Special photovoltaic cable against corrosion

Abstract

The application relates to a kind of anticorrosive special photovoltaic cable in the field of cable, including core, the inner protective layer is covered on core, the reinforcing wire row is arranged on the inner protective layer, the outer protective layer is covered on the reinforcing wire row;The core includes core main body, the porous protective layer is covered on the outer side of core main body, the liquid isolation film is laid on the porous protective layer;The reinforcing wire row includes a plurality of reinforcing wires that are arranged at equal intervals around the core, a shaping net is arranged between the plurality of reinforcing wires, the upper and lower ends of the shaping net are both laid with corrosion-resistant protective film;The outer side of the shaping net is covered with an insulating protective layer, a plurality of segment protective sleeves are detachably arranged on the insulating protective layer, the multiple protection design of the scheme provides comprehensive protection for the cable, the segment protective sleeve cooperates to dynamically protect the cable, releases protective oil to cover the core during dynamic protection, improves the corrosion resistance of the cable, ensures limited protection for the core after the external damage of the cable, and is especially suitable for cable protection in harsh environments.

Description

Technical Field

[0001] This invention relates to a corrosion-resistant special photovoltaic cable, and more particularly to a corrosion-resistant special photovoltaic cable for use in the cable industry. Background Technology

[0002] Existing specialty photovoltaic cables possess unique properties to adapt to outdoor environments and the specific requirements of solar panels. Key characteristics of these cables include high-temperature resistance, UV resistance, bending resistance, and excellent electrical properties. They are commonly used to connect solar panels, inverters, and power distribution systems.

[0003] In terms of application, specialty photovoltaic cables are widely used in residential, commercial, and industrial solar power generation projects. However, these cables have shortcomings in corrosion resistance. Due to long-term exposure to outdoor environments, they may be affected by chemicals, salt spray, moisture, and extreme temperatures, all of which can lead to degradation of the cable insulation and sheath materials. Corrosion problems are particularly severe for photovoltaic systems installed near the sea or industrial areas. Through these improvement measures, the service life and reliability of specialty photovoltaic cables will be significantly enhanced, thereby reducing maintenance costs and improving the efficiency of the entire solar power generation system.

[0004] To address the issue of cable corrosion, a certain type of cable on the market employs an anti-corrosion coating design, giving it a certain market share.

[0005] Chinese invention patent CN202311743572.4 discloses an anti-corrosion PE cable conduit and its manufacturing process. The anti-corrosion PE cable conduit of this invention includes a PE cable conduit body and a protective coating disposed on the outer periphery of the PE cable conduit body. The PE cable conduit body is made of modified polyethylene, which includes polyethylene, p-vinylbenzylamine, vinyl-terminated and hydroxyl-terminated silicone oil, and filler. The protective coating is made of a corrosion-resistant protective coating. In the anti-corrosion PE cable conduit of this application, the protective coating has a high adhesion to the PE cable conduit body, which improves the protective effect of the protective coating on the PE cable conduit body and helps to extend the service life of the PE cable conduit.

[0006] Existing cables have several shortcomings in terms of corrosion resistance. First, the outer sheath materials of many cables, such as PVC (polyvinyl chloride) and PE (polyethylene), are prone to degradation under certain chemicals, oils, or extreme temperature conditions, leading to a decline in physical properties. Second, after the cable is damaged by external forces that damage the outer sheath, the core is easily corroded due to its weak internal corrosion resistance, which in turn affects the cable's conductivity and service life. Summary of the Invention

[0007] In view of the above-mentioned prior art, the technical problem to be solved by the present invention is that when the outer sheath of the existing cable is damaged by external damage, the core is easily corroded due to its weak internal corrosion resistance, which in turn affects the conductivity and service life of the cable.

