Novel wear-resistant power cable and manufacturing method thereof

Abstract

The invention provides a novel wear-resistant power cable and a manufacturing method thereof, the novel wear-resistant power cable comprises a cable core, the outer side of the cable core is provided with a low-smoke halogen-free sheath and a metal net fusion type outer sheath, and there is no gap between the low-smoke halogen-free sheath and the metal net; according to the cable, the mechanical strength is remarkably improved, the problem of abrasion and fracture is effectively prevented, the negative influence of external electromagnetic interference on internal signal transmission is greatly reduced, meanwhile, the good environment corrosion resistance is shown, and therefore the service life of the cable is remarkably prolonged.

Description

Technical Field

[0001] The invention relates to the technical field of cables, and in particular to a novel wear-resistant power cable and a manufacturing method thereof. Background Art

[0002] In the field of cable manufacturing, with the advancement of technology and the growth of demand, the performance requirements for cables are also increasing. Although the traditional cable structure meets the basic electrical transmission and mechanical protection needs to a certain extent, its limitations are gradually revealed when facing complex and changing use environments. In particular, in situations where high mechanical strength, good electromagnetic shielding performance and excellent corrosion resistance are required, traditional cable structures are often difficult to meet the requirements. Specifically, there are the following technical problems:

[0003] 1) When traditional cables are subjected to greater mechanical stress, they often suffer from problems such as wear and tear, making them unable to better adapt to the complex and changeable use environment. For example, when laying and installing cables, they often encounter various harsh and complex construction environments and rough operations. After laying, the outer sheath of the cables often suffers from large-scale wear and tear. In some serious places, the cable conductor may even be damaged, affecting or even destroying the use of the cable.

[0004] 2) In an environment with severe electromagnetic interference, signal transmission inside the cable is easily interfered with, affecting the communication quality.

[0005] 3) In harsh environments such as humidity and corrosive gases, cables are susceptible to corrosion, affecting their service life and performance. Summary of the invention

[0006] In order to solve the technical problems that existing traditional cables are prone to wear and cracking, have poor anti-electromagnetic interference ability and are susceptible to corrosion, the present invention proposes a new type of wear-resistant power cable and a manufacturing method thereof. The cable effectively prevents the problems of wear and cracking by significantly improving the mechanical strength, greatly reduces the negative impact of external electromagnetic interference on internal signal transmission, and exhibits good resistance to environmental corrosion, thereby significantly extending the service life of the cable.

[0007] In order to achieve the above object, the technical solution of the present invention is as follows:

[0008] On the one hand, the present invention provides a new type of wear-resistant power cable, comprising: a cable core, wherein a low-smoke halogen-free sheath and a metal mesh fused outer sheath are provided on the outer side of the cable core, and there is no gap between the low-smoke halogen-free sheath and the metal mesh.

[0009] The present invention provides a novel wear-resistant power cable and a method for manufacturing the same. The cable significantly improves the mechanical strength, effectively prevents the problem of wear and cracking, greatly reduces the negative impact of external electromagnetic interference on internal signal transmission, and exhibits good resistance to environmental corrosion, thereby significantly extending the service life of the cable.

[0010] As a preferred technical solution, the metal mesh is embedded in the low-smoke halogen-free sheath.

[0011] As a preferred technical solution, the cable core comprises: a conductor, and an insulating layer is provided on the outside of the conductor.

[0012] As a preferred technical solution, the conductor comprises: a plurality of annealed oxygen-free flexible copper wires, and there are no gaps between the plurality of annealed oxygen-free flexible copper wires.

[0013] As a preferred technical solution, the copper content in the annealed oxygen-free flexible copper wire is ≥99.9999%.

[0014] As a preferred technical solution, the elongation of the annealed oxygen-free flexible copper wire is 35% to 40%.

[0015] As a preferred technical solution, the insulating layer is a cross-linked polyethylene insulating layer.

[0016] The invention provides a method for manufacturing a novel wear-resistant power cable, comprising the following steps: extruding a metal mesh and a low-smoke halogen-free sheath on a cable core in a fusion manner to form an outer sheath in which the metal mesh and the sheath are completely fused together, while leaving no gap in the cable core.

[0017] As a preferred technical solution, the manufacturing of the cable core includes the following steps:

[0018] Each annealed oxygen-free flexible copper wire of S1 is twisted along a common axis to form a compact conductor inside;

[0019] S2 tightly extrude the cross-linked polyethylene insulation material on the outside of the conductor to form an insulation layer.

