[0031] Figure 10 is Figure 9 a plan cross-sectional view showing the structure;

[0032] Figure 11 is Figure 9 a schematic comparison view of the structures of four different stress cone control bodies of the structure;

[0033] Figure 12 is Figure 11 a plan cross-sectional view showing the structure;

[0034] Figure 13 a schematic structural view of the fusion stress cone made by applying the manufacturing process of the second embodiment of the present invention;

[0035] Figure 14 is Figure 13 a plan cross-sectional view showing the structure;

[0036] Figure 15 is Figure 14 a schematic exploded view showing the structure;

[0037] Figure 16 is Figure 13 a schematic exploded view showing the structure;

[0038] Figure 17 a schematic structural view of the fusion stress cone made by applying the manufacturing process of the third embodiment of the present invention;

[0039] Figure 18 is Figure 13 a schematic exploded view showing the structure;

[0040] Figure 19 is Figure 13 a schematic exploded view showing the structure from another angle;

[0041] Figure 20 is Figure 13 a schematic plan sectional view showing the structure;

[0042] Figure 21 is Figure 20 a schematic exploded view showing the structure.

[0043] Reference numerals:

[0044] Detailed implementation manners

[0045] The following will clearly and completely describe the concept, specific structure and technical effects of the present invention in combination with the embodiments and the drawings, so as to fully understand the purpose, solution and effects of the present invention. It should be noted that, without conflict, the embodiments in the present application and the features in the embodiments can be combined with each other.

[0046] It should be noted that, unless otherwise specified, when a certain feature is referred to as "fixed" or "connected" to another feature, it can be directly fixed or connected to the other feature, or indirectly fixed or connected to the other feature. In addition, the up, down, left, right, top, bottom, etc. used in the present invention are only relative to the mutual positional relationship of the components of the present invention in the drawings.

[0047] In addition, unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by those skilled in the technical field of the present invention. The terms used in the description of the present invention herein are only for the purpose of describing specific embodiments, and are not intended to limit the present invention. The term "and / or" used herein includes any combination of one or more of the related listed items.

[0048] It should be understood that although the terms first, second, third, etc. may be used in the present disclosure to describe various elements, these elements should not be limited to these terms. These terms are only used to distinguish elements of the same type from each other. For example, without departing from the scope of the present disclosure, the first element may also be referred to as the second element, and similarly, the second element may also be referred to as the first element.

[0049] In the first aspect, referring to Figures 1 to 6 , or Figures 9 to 12 , or Figures 13 to 16 , or Figures 17 to 21, The manufacturing process of the prefabricated fused stress cone according to the embodiments of the present invention includes the following steps:

[0050] Manufacture the stress control body 1200, and manufacture the conical stress control body 1200;

[0051] Manufacture the fused stress cone 1000. Place the stress control body 1200 in the first composite mold, and inject non-crosslinked polyethylene raw material into the first composite mold. The non-crosslinked polyethylene raw material passes through the stress control body 1200. Through heating and extrusion, the non-crosslinked polyethylene raw material forms the stress cone insulator 1100. After cooling, the stress control body 1200 is sleeved on the outer wall of the stress cone insulator 1100, and the stress control body 1200 and the stress cone insulator 1100 are melt-grafted and crosslinked to form the fused stress cone 1000 with an integral welded structure.

[0052] In some embodiments of the present invention, the stress control body 1200 is conical. The wider end of the stress control body 1200 is provided with a third ring flange 1210, so that the end of the stress control body 1200 extends radially outward.

[0053] It can be known that the stress control body 1200 is made of a semiconductive raw material. Those skilled in the art can determine the stress curve parameters of the stress control body 1200 according to the requirements of the actual transmission parameters of the cable 2000, and then can determine the shape of the inner cavity of the mold, so that the design of the shape of the stress control body 1200 meets the requirements.

[0054] It can be known that the shape of the stress cone insulator 1100 can also be designed according to the design requirements for the shape of the model in the first composite mold, so that the shape of the fused stress cone 1000 meets the requirements. That is, the stress cone insulator 1100 and the stress control body 1200 are arranged according to the electrical stress structure. The electrical stress is evenly distributed according to the stress cone and maintained at a certain pressure level, which can ensure the working stability of the cable 2000 terminal. And after the stress control body 1200 and the stress cone insulator 1100 are melt-grafted and crosslinked, the surfaces of the stress cone insulator 1100 and the stress control body 1200 in contact with each other are tightly attached, and the two are compounded and crosslinked. That is, the stress control body 1200 and the stress cone insulator 1100 are like an integrally formed structure and will be firmly connected together. It also improves the stability and reliability of the two, ensuring that neither of them will separate or have air gaps under long-term high temperature and high pressure, effectively improving safety.

[0055] It is known that the insulating layer 2200 of the cable 2000 is made of cross-linked polyethylene material. However, when two objects made of the same cross-linked polyethylene material attempt to be joined by melting, it is very difficult to achieve a true fusion between them. This is because after the fusion connection, there is often an obvious and non-fused interface between the two, and this microscopic air gap is the cause of electric field distortion, promoting the hidden danger of the generation of electrical trees, and further leading to the risk of breakdown accidents during the operation of the cable terminal.