[0008] To address the aforementioned problems, this invention provides a corrosion-resistant special photovoltaic cable, comprising a wire core, an inner protective layer covering the wire core, a reinforcing bar array disposed on the inner protective layer, and an outer protective layer covering the reinforcing bar array; the wire core comprises a wire core body, a porous protective layer covering the outer side of the wire core body, and a liquid isolation membrane laid on the porous protective layer;

[0009] The reinforced busbar includes multiple reinforcing wires that are equidistantly bonded around the core. Each reinforcing wire includes a high-strength wire bundle, which is covered with a corrosion-resistant sponge sleeve. A shaping mesh is placed between the multiple reinforcing wires, and both the upper and lower ends of the shaping mesh are covered with a corrosion-resistant protective film.

[0010] The shaping mesh includes raised parts and recessed parts. The raised parts are attached to the reinforcing lines, and the recessed parts are located between two adjacent reinforcing lines. Both the inner and outer ends of the shaping mesh are covered with a corrosion-resistant film.

[0011] The outer side of the shaping net is covered with an insulating protective layer, and a corrosion-resistant resin layer is filled between the insulating protective layer and the recessed part. Multiple segment protective sleeves are detachably installed on the insulating protective layer.

[0012] The aforementioned corrosion-resistant special photovoltaic cables are protected by multiple protective measures, including an outer protective layer, reinforcing wires, a corrosion-resistant resin layer, and an insulation protective layer.

[0013] As a further improvement of this application, a plurality of evenly distributed marking grooves are provided on the insulating protective layer, and the position of the marking grooves is aligned with the center line of the recess; the depth of the marking grooves is 1-3mm.

[0014] As a further improvement of this application, the segmental protective sleeve includes a pair of flexible base layers, multiple pairs of hollow pads are provided on the flexible base layers, multiple fixing pins that penetrate into the hollow pads are installed on the flexible base layers, and an oil storage bag is provided inside the hollow pads, which stores protective oil.

[0015] As a further improvement of this application, one end of the fixing pin is inserted between two adjacent reinforcing lines along the marking groove, and the other end of the fixing pin is inserted into the oil storage bag inside the hollow pad. The distance between two adjacent protective sleeves is less than 5-10cm.

[0016] As another improvement of this application, the method of covering the reinforcing wire with a shaping mesh includes: after the reinforcing wire is equidistantly bonded to the core, it is then covered with a shaping mesh; after covering with the shaping mesh, a corrosion-resistant resin is coated on the shaping mesh to fill the depressions; then an insulating protective layer is covered; and finally, the resin is heated to cure into a corrosion-resistant resin layer.

[0017] As a further improvement to this application, the high-strength wire harness includes thick and thin wire segments, which are distributed alternately, and the high-strength wire harness is woven from corrosion-resistant fibers.

[0018] As a further improvement to this application, the fixing pin includes a hollow seat connected to the flexible base layer, through which a hollow tube is provided. The length of the hollow tube is less than the diameter of the reinforcing wire. Before the segment protective sleeve is installed, a matching insertion hole is pre-drilled on the marking groove. Oil guide holes are provided on the side walls at both ends of the hollow tube.

[0019] As a further improvement to this application, an airbag is provided inside the hollow pad, and a pressure plate matching the oil storage bag is provided inside the cavity of the hollow pad. Multiple compression springs are connected between the pressure plate and the inner wall of the cavity. An exhaust pipe communicating with the airbag is installed on the pressure plate. An identification layer sealing the exhaust pipe outlet is provided on the surface of the hollow pad. Both the identification layer and the insulating protective layer are made of insulating material.

[0020] In summary, this solution's multi-protection design provides comprehensive protection for the cable. The synergistic segmental protective sleeve provides dynamic protection for the cable, releasing protective oil to cover the conductor during dynamic protection, thereby improving the cable's corrosion resistance and ensuring limited protection of the conductor after external damage to the cable. It is especially suitable for cable protection in harsh environments. Attached Figure Description

[0021] Figure 1 This is a perspective view of the first embodiment of this application;

[0022] Figure 2 for Figure 1 Schematic diagram of the structure at point A;

[0023] Figure 3 This is an exploded view of the first embodiment of this application;

[0024] Figure 4 This is a cross-sectional view of the second embodiment of this application;

[0025] Figure 5 for Figure 4 Schematic diagram of the structure at point B;

[0026] Figure 6 This is a perspective view of the fixing pin according to the first and second embodiments of this application.

