A type of wire conductor cable and its preparation method and apparatus

Abstract

This invention relates to the field of cable technology, and proposes a type of conductor cable and its manufacturing method and apparatus, comprising a star-shaped frame, an inner shell, functional wire harnesses, and wire cores. The star-shaped frame has multiple angled regions; the inner shell is disposed within the angled regions of the star-shaped frame, located at the center of the star-shaped frame, and forms a receiving cavity; the functional wire harnesses are arranged within the receiving cavity; the wire cores are arranged in the angled regions, abutting against the star-shaped frame and the inner shell, and the wire cores are bare stranded wire cores. This invention improves the protection of the functional wire harnesses by using a star-shaped frame for integrating them, with the functional wire harnesses covered by the inner shell. This is because the wire cores are fitted to the inner shell and the star-shaped frame, effectively protecting the functional wire harnesses from damage during subsequent compression. Simultaneously, the star-shaped frame achieves a partitioning function, facilitating the integration of different wire cores and improving the convenience of integrating multiple wire core bundles.

Description

Technical Field

[0001] This invention relates to the field of cable technology, and in particular to a shaped conductor cable and its preparation method and apparatus. Background Technology

[0002] Cored cables are cables with a specific core structure and shape, typically used in specific industrial applications and electrical engineering. Their core consists of one or more conductors encased in insulation material, and the entire structure is protected by an outer sheath. Cored cables are widely used in power transmission, communication, and control systems.

[0003] An existing invention patent application with publication number CN107068280A discloses a cable, which includes at least one liquid cooling pipe and at least one bare conductor, wherein the bare conductor is housed in the liquid cooling pipe, and an insulating liquid flows between the inner wall of the liquid cooling pipe and the outer wall of the bare conductor.

[0004] As in the above technical solution, the cable covers the bare conductor and core with an outer insulation layer. This structure creates a cavity inside the cable, which makes it weak against compression and prone to deformation. Although a filling layer can be set to fill the cavity, it is difficult to completely fill the cavity, and gaps will still exist. The relative positions of the cores inside are unstable.

[0005] Another invention patent application with publication number CN118522496A discloses an improved TPU material laser handheld welding line and its preparation method. The laser handheld welding line includes an outer sheath, control line, switch line, signal line, armored optical fiber, and air tube.

[0006] As described in the above technical solution, the cable also contains control lines, switches, signal lines, and light function harnesses. Currently, several core cables also use this method for cable integration. When a large number of bare twisted wires are used in the core, several bare twisted wires will be arranged side by side instead of twisted together. Therefore, the cable is prone to deformation after being squeezed, which will affect the internal integrated function harnesses and the overall application stability of the core cable. Summary of the Invention

[0007] In view of this, the present invention proposes a shaped conductor cable with strong extrusion resistance, which can effectively protect functional wire harnesses and is convenient to integrate, as well as its preparation method and preparation device, to solve the problem that the existing shaped conductor cables have poor extrusion resistance and are not conducive to protecting functional wire harnesses.

[0008] The technical solution of this invention is implemented as follows:

[0009] On one hand, the present invention provides a star-shaped conductor cable, comprising a star-shaped frame, an inner shell, a functional wire harness, and wire cores, wherein,

[0010] The star-shaped frame has multiple angular areas;

[0011] The inner shell is located within the angled area of ​​the star-shaped frame, and is situated at the center of the star-shaped frame, forming a receiving cavity;

[0012] The functional wiring harness is installed inside the accommodating cavity;

[0013] The conductors are arranged in the included area and support the star frame and inner shell. The conductors are bare stranded conductors.

[0014] Based on the above technical solutions, preferably, the star-shaped frame includes a first partition plate and a first reinforcing layer, and the inner shell includes an arc-shaped plate and side plates, wherein...

[0015] The first partition is arranged in a star shape with multiple partitions connected to each other to form an angled area. The first partition has a slot on the side away from the center.

[0016] The curved plate has side plates on both sides, and the two side plates abut against the two adjacent first partition plates to form a receiving cavity;

[0017] The functional wiring harness is located inside the curved plate;

[0018] The first reinforcing layer is fitted onto the star-shaped frame.