[0056] In the present invention, the stress cone insulator 1100 is made of non-cross-linked polyethylene raw material, and the characteristics of this material enable it to be tightly combined with the main body of the insulating layer 2200 of the cable 2000 by means of fusion welding. Specifically, the stress cone insulator 1100 can be cross-linked and combined with the insulating layer 2200 of the cable 2000 by means of melt grafting to form a seamless integral fusion structure. This combination method enables the fusion interface between the two different materials to reach a grafting combination state without air gaps and interfaces, thus ensuring that the stress cone insulator 1100 and the insulating layer 2200 of the cable 2000 can be completely fused to form a unified whole.

[0057] This fusion not only greatly improves the breakdown strength, but also due to the combination and cross-linking of non-cross-linked polyethylene and cross-linked polyethylene, a thermosetting integral structure is formed, that is, an irreversible three-dimensional network structure is possessed. This means that once the two are combined, they cannot be separated by simple physical methods (such as heating or dissolving). In addition, this integral structure also exhibits better high-temperature resistance performance, enabling the cable 2000 and the fused stress cone 1000 to maintain long-term stable operation when the operating temperature of the cable conductor is at 115 °C, thus significantly improving the stability and safety of the cable during power transmission.

[0058] Through this innovative material combination technology, taking the fused stress cone 1000 as the plug-in connector of the cable terminal of the cable 2000, its overall performance has been significantly improved, providing a strong guarantee for the reliability and efficiency of power transmission.

[0059] Reference Figure 7 , in some embodiments of the present invention, before the on-site fusion installation, the outer wall of the cable 2000 is dissected to strip the conductor 2100, the insulating layer 2200, and the insulating shielding layer 2300 from the cable 2000. And polishing and cleaning its surface can improve the fusion effect between the cable 2000 and the stress cone insulator 1100, and further improve the stability and reliability.

[0060] Reference Figure 8 , in some embodiments of the present invention, the following steps are further included:

[0061] For on-site welding installation, 1000 sets of fused stress cones are sleeved on the cable 2000, and the inner wall of the stress cone insulator 1100 is successively attached to the insulation layer 2200 and the insulation shielding layer 2300 of the cable 2000. The fused stress cone 1000 and the cable 2000 are placed in the second composite mold. Through heating, the stress cone insulator 1100 and the insulation layer 2200 of the cable 2000 are melted, grafted, cross-linked and combined to form an integral welding structure.

[0062] In some embodiments of the present invention, after the second composite mold is started, it is heated to 125°C to 205°C and maintained for 40 minutes to 60 minutes.

[0063] Making the second composite mold work at a state of being heated to 125°C to 205°C and maintained for 40 minutes to 60 minutes can improve the effect of the fused grafting combination between the insulation layer 2200 of the cable 2000 and the stress cone insulator 1100, enabling the two to be fully fused to form a unified whole, that is, the stress cone insulator 1100 is just like growing on the insulation layer 2200 of the cable 2000.

[0064] Specifically, in some embodiments of the present invention, the second composite mold can work at 135°C to 195°C and be maintained for 45 minutes to 55 minutes.

[0065] The stress cone insulator 1100 and the insulation layer 2200 of the cable 2000 are melted, grafted, cross-linked and combined to form an integral welding structure, enabling the fusion interface between the two to have no air gap, and thus having the characteristic of high breakdown strength. Since the stress cone insulator 1100 is made of non-crosslinked polyethylene raw material, the characteristics of this material enable it to be tightly combined with the main body of the insulation layer 2200 of the cable 2000 by means of welding. Specifically, the stress cone insulator 1100 can be combined and cross-linked with the insulation layer 2200 of the cable 2000 by means of melt grafting to form a seamless integral fusion structure. This combination method enables the fusion interface between two different materials to reach a state of grafting combination without air gap and without interface, thus ensuring that the stress cone insulator 1100 and the insulation layer 2200 of the cable 2000 can be fully fused to form a unified whole.

[0066] In some embodiments of the present invention, both ends of the stress cone insulator 1100 extend outward along the axis direction of the stress cone insulator 1100. The stress cone insulator 1100 has a connection hole 1140 for sleeving the cable 2000. The connection hole 1140 extends along the axis of the stress cone insulator 1100 and penetrates through the stress cone insulator 1100.

[0067] It can be known that the stress cone insulator 1100 can have the connection hole 1140 directly processed by the first composite mold, or the connection hole 1140 can be prefabricated without processing and then processed on-site according to the size of the cable 2000, and the size of the connection hole 1140 is determined by drilling. During actual on-site processing, the cable 2000 is threaded into the connection hole 1140 to obtain an assembly, and then processed using the second composite mold. After cooling, the fused stress cone 1000 will adhere to the insulating layer 2200 of the cable 2000 to form an integral structure, that is, the stress cone insulator 1100 is like growing on the cable 2000.

[0068] It can be known that in some embodiments of the present invention, the stress control body 1200 conforms to the stress curve. Therefore, the shape of the mold cavity in the stress control body mold can be designed according to the stress curve, so that the shape of the stress control body 1200 meets the requirements, that is, by using molds with different mold cavity shapes, the shape of the stress control body 1200 can include but is not limited to Figures 9 to 12 the four shapes in; among them, Figures 9 to 12 A1, A2, A3, and A4 in are the fused stress cones 1000 of the same group, Figures 9 to 12 B1, B2, B3, and B4 in are the fused stress cones 1000 of the same group, Figures 9 to 12 C1, C2, C3, and C4 in are the fused stress cones 1000 of the same group, Figures 9 to 12 D1, D2, D3, and D4 in are the fused stress cones 1000 of the same group. Combining with the drawings, it can be known that the specific shapes of the stress control body 1200 and the stress cone insulator 1100 can be designed according to the actual working parameters of the cable 2000 and combined with the stress curve to design molds with corresponding shapes, and then the required shapes can be processed.