[0027] Explanation of the labels in the diagram:

[0028] 1. Core wire, 2. Reinforcing wire, 21. High-strength wire harness, 22. Corrosion-resistant sponge sleeve, 3. Shaping mesh, 31. Raised part, 32. Recessed part, 4. Corrosion-resistant resin layer, 5. Insulation protective layer, 6. Segment protective sleeve, 61. Flexible base layer, 62. Hollow pad, 621. Airbag, 622. Pressure plate, 623. Exhaust pipe, 624. Compression spring, 63. Fixing pin, 631. Hollow seat, 632. Hollow insertion tube. Detailed Implementation

[0029] The two embodiments of this application will be described in detail below with reference to the accompanying drawings.

[0030] Implementation method 1:

[0031] Figure 1-5 The diagram shows a corrosion-resistant special photovoltaic cable, including a core 1, an inner protective layer covering the core 1, a reinforcing bar on the inner protective layer, and an outer protective layer covering the reinforcing bar; the core 1 includes a core body, a porous protective layer covering the outside of the core body, and a liquid isolation membrane laid on the porous protective layer.

[0032] The reinforced wire array includes multiple reinforcing wires 2 that are equidistantly bonded around the core 1. Each reinforcing wire 2 includes a high-strength wire bundle 21, which is covered with a corrosion-resistant sponge sleeve 22. The high-strength wire bundle 21 includes thick and thin wire segments that are alternately distributed. The high-strength wire bundle is made of corrosion-resistant fiber braiding. There are some gaps between the reinforcing wires 2 so that protective oil can be injected into the reinforced wire array for reinforcement and protection as needed.

[0033] The purpose of providing thick and thin wire segments in the high-strength wire harness 21 is that when protective oil is injected into the space between two adjacent reinforcing wires 2, the protective oil can be discharged into the gaps between other reinforcing wires 2 through the thin wire segments, making it easy to achieve rapid coverage of the wire core 1 surface with protective oil.

[0034] A shaping mesh 3 is set between multiple reinforcing lines 2, and both the upper and lower ends of the shaping mesh 3 are covered with a corrosion-resistant protective film;

[0035] The method of covering the reinforcing wire 2 with the shaping mesh 3 includes: after the reinforcing wire 2 is equidistantly bonded to the core 1, the shaping mesh 3 is used for covering. After covering the shaping mesh 3, a corrosion-resistant resin is coated on the shaping mesh 3 to fill the recess 32. Then, an insulating protective layer 5 is covered, and finally, the resin is heated to cure into a corrosion-resistant resin layer 4.

[0036] The shaping mesh 3 includes a protrusion 31 and a recess 32. The protrusion 31 is attached to the reinforcing line 2, and the recess 32 is located between two adjacent reinforcing lines 2. Both the inner and outer ends of the shaping mesh 3 are covered with a corrosion-resistant film. The corrosion-resistant film is a thin film covering the shaping mesh 3. The corrosion-resistant film includes a fluoropolymer protective film and a polytetrafluoroethylene (PTFE) film.

[0037] The outer side of the shaping net 3 is covered with an insulating protective layer 5, and a corrosion-resistant resin layer 4 is filled between the insulating protective layer 5 and the recessed part 32. Multiple segment protective sleeves 6 are detachably installed on the insulating protective layer 5.

[0038] The segmental protective sleeve 6 includes a pair of flexible base layers 61, which are snapped together or fixed by screws at their joints. Multiple pairs of hollow pads 62 are provided on the flexible base layers 61, and multiple fixing pins 63 are installed on the flexible base layers 61 and inserted into the hollow pads 62. An oil storage bag is provided inside the hollow pads 62, and the oil storage bag stores protective oil. A suitable protective oil, such as silicone oil, is selected and filled by those skilled in the art.