[0019] Based on the above technical solutions, preferably, the star-shaped frame also includes an expansion plate, which is disposed on the side of the first partition plate away from the center.

[0020] The thickness of the outer expansion plate is less than or equal to half the thickness of the first partition plate. There are two outer expansion plates, which are folded and pressed against each other to hold the wire core.

[0021] Based on the above technical solutions, preferably, the arc-shaped plate and the star-shaped frame are arranged concentrically, and the accommodating cavity is fan-shaped;

[0022] The length of the straight side of the accommodating cavity is greater than or equal to the diameter of the functional wire harness, and the accommodating cavity is filled with foamed filling material.

[0023] Based on the above technical solutions, preferably, the star-shaped frame includes a second spacer and a second reinforcing layer, and the inner shell includes a tube frame and a limiting plate, wherein...

[0024] The tube rack has a cylindrical tube structure, the functional wiring harness is placed inside the tube rack, and the tube rack is filled with foam filling material;

[0025] Multiple limiting plates and second partition plates are arranged around the pipe rack;

[0026] One side of the second partition plate is inserted into and limited by two limiting plates;

[0027] A second reinforcing layer is provided on the other side of each of the multiple second partition plates. The multiple second reinforcing layers are curved in an arc and abut against each other to form an annular shell.

[0028] Based on the above technical solutions, preferably, two adjacent second reinforcing layers overlap each other, and the overlapping portion of the two second reinforcing layers is extended by stamping so that the thickness of the overlapping portion is less than the thickness of the other portions.

[0029] Based on the above technical solutions, preferably, it also includes reinforcing strips, and the star-shaped frame is made of metal or flexible insulating material;

[0030] The reinforcing strips are connected to the star-shaped frame and are laid out along the length or radial direction of the star-shaped frame.

[0031] Based on the above technical solutions, the preferred embodiment further includes an insulation layer, an armor layer, and a cabling layer, wherein...

[0032] The insulation layer is fitted onto the star-shaped frame;

[0033] The armor layer is fitted over the insulating layer;

[0034] The cabling layer is installed on top of the armor layer.

[0035] On the other hand, the present invention discloses a method for preparing the above-mentioned shaped conductor cable, comprising the following steps:

[0036] S1. The first partition of the incoming star-shaped frame is a strip structure, and the first partition is fully unfolded by the unfolding device;

[0037] S2. Lay the functional wiring harness in the included angle area formed by the first partition plate and cover it with an inner shell;

[0038] S3. Lay the wire cores together with the star-shaped frame and inner shell;

[0039] S4. Wrap the first reinforcing layer on the outside to form a complete star-shaped frame;

[0040] S5. The star frame, inner shell, functional wire harness and wire core are covered by at least one metal layer;

[0041] S6. Extrude the metal layer to reduce its diameter.

[0042] Furthermore, the present invention provides a preparation apparatus for the above-mentioned method for preparing profiled conductor cables, comprising an unfolding device, which includes a carrier, an inner support, a forming roller, and a limiting roller, wherein...

[0043] The carrier is a frame structure;

[0044] Multiple internal supports are arranged in a circular array on the carrier frame. The internal supports include connecting parts and positioning parts, and connecting parts are provided on both sides of the positioning parts.

[0045] The forming roller is rotatably connected to the connecting part, and the forming rollers on two adjacent inner supports cooperate with each other to form a pair of rollers, which are used to unfold the first partition plate of the star-shaped frame;

[0046] The limiting roller is rotatably connected to the positioning part and is used to position the star-shaped frame.

[0047] The shaped conductor cable and its preparation method and apparatus of the present invention have the following advantages over the prior art:

[0048] Beneficial effects:

[0049] (1) By setting up a star-shaped frame to integrate functional wire harnesses and wire cores, and the functional wire harnesses are covered by the inner shell, the protection capability of the functional wire harnesses can be improved. This is because the wire cores are attached to the inner shell and the star-shaped frame, which can effectively protect the functional wire harnesses from damage when they are squeezed. At the same time, the star-shaped frame realizes the partitioning function, which facilitates the integration of different wire cores, improves the convenience of integrating multiple wire cores, and also improves the overall compression resistance of the cable.