[0069] In some embodiments of the present invention, the steps of manufacturing the stress control body 1200 specifically include:

[0070] Start the first extruder filled with semi-conductive raw materials, preheat the first extruder at 100°C to 190°C, and the preheating duration is 30 minutes to 50 minutes;

[0071] Start the stress control body mold with the mold closed and locked, heat it to 120°C to 190°C, and maintain it for 35 minutes to 45 minutes;

[0072] Start the first extruder to inject molten semi-conductive raw materials from the first extruder into the stress control body mold;

[0073] When the glue overflows from the glue overflow port of the stress control body mold, stop the glue extrusion of the first extruder, and raise the temperature of the stress control body mold to 180°C to 230°C, and maintain it for 1 hour 30 minutes to 2 hours 30 minutes;

[0074] Stop heating the stress control body mold. After the stress control body mold is cooled to room temperature, take out the stress control body 1200.

[0075] Further, in some embodiments of the present invention, the steps of manufacturing the stress control body 1200 specifically include:

[0076] Start the first extruder filled with semiconductive raw materials, preheat the first extruder at 110°C to 180°C, and the preheating duration is 35 minutes to 45 minutes;

[0077] Start the stress control body mold with the mold closed and locked, heat it to 130°C to 180°C, and maintain for 35 minutes to 45 minutes;

[0078] Start the first extruder to inject molten semiconductive raw materials from the first extruder into the stress control body mold;

[0079] When the overflow port of the stress control body mold discharges glue, stop the glue extrusion of the first extruder, and raise the temperature of the stress control body mold to 190°C to 220°C, and maintain for 1 hour and 40 minutes to 2 hours;

[0080] Stop heating the stress control body mold. After the stress control body mold is cooled to room temperature, take out the stress control body 1200.

[0081] According to the method of manufacturing the stress control body 1200 using the stress control body mold of the present invention, the semiconductive material in the mold cavity can be fully cross-linked, avoiding problems such as air gaps, thereby ensuring the stability and reliability of the stress control body 1200.

[0082] In some embodiments of the present invention, the stress control body 1200 is integrally made of a super-smooth semiconductive material. The stress control body 1200 uses a super-smooth semiconductive material, which can effectively and evenly disperse the electric field, reduce the electric field concentration phenomenon, thereby reducing the electric field strength and avoiding the occurrence of breakdown discharge; at the same time, it can improve the material bonding degree, ensure a high material bonding degree with the stress cone insulator 1100, and form a more stable stress cone structure; it can also make the stress cone control body structure lighter, while being easy to process and install, saving costs; and it can improve reliability, and the residual processing stress on the super-smooth surface is extremely small, which helps to improve the reliability and stability of the cable 2000 during power transmission.

[0083] In some embodiments of the present invention, the specific steps of manufacturing the fused stress cone 1000 include:

[0084] Start the second extruder filled with non-crosslinked polyethylene raw materials, preheat the second extruder at 120°C to 200°C, and the preheating duration is 30 minutes to 50 minutes;

[0085] Place the stress control body 1200 at the corresponding position in the cavity of the first composite die, close the die and lock it, start the first composite die, heat it to 120°C to 170°C, and maintain for 20 minutes to 40 minutes;

[0086] Start the second extruder, and let the second extruder inject molten non-crosslinked polyethylene raw material into the first composite die, and keep the pressure in the first composite die at 10 kg / cm² to 18 kg / cm²;

[0087] When the overflow port of the first composite die discharges glue, stop the second extruder from extruding glue, and raise the temperature of the first composite die to 150°C to 190°C, and maintain for 40 minutes to 60 minutes, so that the stress control body 1200 and the stress cone insulator 1100 are melted, grafted and crosslinked to form a fused stress cone 1000 with an integral welded structure;

[0088] Stop heating the first composite die. After the first composite die cools to room temperature, take out the fused stress cone 1000.

[0089] In some embodiments of the present invention, the specific steps for manufacturing the fused stress cone 1000 include:

[0090] Start the second extruder filled with non-crosslinked polyethylene raw material, preheat the second extruder at 130°C to 190°C, and the preheating duration is 35 minutes to 45 minutes;

[0091] Place the stress control body 1200 at the corresponding position in the cavity of the first composite die, close the die and lock it, start the first composite die, heat it to 130°C to 160°C, and maintain for 25 minutes to 35 minutes;

[0092] Start the second extruder, and let the second extruder inject molten non-crosslinked polyethylene raw material into the first composite die, and keep the pressure in the first composite die at 11 kg / cm² to 17 kg / cm²;

[0093] When the overflow port of the first composite die discharges glue, stop the second extruder from extruding glue, and raise the temperature of the first composite die to 160°C to 180°C, and maintain for 45 minutes to 55 minutes, so that the stress control body 1200 and the stress cone insulator 1100 are melted, grafted and crosslinked to form a fused stress cone 1000 with an integral welded structure;

[0094] Stop heating the first composite die. After the first composite die cools to room temperature, take out the fused stress cone 1000.

[0095] A prefabricated fused stress cone according to an embodiment of the present invention includes a stress cone insulator 1100 and a stress control body 1200. The stress cone insulator 1100 is made of non-crosslinked polyethylene raw material and is used to sleeve the cable 2000. The stress control body 1200 is sleeved on the outer wall of the stress cone insulator 1100, and the stress control body 1200 and the stress cone insulator 1100 are in a molten graft crosslinking combination to form an integral welded structure.