[0039] Multiple evenly distributed marking grooves are provided on the insulating protective layer 5, and the position of the marking grooves is aligned with the center line of the recess 32; the depth of the marking grooves is 1-3mm; one end of the fixing pin 63 is inserted between two adjacent reinforcing lines 2 along the marking groove, and the other end of the fixing pin 63 is inserted into the oil storage bag inside the hollow pad 62; the distance between two adjacent protective sleeves 6 is less than 5-10cm.

[0040] The protective oil inside the hollow pad 62 is slowly released into the reinforced wire strip through the fixing pin 63, so that the surface of the wire core 1 is covered with protective oil. On the one hand, this improves the heat dissipation effect of the wire core 1, and on the other hand, it isolates external corrosive substances and external air from the wire core 1.

[0041] When installing the segmental protective sleeve 6, select the marking groove at the installation location and make an insertion hole. The insertion hole must penetrate the corrosion-resistant resin layer 4 and the shaping mesh 3. Then install the fixing pin 63. During installation, the hollow seat 631 of the fixing pin 63 is inserted into the marking groove, and one end of the hollow insertion tube 632 is inserted into the reinforcing wire row. Then install the flexible base layer 61. During installation, the flexible base layer 61 covers the hollow insertion tube 632 and one end of the hollow insertion tube 632 is inserted into the oil storage bag. After the pair of flexible base layers 61 are installed, the insulating protective layer 5 is tightly wrapped. Then fix the joint of the pair of flexible base layers 61. When fixing the joint, you can choose to use adhesive or screws as needed. After fixing the joint, the installation of the segmental protective sleeve 6 is completed.

[0042] When the cable of this solution is used, the external insulation protection is provided by the insulation protection layer 5. When the external environment is poor, external pollutants are easy to accumulate in the marking groove. When the insulation protection layer 5 is corroded and fails, the corrosive substances are easy to come into contact with the corrosion resistant resin layer 4 first. The corrosion resistant resin layer 4 provides the first level of protection after the insulation protection layer 5 fails.

[0043] When the insulation protective layer 5 is accidentally damaged, external corrosive substances enter the insulation protective layer 5 from the broken part. It is initially protected by the corrosion-resistant resin layer 4. After the corrosion-resistant resin layer 4 is corroded and damaged, it is then protected by the shaping net 3.

[0044] Since the shaping mesh 3 of this solution is provided with protrusions 31 and recesses 32, the protrusions 31 are attached to the reinforcing line 2. When the corrosive substance penetrates from the protrusions 31, it is isolated by the reinforcing line 2, while when it penetrates from the recesses 32, it is isolated and protected by the thicker corrosion-resistant resin layer 4.

[0045] The raised portion 31 of the shaping mesh 3 in this solution can play a buffering and protective role. When it is damaged by external forces, it is protected by the raised portion 31 and the reinforcing line 2. That is, when it is damaged by external forces, the damaged position on the shaping mesh 3 is likely to appear in the area of ​​the raised portion 31. In this way, when the cable is damaged by external forces, the damaged opening is sealed by the reinforcing line 2, and corrosion protection is achieved by the reinforcing line 2, ensuring that the wire core 1 is not easily in contact with external corrosive substances.

[0046] The multi-protection design of this embodiment provides comprehensive protection for the cable through multiple protective measures, including the outer protective layer 3, the reinforcing wire 2, the corrosion-resistant resin layer 4, and the insulation protective layer 5. This significantly improves the cable's corrosion resistance and service life. The use of high-strength wire harnesses braided with corrosion-resistant fibers and corrosion-resistant sponge sheaths, as well as the setting of the corrosion-resistant resin layer, ensures that the cable maintains good performance even in harsh environments and effectively prevents corrosive substances from contacting the wire core 1.