[0020] As a preferred technical solution, nitrogen protection is used in step S1 to control the annealing current so that the elongation of the annealed oxygen-free flexible copper wire is between 35% and 40%.

[0021] The present invention provides a novel wear-resistant power cable and a manufacturing method thereof, which has the following beneficial effects:

[0022] 1) The cable significantly improves mechanical strength, effectively prevents wear and tear, greatly reduces the negative impact of external electromagnetic interference on internal signal transmission, and exhibits good resistance to environmental corrosion, thereby significantly extending the service life of the cable;

[0023] 2) The present invention significantly improves the mechanical strength of the cable by providing a low-smoke halogen-free sheath and a metal mesh fused outer sheath on the outside of the cable core, so that the cable can better adapt to the complex and changeable use environment;

[0024] The present invention utilizes the conductivity of the metal mesh to form an effective electromagnetic shielding layer, which can significantly reduce the impact of external electromagnetic interference on the internal signal of the cable and ensure the stability and accuracy of signal transmission;

[0025] The present invention provides a solid protective layer for the cable by fusing the metal mesh and the low-smoke halogen-free sheath, effectively resisting the corrosion of the external environment and prolonging the service life of the cable.

[0026] 3) The metal mesh is embedded in the low-smoke halogen-free sheath, making the overall structure of the cable more compact; this design reduces the diameter and volume of the cable, making the cable more flexible and convenient during installation and use;

[0027] The metal mesh is embedded inside the low-smoke halogen-free sheath, which is closer to the conductor and insulation layer inside the cable, so it can provide electromagnetic shielding more effectively; this design can more effectively prevent external electromagnetic interference from interfering with the internal signal of the cable, and improve the stability and reliability of signal transmission;

[0028] The metal mesh is embedded in the low-smoke halogen-free sheath and protected by the low-smoke halogen-free sheath, which can more effectively resist the corrosion of the external environment; this design can extend the service life of the cable and reduce the risk of cable damage caused by corrosion;

[0029] The metal mesh is embedded in the low-smoke halogen-free sheath, which reduces the contact area between the metal mesh and the outside world and reduces the safety hazards caused by damage or falling off of the metal mesh.

[0030] 4) There are no gaps between multiple annealed oxygen-free flexible copper wires, which means that they form a close contact; this close contact can reduce the loss of current during transmission and improve the conductivity of the conductor;

[0031] There are no gaps between the multiple annealed oxygen-free flexible copper wires, so that the conductor can maintain overall stability when subjected to external forces; this stability can prevent the conductor from being deformed or broken due to external forces, thereby improving its mechanical strength.

[0032] 5) The copper content of the annealed oxygen-free flexible copper wire is ≥99.9999%, and the high-purity copper has an extremely low resistivity, which means that the current encounters very little resistance when passing through, thereby being able to efficiently transmit electrical energy; in applications such as power cables and signal transmission lines, the high-purity copper wire can ensure signal clarity and transmission speed, and reduce energy loss and signal attenuation;

[0033] After annealing, high-purity copper wire can show good ductility and flexibility. This makes the copper wire easy to process and shape during the manufacturing process, while also being able to resist the influence of external stress and not prone to breakage or deformation. This property is particularly important when manufacturing precision electronic components and complex cable structures.

[0034] 6) The elongation of the annealed oxygen-free flexible copper wire is 35% to 40%. The high elongation of the annealed oxygen-free flexible copper wire enables the cable to better adapt to deformation processes such as bending and twisting, and is not prone to breakage or damage, thereby extending the service life of the cable;

[0035] During signal transmission, the flexibility and tensile strength of the cable are crucial to maintaining signal stability and clarity; high elongation copper wire can reduce signal loss caused by cable deformation or stretching, ensuring accurate signal transmission.

[0036] 7) An insulating layer is provided on the outside of the conductor, and the insulating layer is a cross-linked polyethylene insulating layer. The main function of the cross-linked polyethylene insulating layer is to provide electrical insulation and prevent current from passing through the conductor sheath into the surrounding environment or other conductors; it can ensure the safety and stability of the cable when transmitting electric energy, and effectively prevent the occurrence of electrical accidents such as electric shock and short circuit; the cross-linked polyethylene insulating layer has excellent electrical properties and can make the electric field evenly distributed in the cable; this helps to reduce the risk of breakdown caused by electric field concentration and improve the electrical strength and stability of the cable.