[0096] In the present invention, the stress cone insulator 1100 is made of non-crosslinked polyethylene raw material, and the characteristics of this material enable it to be tightly combined with the main body of the insulating layer 2200 of the cable 2000 by means of welding. Specifically, the stress cone insulator 1100 and the insulating layer 2200 of the cable 2000 can be crosslinked and combined by means of melt grafting to form a seamless integral fusion structure. This combination method enables the fusion interface between the two different materials to reach a grafting combination state without air gaps and interfaces, thereby ensuring that the stress cone insulator 1100 and the insulating layer 2200 of the cable 2000 can be completely fused to form a unified whole.

[0097] This fusion not only greatly improves the breakdown strength, but also forms a thermosetting integral structure due to the combination of non-crosslinked polyethylene and crosslinked polyethylene, that is, it has an irreversible three-dimensional network structure. This means that once the two are combined, they cannot be separated by simple physical methods (such as heating or dissolving). In addition, this integral structure also exhibits better high-temperature resistance, enabling the cable 2000 and the fused stress cone to work stably and for a long time in an environment up to 150°C, thereby significantly improving the stability and safety of the cable during power transmission.

[0098] Through this innovative material combination technology, taking the fused stress cone 1000 as the plug-and-play connector of the cable terminal of the cable 2000, its overall performance has been significantly improved, providing a strong guarantee for the reliability and efficiency of power transmission.

[0099] First Embodiment:

[0100] The manufacturing process of the prefabricated fused stress cone according to the first embodiment of the present invention includes the following steps:

[0101] Manufacture the stress control body 1200, and manufacture the stress control body 1200 in a conical shape;

[0102] Fabricate the fused stress cone 1000, place the stress control body 1200 in the first composite mold, and inject non-crosslinked polyethylene raw material into the first composite mold. The non-crosslinked polyethylene raw material passes through the stress control body 1200. Through heating and extrusion, the non-crosslinked polyethylene raw material forms the stress cone insulator 1100. After cooling, the stress control body 1200 is sleeved on the outer wall of the stress cone insulator 1100, and the stress control body 1200 and the stress cone insulator 1100 are melt-grafted and crosslinked to form the fused stress cone 1000 with an integral welded structure.

[0103] Specifically, in the first embodiment, the steps of fabricating the stress control body 1200 specifically include:

[0104] Start the first extruder filled with semiconductive raw material, preheat the first extruder to 145°C, and the preheating duration is 40 minutes;

[0105] Start the stress control body mold with the mold closed and locked, heat it to 155°C, and maintain for 40 minutes;

[0106] Start the first extruder, and make the first extruder inject the molten semiconductive raw material into the stress control body mold;

[0107] When the overflow port of the stress control body mold discharges glue, stop the first extruder from extruding glue, and raise the temperature of the stress control body mold to 205°C, and maintain for 1 hour and 50 minutes;

[0108] Stop heating the stress control body mold, cool the stress control body mold to room temperature, and then take out the stress control body 1200.

[0109] In the first embodiment, the specific steps of fabricating the fused stress cone 1000 include:

[0110] Start the second extruder filled with non-crosslinked polyethylene raw material, preheat the second extruder to 160°C, and the preheating duration is 40 minutes;

[0111] Place the stress control body 1200 in the corresponding position in the cavity of the first composite mold and close and lock the mold. Start the first composite mold, heat it to 145°C, and maintain for 30 minutes;

[0112] Start the second extruder, and make the second extruder inject the molten non-crosslinked polyethylene raw material into the first composite mold, and keep the pressure in the first composite mold at 14 kg / cm²;

[0113] When the overflow port of the first composite mold discharges glue, stop the second extruder from extruding glue, and raise the temperature of the first composite mold to 170°C, and maintain for 50 minutes, so that the stress control body 1200 and the stress cone insulator 1100 are melt-grafted and crosslinked to form the fused stress cone 1000 with an integral welded structure;

[0114] Stop heating the first composite mold. After the first composite mold cools down to room temperature, take out the fused stress cone 1000.

[0115] In the first embodiment, after applying the manufacturing process of the first aspect embodiment, a prefabricated fused stress cone 1000 is made for connecting the cable 2000, including a stress cone insulator 1100 and a stress control body 1200; the stress cone insulator 1100 is made of non-crosslinked polyethylene raw material. The two ends of the stress cone insulator 1100 extend outward along the axis direction of the stress cone insulator 1100. The stress cone insulator 1100 is used for sleeving the cable 2000; the stress control body 1200 is sleeved on the outer wall of the stress cone insulator 1100, and the stress control body 1200 and the stress cone insulator 1100 are melt grafted and crosslinked to form an integral welded structure.

[0116] Refer to Figures 1 to 6 , in the first embodiment, the stress cone insulator 1100 includes a first cylindrical barrel portion 1110, a first stress cone connection portion 1120, and a second cylindrical barrel portion 1130; the longest diameter of the cross section of the first cylindrical barrel portion 1110 is the first diameter; the first stress cone connection portion 1120 is conical. The wider end of the first stress cone connection portion 1120 is connected to one end of the first cylindrical barrel portion 1110, and the first stress cone connection portion 1120 penetrates into the stress control body 1200; the longest diameter of the cross section of the second cylindrical barrel portion 1130 is the second diameter, and the second diameter is smaller than the first diameter. One end of the second cylindrical barrel portion 1130 is connected to the narrower end of the first stress cone connection portion 1120 and the connection is continuously transitional.