[0047] The second implementation method:

[0048] Figure 5-6 As shown, an airbag 621 is installed inside the hollow pad 62, and a pressure plate 622 matching the oil storage bag is installed inside the cavity of the hollow pad 62. Multiple compression springs 624 are connected between the pressure plate 622 and the inner wall of the cavity. An exhaust pipe 623 communicating with the airbag 621 is installed on the pressure plate 622. An identification layer sealing the exhaust port of the exhaust pipe 623 is provided on the surface of the hollow pad 62. Both the identification layer and the insulating protective layer 5 are made of insulating material.

[0049] The fixing pin 63 includes a hollow seat 631 connected to the flexible base layer 61. A hollow insertion tube 632 is provided through the hollow seat 631. The length of the hollow insertion tube 632 is less than the diameter of the reinforcing line 2. Before the segment protective sleeve is installed, the marking groove is pre-opened with an insertion hole that matches the hollow insertion tube 632. Oil guide holes are opened on the side walls at both ends of the hollow insertion tube 632.

[0050] When the airbag 621 inflates, the pressure plate 622 does not pressurize the oil reservoir. After the airbag 621 deflates, the compression spring 624 returns to its original position, causing the pressure plate 622 to pressurize the oil reservoir. At this time, the oil contained in the oil reservoir is quickly discharged through the fixing needle 63 to the reinforcing line.

[0051] When the external environment of the cable is poor, both the insulation protective layer 5 and the marking layer are subject to external corrosion. Since the marking layer is thinner than the insulation protective layer 5, it will be corroded and damaged first in a poor environment. At this time, the airbag 621 will release air through the exhaust pipe 623. When the pressure plate 622 is not supported by the airbag 621, it will reset under the compression spring 623. During the reset process, the oil storage bag will be pressurized, causing the protective oil in the oil storage bag to be squeezed towards the fixing needle 63 and discharged to the reinforcing wire through the fixing needle 63. After the protective oil is injected into the reinforcing wire row, it will flow along the gap between two adjacent reinforcing wires 2 to cover the cable area between two adjacent protective sleeves 6. After the insulation protective layer 5 of the cable is corroded and damaged, due to the reinforcing effect of the protective oil, when the shaping net 3 is corroded and damaged, the protective oil will cover the corrosion damage point, which will isolate the corrosive substances from further corroding the wire core. At the same time, the corrosion-resistant sponge sleeve 22 on the high-strength wire harness 21 will also absorb the protective oil to improve the corrosion resistance of the reinforcing wire 2, making the reinforcing wire 2 less susceptible to corrosion damage, and ensuring that the cable still has good strength when it is corroded.

[0052] This embodiment implements a dynamic protection mechanism for the cable. Through the combination of the airbag 621 and the compression spring 624, it provides a protective measure that responds quickly to changes in the external environment. When harsh external conditions cause corrosion damage to the marking layer, the airbag 621 deflates, and the compression spring 624 returns to its original position, thereby applying pressure to the oil reservoir. This causes the protective oil to be rapidly discharged to the reinforced conductors of the cable. After the protective oil is rapidly discharged, it covers the reinforced conductors between two adjacent protective sleeve sections 6. This design ensures that when the cable insulation layer is damaged, the protective oil can promptly cover the damaged area, effectively isolating corrosive substances and preventing further damage to the conductors.

[0053] During cable use, the protective oil is slowly released through the fixing pin, allowing the protective oil to be effectively distributed inside the cable. This dynamic protection mechanism not only improves the cable's corrosion resistance but also extends its service life, making it particularly suitable for cable protection in harsh environments.

[0054] In summary, the multi-protection design of this embodiment provides comprehensive protection for the cable. The synergistic segment protection sleeve 6 provides dynamic protection for the cable. During dynamic protection, protective oil is released to cover the conductor 1, which improves the cable's corrosion resistance and ensures limited protection for the conductor 1 after external damage to the cable. It is especially suitable for cable protection in harsh environments.

[0055] In light of current practical needs, the above-described embodiments adopted in this application are not limited to these. Any changes made within the scope of knowledge possessed by those skilled in the art without departing from the concept of this application still fall within the protection scope of this invention.