[0037] 8) The use of low-smoke halogen-free sheath and metal mesh fused outer sheath greatly improves the wear resistance of the cable sheath. The low-smoke halogen-free sheath and the metal mesh are fused together, and the metal mesh is embedded in the low-smoke halogen-free sheath, which can greatly increase the tensile strength and adhesion of the sheath, prevent the cable from being damaged during the construction process, and increase the service life of the cable. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 A schematic structural diagram of a novel wear-resistant power cable provided by the present invention;

[0039] Among them, 1-conductor; 2-insulating layer; 3-metal mesh; 4-low smoke zero halogen sheath. DETAILED DESCRIPTION

[0040] The preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings.

[0041] like Figure 1 As shown, the present invention provides a novel wear-resistant power cable, comprising: a cable core, a low-smoke halogen-free sheath 4 and a metal mesh 3 fused outer sheath are arranged on the outside of the cable core, and there is no gap between the low-smoke halogen-free sheath 4 and the metal mesh 3.

[0042] The present invention provides a new type of wear-resistant power cable with a simple structure. The cable effectively prevents the problem of wear and cracking by significantly improving the mechanical strength, greatly reduces the negative impact of external electromagnetic interference on internal signal transmission, and exhibits good resistance to environmental corrosion, thereby significantly extending the service life of the cable.

[0043] The present invention significantly improves the mechanical strength of the cable by providing a low-smoke halogen-free sheath 4 and a metal mesh 3 fused outer sheath on the outside of the cable core, so that the cable can better adapt to the complex and changeable use environment;

[0044] The present invention utilizes the conductivity of the metal mesh 3 to form an effective electromagnetic shielding layer, which can significantly reduce the impact of external electromagnetic interference on the internal signal of the cable and ensure the stability and accuracy of signal transmission;

[0045] The present invention provides a solid protective layer for the cable by fusing the metal mesh 3 and the low-smoke halogen-free sheath 4 together, effectively resisting the corrosion of the external environment and prolonging the service life of the cable.

[0046] Preferably, if Figure 1 As shown, the metal mesh 3 is embedded in the low-smoke halogen-free sheath 4;

[0047] The metal mesh 3 is embedded in the low-smoke halogen-free sheath 4, making the overall structure of the cable more compact; this design reduces the diameter and volume of the cable, making the cable more flexible and convenient during installation and use;

[0048] The metal mesh 3 is embedded in the low-smoke halogen-free sheath 4, which is closer to the conductor 1 and the insulation layer 2 inside the cable, so it can provide electromagnetic shielding more effectively; this design can more effectively prevent external electromagnetic interference from interfering with the internal signal of the cable, and improve the stability and reliability of signal transmission;

[0049] The metal mesh 3 is embedded in the low-smoke halogen-free sheath 4 and protected by the low-smoke halogen-free sheath 4, so it can more effectively resist the corrosion of the external environment; this design can extend the service life of the cable and reduce the risk of cable damage caused by corrosion;

[0050] The metal mesh 3 is embedded in the low-smoke zero-halogen sheath 4, which reduces the contact area between the metal mesh 3 and the outside world and reduces the potential safety hazard caused by damage or falling off of the metal mesh.

[0051] Preferably, if Figure 1As shown, the cable core includes: a conductor 1, and an insulating layer 2 is provided on the outside of the conductor 1; the insulating layer 2 on the outside of the conductor 1 plays a vital role in the cable structure; it not only ensures the electrical insulation performance of the cable, but also protects the conductor 1 from various adverse factors, thereby improving the durability and safety of the cable.

[0052] Preferably, if Figure 1 As shown, the conductor 1 comprises: a plurality of annealed oxygen-free flexible copper wires, and there is no gap between the plurality of annealed oxygen-free flexible copper wires;

[0053] There is no gap between multiple annealed oxygen-free flexible copper wires, which means that they form a close contact between the twisted wires; this close contact can reduce the loss of current during transmission and improve the conductivity of the conductor;

[0054] There are no gaps between the multiple annealed oxygen-free flexible copper wires, so that the conductor can maintain overall stability when subjected to external forces; this stability can prevent the conductor from being deformed or broken due to external forces, thereby improving its mechanical strength.

[0055] Preferably, the copper content in the annealed oxygen-free flexible copper wire is ≥ 99.9999%;

[0056] The copper content of the annealed oxygen-free flexible copper wire is ≥99.9999%, and the high-purity copper has an extremely low resistivity, which means that the current encounters very little resistance when passing through, so that the electric energy can be transmitted efficiently; in applications such as power cables and signal transmission lines, the high-purity copper wire can ensure the clarity and transmission speed of the signal, and reduce energy loss and signal attenuation;

[0057] After annealing, high-purity copper wire can show good ductility and flexibility; this makes the copper high-purity copper wire easy to process and shape during the manufacturing process, and it can also resist the influence of external stress and is not prone to breakage or deformation; this property is particularly important when manufacturing precision electronic components and complex cable structures.