[0117] In the first embodiment, a first ring flange 1111 is provided at the connection between the first cylindrical barrel portion 1110 and the first stress cone connection portion 1120, and the first ring flange 1111 surrounds the first stress cone connection portion 1120. Setting the first ring flange 1111 can meet the requirements of the electric stress structure setting, and further ensure the adaptation with the stress control body 1200 and ensure that the stress cones are evenly distributed and maintained at a certain pressure level after the electric stress installation, thus ensuring the working stability of the cable 2000 terminal. At the same time, the stress control body 1200 is arranged on the first stress cone connection portion 1120 and is melt connected to the first stress cone connection portion 1120; at this time, the side of the first ring flange 1111 facing the axis of the stress cone insulator 1100 is melt connected to the surface of the stress control body 1200, which can not only ensure that the stress control body 1200 can be firmly connected to the stress cone insulator 1100, but also ensure that the stress cones of the electric stress installation are evenly distributed and maintained at a certain pressure level.

[0118] In the first embodiment, the first cylindrical barrel portion 1110, the first stress cone connection portion 1120, and the second cylindrical barrel portion 1130 are integrally formed structures. The inner wall opening diameters of the first cylindrical barrel portion 1110, the first stress cone connection portion 1120, and the second cylindrical barrel portion 1130 are the same, and a connection hole 1140 is formed through the stress cone insulator 1100. The connection hole 1140 is used for sleeving the cable 2000. It can be known that the first cylindrical barrel portion 1110, the first stress cone connection portion 1120, and the second cylindrical barrel portion 1130 can be made by molds with corresponding cavity shapes.

[0119] In the first embodiment, the stress control body 1200 is in a conical shape. The wider end of the stress control body 1200 is provided as the third ring flange 1210, so that the end of the stress control body 1200 extends radially outward. When the stress control body 1200 is fused and connected to the stress cone insulator 1100, the outer wall of the third ring flange 1210 is fused and connected to the side of the first ring flange 1111 facing the axis of the stress cone insulator 1100. After the two are matched, it can not only ensure the stability between the two, but also ensure that the stress cones of the electrical stress installation are evenly distributed and maintained at a certain pressure level.

[0120] With the above processing parameters, the stress cone insulator 1100 and the stress control body 1200 can be fully grafted, combined, and crosslinked, so that there will be no air gaps or separations at the interface between the stress cone insulator 1100 and the stress control body 1200, and the stability of the fused stress cone 1000 can be improved. At the same time, prefabricating the fused stress cone 1000 in advance can facilitate transportation and storage, and will not cause the performance of the fused stress cone 1000 to decline due to long-term storage. And spare parts can be provided at the power transmission site. When problems occur and replacement or new requirements are needed, the stocked items can be directly taken for installation, improving convenience and reliability.

[0121] In the first embodiment, when the fused stress cone 1000 is welded and installed on site, referring to Figure 8 , the following steps are further included:

[0122] For on-site welding installation, the fused stress cone 1000 is sleeved on the cable 2000, and the inner wall of the stress cone insulator 1100 is sequentially attached to the insulation layer 2200 and the insulation shielding layer 2300 of the cable 2000. The fused stress cone 1000 and the cable 2000 are placed in the second composite mold. By heating, specifically, making the second composite mold work at a temperature of 165°C and maintaining it for 50 minutes, the stress cone insulator 1100 and the insulation layer 2200 of the cable 2000 can be fused, grafted, crosslinked, and combined to form an integral welded structure.

[0123] After cooling, take it out, then the insulating layer 2200 of the cable 2000 and the stress cone insulator 1100 will be melt-grafted and combined, so that the two are fully fused to form an integral whole, that is, the stress cone insulator 1100 grows on the insulating layer 2200 of the cable 2000. Among them, before on-site fusion installation, the surface of the cable 2000 has been anatomized and polished and cleaned in advance as required.

[0124] Second Embodiment:

[0125] The main difference in the manufacturing process between the second embodiment and the first embodiment is that the cavity shape of the corresponding mold in the second embodiment is different, that is, the shape of the overall fused stress cone 1000 will be different, but the overall process is still carried out according to the manufacturing process of the prefabricated fused stress cone in the first aspect of the present invention. Among them, the temperature and the time of heating and extrusion may be appropriately adjusted according to actual needs.

[0126] Refer to Figures 13 to 16 , in the second embodiment, the stress cone insulator 1100 includes a conical cylindrical part 1150, a second stress cone connecting part 1160, and a third cylindrical part 1170; the second stress cone connecting part 1160 is conical, and the wider end of the second stress cone connecting part 1160 is connected to the wider end of the conical cylindrical part 1150, and the first stress cone connecting part 1120 is inserted into the stress control body 1200; one end of the third cylindrical part 1170 is connected to the narrower end of the first stress cone connecting part 1120 and the connection is a continuous transition.

[0127] In the second embodiment, a second ring flange 1151 is provided at the connection between the conical cylindrical part 1150 and the second stress cone connecting part 1160, and the second ring flange 1151 surrounds the second stress cone connecting part 1160. The conical cylindrical part 1150, the second stress cone connecting part 1160, and the third cylindrical part 1170 are an integrally formed structure. The inner wall opening diameters of the conical cylindrical part 1150, the second stress cone connecting part 1160, and the third cylindrical part 1170 are the same and form a connection hole 1140 penetrating the stress cone insulator 1100, and the connection hole 1140 is used for sleeving the cable 2000.