Claims

1. A corrosion-resistant special photovoltaic cable, comprising a conductor (1), wherein the conductor (1) is covered with an inner protective layer, a reinforcing bar is disposed on the inner protective layer, and an outer protective layer is covered on the reinforcing bar; characterized in that: The wire core (1) includes a wire core body, the outer side of which is covered with a porous protective layer, and a liquid isolation membrane is laid on the porous protective layer; The reinforced wire array includes multiple reinforced wires (2) that are equidistantly bonded around the core (1). Each reinforced wire (2) includes a high-strength wire bundle (21) covered with a corrosion-resistant sponge sleeve (22). A shaping mesh (3) is provided between the multiple reinforced wires (2). Both the upper and lower ends of the shaping mesh (3) are covered with a corrosion-resistant protective film. The shaping mesh (3) includes a protrusion (31) and a recess (32). The protrusion (31) is attached to the reinforcing line (2), and the recess (32) is located between two adjacent reinforcing lines (2). The inner and outer ends of the shaping mesh (3) are covered with a corrosion-resistant film. The outer side of the shaping net (3) is covered with an insulating protective layer (5). A corrosion-resistant resin layer (4) is filled between the insulating protective layer (5) and the recess (32). Multiple segment protective sleeves (6) are detachably provided on the insulating protective layer (5). Each segment protective sleeve (6) includes a pair of flexible base layers (61). Multiple pairs of hollow pads (62) are provided on the flexible base layers (61). Multiple fixing pins (63) that penetrate the hollow pads (62) are installed on the flexible base layers (61). An oil storage bag is provided inside the hollow pads (62). The oil storage bag stores protective oil. One end of the fixing pin (63) is inserted between two adjacent reinforcing lines (2) along the marking groove. The other end of the fixing pin (63) is inserted into the oil storage bag inside the hollow pads (62). The distance between two adjacent segment protective sleeves (6) is less than 5-10 cm.

2. The corrosion-resistant special photovoltaic cable according to claim 1, characterized in that: The insulating protective layer (5) has multiple uniformly distributed marking grooves, and the marking grooves are aligned with the center line of the recess (32); the depth of the marking grooves is 1-3mm.

3. The corrosion-resistant special photovoltaic cable according to claim 1, characterized in that: The method of covering the reinforcing wire (2) with the shaping mesh (3) includes: after the reinforcing wire (2) is equidistantly bonded to the core (1), the shaping mesh (3) is used to cover it. After covering the shaping mesh (3), a corrosion-resistant resin is coated on the shaping mesh (3) to fill the recess (32). Then, an insulating protective layer (5) is covered. Finally, the resin is heated to cure into a corrosion-resistant resin layer (4).

4. The corrosion-resistant special photovoltaic cable according to claim 1, characterized in that: The high-strength wire harness (21) includes thick wire segments and thin wire segments, which are distributed alternately. The high-strength wire harness is woven from corrosion-resistant fibers.

5. The corrosion-resistant special photovoltaic cable according to claim 1, characterized in that: The fixing pin (63) includes a hollow seat (631) connected to the flexible base layer (61). A hollow tube (632) is provided through the hollow seat (631). The length of the hollow tube (632) is less than the diameter of the reinforcing line (2). Before the segment protective sleeve is installed, a matching insertion hole is pre-opened on the marking groove. Oil guide holes are opened on the side walls at both ends of the hollow tube (632).

6. The corrosion-resistant special photovoltaic cable according to claim 1, characterized in that: An airbag (621) is provided inside the hollow pad (62). A pressure plate (622) matching the oil storage bag is provided inside the cavity of the hollow pad (62). Multiple compression springs (624) are connected between the pressure plate (622) and the inner wall of the cavity. An exhaust pipe (623) communicating with the airbag (621) is installed on the pressure plate (622). An identification layer that seals the exhaust pipe (623) outlet is provided on the surface of the hollow pad (62). The identification layer and the insulating protective layer (5) are both made of insulating material.

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