[0058] Preferably, the elongation of the annealed oxygen-free flexible copper wire is 35% to 40%;

[0059] The elongation of the annealed oxygen-free flexible copper wire is 35% to 40%. The high elongation of the annealed oxygen-free flexible copper wire enables the cable to better adapt to deformation processes such as bending and twisting, and is less likely to break or be damaged, thereby extending the service life of the cable;

[0060] During signal transmission, the flexibility and tensile strength of the cable are crucial to maintaining signal stability and clarity; high elongation copper wire can reduce signal loss caused by cable deformation or stretching, ensuring accurate signal transmission.

[0061] Preferably, the insulating layer 2 is a cross-linked polyethylene insulating layer; an insulating layer 2 is provided on the outside of the conductor 1, and the insulating layer 2 is a cross-linked polyethylene insulating layer. The main function of the cross-linked polyethylene insulating layer is to provide electrical insulation and prevent current from passing through the outer skin of the conductor 1 into the surrounding environment or other conductors; it can ensure the safety and stability of the cable when transmitting electric energy, and effectively prevent the occurrence of electrical accidents such as electric shock and short circuit; the cross-linked polyethylene insulating layer has excellent electrical properties and can make the electric field evenly distributed in the cable; this helps to reduce the risk of breakdown caused by electric field concentration and improve the electrical strength and stability of the cable.

[0062] The present invention provides a novel method for manufacturing a wear-resistant power cable, comprising the following steps: extruding a metal mesh 3 and a low-smoke halogen-free sheath 4 on a cable core in a fusion manner to form an outer sheath in which the metal mesh 3 and the low-smoke halogen-free sheath 4 are completely fused, and at the same time, there is no gap in the cable core;

[0063] The present application adopts fusion extrusion technology to tightly combine the metal mesh 3 and the low-smoke halogen-free sheath 4 to form an integrated outer sheath; this technology ensures a close fit between the outer sheath and the cable core, thereby improving the overall performance of the cable;

[0064] Through fine process control, the present application realizes a design without gaps in the cable core; this design helps prevent external substances such as moisture and dust from penetrating into the cable, thereby improving the moisture and corrosion resistance of the cable;

[0065] The addition of the metal mesh 3 significantly improves the wear resistance of the cable; when the cable is rubbed or squeezed by external force, the metal mesh 3 can disperse and absorb part of the pressure, protecting the internal cable core and the insulation layer 2 from damage;

[0066] The low smoke halogen-free sheath 4 has good electrical insulation performance, while the metal mesh 3 plays the role of electromagnetic shielding; this combination makes the transmission performance of the cable more stable in an electromagnetic interference environment, while preventing the cable itself from radiating electromagnetic interference outward;

[0067] Low-smoke halogen-free materials do not produce toxic and harmful smoke and hydrogen halide gas when burned, and are more friendly to the environment and human health; in addition, the metal mesh 3 also has certain fireproof properties and can provide additional protection for the cable in the event of a fire.

[0068] Preferably, the manufacturing of the cable core comprises the following steps:

[0069] Each annealed oxygen-free flexible copper wire of S1 is twisted along a common axis to form a compact conductor 1;

[0070] S2 tightly extrude the cross-linked polyethylene insulation material on the outside of the conductor 1 to form an insulation layer 2;

[0071] There are no visible bubbles and impurities on the cross section of the insulating layer 2, the insulating layer 2 has a round appearance, the insulating layer 2 is fully cross-linked and can be easily peeled off from the conductor 1;

[0072] The absence of bubbles and impurities in the insulating layer 2 can ensure the electrical insulation performance of the cable; bubbles and impurities may cause uneven distribution of the electric field and increase the risk of breakdown; the insulating layer 2 without bubbles and impurities can provide a stable and uniform insulating environment to ensure that the current will not leak into the external environment when it is transmitted in the conductor 1;

[0073] The rounded insulating layer 2 can ensure that when the cable is bent or subjected to external force, the insulating layer 2 will not generate stress concentration due to its irregular shape, thereby preventing the insulating layer 2 from being broken or damaged;

[0074] The cross-linked polyethylene insulation layer 2 is fully cross-linked to improve its heat resistance, aging resistance and mechanical strength; this allows the cable to maintain good performance in harsh environments such as high temperature and humidity, and extend the service life of the cable;

[0075] The insulating layer 2 is easily peeled off from the conductor 1, which is convenient for the repair and replacement of the cable; when a cable fails, the insulating layer 2 can be easily peeled off to check and repair the fault of the conductor 1 without damaging the entire cable structure.