[0128] In the second embodiment, the overall stress control body 1200 is also conical. A third ring flange 1210 is also provided at the wider end of the stress control body 1200, so that the end of the stress control body 1200 extends radially outward. When the stress control body 1200 is melt-connected to the stress cone insulator 1100, the outer wall of the third ring flange 1210 is melt-connected to the side of the second ring flange 1151 facing the axis of the stress cone insulator 1100. After the two are combined, it can not only ensure the stability between the two, but also ensure that the stress cones of the electrical stress installation are evenly distributed and maintained at a certain pressure level.

[0129] Similarly, in the second embodiment, through the steps of on-site fusion installation, the fusion stress cone 1000 is sleeved on the cable 2000, and through heating and extrusion, the cable 2000 and the fusion stress cone 1000 are melt-connected to form an integral structure.

[0130] It can be known that the main difference between the second embodiment and the first embodiment lies in that a part of the surface of the stress cone insulator 1100 has a greater inclination and is cone-shaped, which is mainly designed according to the actual requirements of the cable 2000.

[0131] Third embodiment:

[0132] Referring to Figures 17 to 21 , the main difference in the manufacturing process between the third embodiment and the second embodiment is that the cavity shape of the corresponding mold in the third embodiment is different, that is, the shape of the insulator of the fusion stress cone 1000 will be different. The stress cone insulator 1100 in the third embodiment is also cone-shaped, but compared with the second embodiment, the cone angle of the conical cylinder part 1150 in the third embodiment is smaller. Therefore, the main difference between the third embodiment and the second embodiment lies in that the surface inclination of the stress cone insulator 1100 is smaller, which is mainly designed according to the actual requirements of the cable 2000. The overall process steps still follow the manufacturing process of the prefabricated fusion stress cone in the first aspect of the present invention, and among them, the temperature and the heating and extrusion time may be appropriately adjusted according to actual requirements.

[0133] Combined with the embodiments of the first aspect, it can be known that the conical cylinder part 1150, the second stress cone connection part 1160, and the third cylindrical cylinder part 1170 can be made by molds with corresponding cavity shapes.

[0134] In addition, it can be known that the stress cone insulator 1100 can also be first made into a structure in the form of a whole cylinder, then the stress control body 1200 is sleeved on it, and in cooperation with the stress control body 1200 and the cavity shape in the corresponding mold, through heating and extrusion, and then in cooperation with the shape of the inner wall of the stress control body 1200 and the interaction of the mold, at the corresponding position of the stress cone insulator 1100, the shape of the first stress cone connection part 1120 or the second stress cone connection part 1160 is pressed. The shapes of the first cylindrical cylinder part 1110 and the second cylindrical cylinder part 1130, or the conical cylinder part 1150 and the third cylindrical cylinder part 1170 are formed by being pressed by the cavity shape in the mold; furthermore, if the stress cone insulator 1100 is first made and then the stress control body 1200 is sleeved on it to form the fusion stress cone 1000 in the mold, the stress cone insulator 1100 on the fusion stress cone 1000 will increase in the direction of extending towards both ends in length compared with the original stress cone insulator 1100, and the thickness will be smaller than the original.

[0135] Second aspect, a manufacturing process of a prefabricated fused stress cone according to an embodiment of the present invention includes the following steps:

[0136] Manufacture a stress control body 1200, and manufacture the stress control body 1200 in a conical shape;

[0137] Manufacture a stress cone insulator 1100. The stress cone insulator 1100 is made of non-crosslinked polyethylene raw material, and both ends of the stress cone insulator 1100 extend outward along the axis direction of the stress cone insulator 1100;

[0138] Manufacture a fused stress cone 1000. Sheath the stress control body 1200 on the outer wall of the stress cone insulator 1100, and synchronously place them in a first composite mold. Through heating and extrusion, make the stress control body 1200 and the stress cone insulator 1100 be fused, grafted, and crosslinked to form a fused stress cone 1000 with an integral welded structure.

[0139] Compared with the manufacturing process of the prefabricated fused stress cone in the first aspect embodiment, the main difference in the second aspect is that: the stress control body 1200 and the stress cone insulator 1100 are separately manufactured, and finally, the first composite mold is used for heating and extrusion to make the two be fused, grafted, and crosslinked to form a fused stress cone 1000 with an integral welded structure. Compared with the embodiment of the first aspect, by separately manufacturing the stress control body 1200 and the stress cone insulator 1100, stress cone insulators 1100 with the same specifications can be mass-produced in advance, and then different stress control bodies 1200 are used for combined installation to form the required fused stress cone 1000.

[0140] Third aspect, a manufacturing process of a prefabricated fused stress cone according to an embodiment of the present invention includes the following steps:

[0141] Manufacture a stress cone insulator 1100. The stress cone insulator 1100 is made of non-crosslinked polyethylene raw material, and both ends of the stress cone insulator 1100 extend outward along the axis direction of the stress cone insulator 1100. The stress cone insulator 1100 has a connection hole 1140 for sleeving a cable 2000. The connection hole 1140 extends along the axis of the stress cone insulator 1100 and penetrates the stress cone insulator 1100;

[0142] On-site welding installation. Sheath the stress cone insulator 1100 on the cable 2000, and the inner wall of the stress cone insulator 1100 is sequentially attached to the insulating layer 2200 and the insulating shielding layer 2300 of the cable 2000. Place the stress cone insulator 1100 and the cable 2000 in a third composite mold. Through heating, make the stress cone insulator 1100 and the insulating layer 2200 of the cable 2000 be fused, grafted, and crosslinked to form an integral welded structure;

[0143] Fabricate a stress control body 1200, and fabricate a conical stress control body 1200.

[0144] Fabricate a fused stress cone 1000. Sheath the stress control body 1200 on the outer wall of the stress cone insulator 1100, and synchronously place the stress control body 1200, the stress cone insulator 1100, and the cable 2000 into a second composite mold. Through heating and extrusion, the stress control body 1200 and the stress cone insulator 1100 are fused, grafted, and crosslinked together to form a fused stress cone 1000 with an integral welded structure.

[0145] Compared with the fabrication process of the prefabricated fused stress cone in the second aspect embodiment, the main difference in the third aspect embodiment is that the stress control body 1200 and the stress cone insulator 1100 are also fabricated separately. However, in the third aspect embodiment, the stress cone insulator 1100 and the cable 2000 are first fused and installed, and finally, the second composite mold is used to heat and extrude the stress cone and the stress cone insulator 1100, so that the two are fused, grafted, and crosslinked together to form a fused stress cone 1000 with an integral welded structure. Compared with the first aspect embodiment, the main difference in the present invention is the different fabrication processes, and the effect achieved by the final fused stress cone 1000 can reach substantially the same effect as that of the first aspect embodiment.

[0146] It should be noted that in the embodiments of the present invention, the structures of the first composite mold, the second composite mold, the third composite mold, the stress control body mold, the mold for fabricating the stress cone insulator 1100, and the first extruder and the second extruder are all commonly used equipment in the field of processing. Therefore, they are not specifically described in the present invention.

[0147] According to an embodiment of the present invention, by setting it in this way, at least the following effects can be achieved. The stress cone insulator 1100 made of non-crosslinked polyethylene raw material can be compound crosslinked with the stress control body 1200 through heating and extrusion. At the same time, because the stress cone insulator 1100 is made of non-crosslinked polyethylene raw material, the characteristics of this material enable it to combine and crosslink with crosslinked polyethylene, that is, the stress cone insulator 1100 can be combined and crosslinked with the insulating layer 22000 of the cable 2000 by means of melt grafting to form a seamless integrated fusion structure. This combination method enables the fusion interface between two different materials to reach a grafting combination state without air gaps and interfaces, thereby ensuring that the stress cone insulator 1100 and the insulating layer of the cable can be completely fused to form a unified whole. During the power transmission operation of the cable, it is possible to eliminate or avoid the situation of electric field distortion and breakdown caused by microscopic air gaps in the insulation structure, effectively improving the safety and reliability of the power transmission of the cable 2000; in addition, prefabricating the fused stress cone 1000 or the stress cone insulator 1100 and the stress control body 1200 in advance not only simplifies the steps and difficulties of on-site welding installation, but also facilitates transportation and storage. The fused stress cone 1000 or the stress cone insulator 1100 and the stress control body 1200 required can be stored in advance at the power transmission site, which is convenient for replacement and on-site welding installation at any time, effectively improving the convenience and reliability.

[0148] The above are only the preferred embodiments of the present invention. The present invention is not limited to the above embodiments. As long as it achieves the technical effects of the present invention by the same means, any modifications, equivalent replacements, improvements, etc. made within the spirit and principle of the present disclosure shall be included within the scope of protection of the present disclosure. All should belong to the scope of protection of the present invention. Within the scope of protection of the present invention, its technical solutions and / or implementation manners can have various different modifications and changes.

Claims

1. A process for manufacturing a prefabricated fusion stress cone, characterized in that: The following steps are involved: Manufacturing a stress control body (1200), manufacturing the stress control body (1200) in a cone shape; A fused stress cone (1000) is manufactured, the stress control body (1200) is placed in a first composite mold, and a molten non-cross-linked polyethylene raw material is injected into the first composite mold, the molten non-cross-linked polyethylene raw material passes through the stress control body (1200), and the non-cross-linked polyethylene raw material in the first composite mold forms a stress cone insulator (1100) through heating and extrusion. After cooling, the stress control body (1200) is sleeved on the outer wall of the stress cone insulator (1100), and the stress control body (1200) and the stress cone insulator (1100) are melt-grafted and cross-linked to form a fused stress cone (1000) with an integrated fused structure; The stress cone insulator (1100) is used to be melt-grafted and cross-linked with the insulation layer (2200) of the cable (2000) by heating to form an integrated fusion structure, and the insulation layer (2200) is a cross-linked polyethylene material.

2. The manufacturing process of the prefabricated fusion stress cone according to claim 1, characterized in that: The following steps are also included: On-site welding installation, the fused stress cone (1000) is sleeved on the cable (2000), and the inner wall of the stress cone insulator (1100) is sequentially attached to the insulation layer (2200) and the insulation shielding layer (2300) of the cable (2000), the fused stress cone (1000) and the cable (2000) are placed in a second composite mold, and the stress cone insulator (1100) and the insulation layer (2200) of the cable (2000) are melt-grafted and cross-linked by heating to form an integrated welding structure.

3. The manufacturing process of the prefabricated fusion stress cone according to claim 2, characterized in that: Before the on-site welding installation, the outer wall of the cable (2000) is dissected so that the cable (2000) is stripped to reveal the conductor (2100), the insulation layer (2200), and the insulation shielding layer (2300).