[0076] Preferably, nitrogen protection is used in step S1 to control the annealing current so that the elongation of the annealed oxygen-free flexible copper wire is between 35% and 40%, thereby ensuring the roundness and softness of the conductor.

[0077] By controlling the annealing current and nitrogen protection, the elongation of the annealed oxygen-free flexible copper wire is between 35% and 40%. This elongation range (35% to 40%) can ensure that the copper wire has good ductility, so that it is not easy to break or deform in the subsequent twisting and insulation layer 2 extrusion process;

[0078] Proper annealing treatment can also maintain the softness of the annealed oxygen-free flexible copper wire, making it easy to bend and shape; this is particularly important for the manufacture of cables with complex structures, which can ensure that the cable will not crack or break due to the excessive hardness of the annealed oxygen-free flexible copper wire when it is bent or subjected to external forces; nitrogen protection can prevent the annealed oxygen-free flexible copper wire from being oxidized or contaminated during high-temperature annealing, thereby reducing the formation of internal defects; these defects may affect the mechanical and electrical properties of the annealed oxygen-free flexible copper wire, and thus affect the performance of the entire cable;

[0079] The oxygen-free flexible copper wire has better plasticity after annealing, so it is easier to be twisted along a common axis to form a compact conductor 1; this compact conductor 1 structure helps to reduce resistance, improve conductivity, and enhance the mechanical strength of the cable.

[0080] It is to be understood that the present invention is described by some embodiments, and it is known to those skilled in the art that various changes or equivalent substitutions may be made to these features and embodiments without departing from the spirit and scope of the present invention. In addition, under the teachings of the present invention, these features and embodiments may be modified to adapt to specific circumstances and materials without departing from the spirit and scope of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed herein, and all various changes or equivalent substitutions falling within the scope of the claims of the present application are included. In addition, under the teachings of the present invention, these features and embodiments may be modified to adapt to specific circumstances and materials without departing from the spirit and scope of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed herein, and all embodiments falling within the scope of the claims of the present application are within the scope protected by the present invention.

Claims

1. A new type of wear-resistant power cable, characterized in that: include: A cable core, wherein a low-smoke halogen-free sheath and a metal mesh fused outer sheath are arranged on the outer side of the cable core, and there is no gap between the low-smoke halogen-free sheath and the metal mesh.

2. The new wear-resistant power cable according to claim 1 is characterized in that: The metal mesh is embedded in the low-smoke halogen-free sheath.

3. The new wear-resistant power cable according to claim 1 is characterized in that: The cable core comprises: a conductor, and an insulating layer is arranged on the outer side of the conductor.

4. The new wear-resistant power cable according to claim 3 is characterized in that: The conductor comprises: a plurality of annealed oxygen-free flexible copper wires, and there are no gaps between the plurality of annealed oxygen-free flexible copper wires.

5. The new wear-resistant power cable according to claim 4 is characterized in that: The copper content in the annealed oxygen-free flexible copper wire is ≥99.9999%.

6. The new wear-resistant power cable according to claim 4 is characterized in that: The elongation of the annealed oxygen-free flexible copper wire is 35% to 40%.

7. The new wear-resistant power cable according to claim 3 is characterized in that: The insulating layer is a cross-linked polyethylene insulating layer.

8. A method for manufacturing a new type of wear-resistant power cable, characterized in that: The following steps are involved: The metal mesh and low-smoke halogen-free sheath are fused and extruded on the cable core to form an outer sheath in which the metal mesh and the sheath are completely fused together, and at the same time, there is no gap in the cable core.

9. The method for manufacturing a new type of wear-resistant power cable according to claim 8, characterized in that: The manufacturing of the cable core comprises the following steps: Each annealed oxygen-free flexible copper wire of S1 is twisted along a common axis to form a compact conductor inside; S2 tightly extrude the cross-linked polyethylene insulation material on the outside of the conductor to form an insulation layer.

10. The method for manufacturing a novel wear-resistant power cable according to claim 9, characterized in that: In step S1, nitrogen protection is used to control the annealing current so that the elongation of the annealed oxygen-free flexible copper wire is between 35% and 40%.

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