4. The manufacturing process of the prefabricated fusion stress cone according to claim 2, characterized in that: After the second composite mold is started, it is heated to 125° C. to 205° C. and maintained for 40 minutes to 60 minutes.

5. The manufacturing process of the prefabricated fusion stress cone according to claim 1 or 2, characterized in that: The steps of manufacturing the stress control body (1200) specifically include: Starting a first extruder loaded with a semi-conductive raw material, preheating the first extruder at 100° C. to 190° C. for 30 to 50 minutes; Start the stress control body mold with mold clamping and heating to 120℃ to 190℃ and keep it for 30 minutes to 50 minutes; Starting the first extruder to allow the first extruder to inject the molten semiconductive raw material into the stress control body mold; When glue is discharged from the overflow port of the stress control body mold, the first extruder is stopped from extruding glue, and the stress control body mold is heated to 180° C. to 230° C. and maintained for 1 hour and 30 minutes to 2 hours and 30 minutes; The heating of the stress control body mold is stopped, and the stress control body mold is allowed to cool to room temperature, and then the stress control body is taken out (1200).

6. The manufacturing process of the prefabricated fusion stress cone according to claim 1 or 2, characterized in that: The specific steps of making the fusion stress cone (1000) include: Starting a second extruder loaded with non-cross-linked polyethylene raw material, and preheating the second extruder at 120° C. to 200° C. for 30 to 50 minutes; Placing the stress control body (1200) at a corresponding position in the mold cavity of the first composite mold and locking the mold, starting the first composite mold, heating it to 120° C. to 170° C., and maintaining it for 20 minutes to 40 minutes; Starting the second extruder to inject the molten non-cross-linked polyethylene raw material into the first composite mold, and maintaining the pressure in the first composite mold at 10 kg / cm² to 18 kg / cm²; When glue is discharged from the overflow port of the first composite mold, the second extruder is stopped from extruding glue, and the first composite mold is heated to 150° C. to 190° C. and maintained for 40 to 60 minutes, so that the stress control body (1200) and the stress cone insulator (1100) are melt-grafted and cross-linked to form the fused stress cone (1000) of an integrated fusion structure; The heating of the first composite mold is stopped, the first composite mold is cooled to room temperature, and then the fusion stress cone (1000) is taken out.

7. The manufacturing process of the prefabricated fusion stress cone according to claim 1, characterized in that: The two ends of the stress cone insulator (1100) extend outwards respectively along the axial direction of the stress cone insulator (1100); the stress cone insulator (1100) has a connection hole (1140) for sleeved cables (2000); the connection hole (1140) extends along the axial direction of the stress cone insulator (1100) and passes through the stress cone insulator (1100).

8. A process for manufacturing a prefabricated fusion stress cone, characterized in that: The following steps are involved: Manufacturing a stress control body (1200), manufacturing the stress control body (1200) in a cone shape; A stress cone insulator (1100) is prepared, wherein the stress cone insulator (1100) is made of a non-cross-linked polyethylene raw material; Manufacturing a fused stress cone (1000), sleeve-mounting the stress control body (1200) on the outer wall of the stress cone insulator (1100), and simultaneously placing the stress control body (1200) in a first composite mold, and melting, grafting, and cross-linking the stress control body (1200) and the stress cone insulator (1100) through heating and extrusion to form a fused stress cone (1000) with an integrated fused structure; The stress cone insulator (1100) is used to be melt-grafted and cross-linked with the insulation layer (2200) of the cable (2000) by heating to form an integrated fusion structure, and the insulation layer (2200) is a cross-linked polyethylene material.

9. A process for manufacturing a prefabricated fusion stress cone, characterized in that: The following steps are involved: A stress cone insulator (1100) is prepared, wherein the stress cone insulator (1100) is made of a non-cross-linked polyethylene raw material; On-site welding installation, the stress cone insulator (1100) is sleeved on the cable (2000), and the inner wall of the stress cone insulator (1100) is sequentially attached to the insulation layer (2200) and the insulation shielding layer (2300) of the cable (2000), the stress cone insulator (1100) and the cable (2000) are placed in a third composite mold, and the stress cone insulator (1100) and the insulation layer (2200) of the cable (2000) are melt-grafted and cross-linked by heating to form an integrated welding structure, wherein the insulation layer (2200) is a cross-linked polyethylene material; Manufacturing a stress control body (1200), manufacturing the stress control body (1200) in a cone shape; A fused stress cone (1000) is manufactured, the stress control body (1200) is sleeved on the outer wall of the stress cone insulator (1100), and the stress control body (1200), the stress cone insulator (1100) and the cable (2000) are simultaneously placed in a second composite mold, and the stress control body (1200) and the stress cone insulator (1100) are melt-grafted and cross-linked by heating and extrusion to form a fused stress cone (1000) with an integrated fused structure.

10. A prefabricated fusion stress cone, characterized in that: include: A stress cone insulator (1100), wherein the stress cone insulator (1100) is made of a non-cross-linked polyethylene material, and is used for sleeved cables (2000). The stress cone insulator (1100) is melt-grafted and cross-linked with an insulating layer (2200) of the cable (2000) by heating to form an integrated fusion structure, wherein the insulating layer (2200) is a cross-linked polyethylene material; A stress control body (1200) is sleeved on the outer wall of the stress cone insulator (1100); the stress control body (1200) and the stress cone insulator (1100) are combined by melt grafting and cross-linking to form an integrated fusion structure.

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