[0050] (2) In the star-shaped frame structure, a first partition plate and a first reinforcing layer are used. Multiple first partition plates are an integral structure. After the first partition plate limits and integrates the wire core, the outer layer is set with a first reinforcing layer to maintain structural stability. When the inner shell covers the functional wire harness, it is held against the first partition plate by the side plate. This ensures that the position of the inner shell and the star-shaped frame is relatively stable, so as to avoid the problem of misalignment caused by squeezing and slippage during integration.

[0051] (3) By setting an expansion plate on the side of the first partition plate of the star frame, the expansion plate can be folded to pre-position the wire core after the wire core is integrated, which facilitates the subsequent laying of the first reinforcing layer to ensure the stability of the overall structure.

[0052] (4) In the star-shaped frame structure, a second partition plate and a second reinforcing layer are used. Multiple second partition plates are separate structures, and multiple second reinforcing layers are also provided. The inner shell adopts a tube rack structure to facilitate the housing of functional wire harnesses. The tube rack of the inner shell also uses a limiting plate to limit the insertion of the second partition plate. In this structure, the second partition plate and the second reinforcing layer are used to improve the compressive strength of the cable. The structure of the second partition plate and the second reinforcing layer is connected, and the structure of the inner shell can better protect the functional wire harnesses.

[0053] (5) In the preparation method of this cable, the first partition plate of the incoming star frame is folded into a strip structure. The first partition plate is unfolded by an unfolding device, and then the functional wire harness and wire core are integrated. This can ensure the convenience of production and facilitate the storage of star frame raw materials. At the same time, in this preparation method, a metal layer is used to cover the wire harness and it is subjected to extrusion and diameter reduction treatment. This can ensure that the components of the cable fit tightly and reduce the diameter of the cable.

[0054] (6) In the unfolding device of this preparation apparatus, the inner support is arranged in a ring array and is equipped with forming rollers and limiting rollers. The forming rollers can guide the first spacer of the star frame, while the limiting rollers can center multiple first spacers. This ensures that the position of the star frame and other components is relatively stable during feeding, thus ensuring production accuracy. Attached Figure Description

[0055] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0056] Figure 1 This is a perspective view of the profiled conductor cable of the present invention;

[0057] Figure 2 For the present invention Figure 1 Enlarged view of the structure at point A in the middle;

[0058] Figure 3 This is a schematic diagram of the end face structure of the profiled conductor cable of the present invention;

[0059] Figure 4 A structural diagram showing the star-shaped cable of the present invention with an outer expansion plate;

[0060] Figure 5 A schematic diagram of the end face structure of the star-shaped conductor cable of the present invention with an outer expansion plate;

[0061] Figure 6 This is a perspective view of the outer expansion plate closing structure of the profiled conductor cable of the present invention;

[0062] Figure 7 This is a perspective view of the inner shell of the profiled conductor cable of the present invention;

[0063] Figure 8 This is a diagram showing the structure of the first spacer plate being retracted in the star-shaped frame of the profiled conductor cable of the present invention;

[0064] Figure 9This is a structural diagram of the star-shaped frame mounting reinforcement strip for the profiled conductor cable of the present invention;

[0065] Figure 10 This is a perspective view of the wire conductor cable manufacturing apparatus of the present invention;

[0066] Figure 11 This is a front view of the application state of the profiled conductor cable manufacturing apparatus of the present invention;

[0067] Figure 12 This is a perspective view of the application state of the profiled conductor cable manufacturing apparatus of the present invention;

[0068] Figure 13 A perspective view of the star-shaped conductor cable of the present invention employing a second spacer structure;

[0069] Figure 14 This is a schematic diagram of the end face structure of the star-shaped conductor cable of the present invention, which adopts a second spacer structure.

[0070] Figure 15 This is a perspective view of the inner shell of the profiled conductor cable of the present invention, which uses a tube frame and a limiting plate;

[0071] Figure 16 This is a structural diagram showing the inner shell of the profiled conductor cable of the present invention, which uses a second spacer plate overlapping each other.

[0072] In the diagram: 1. Star-shaped frame; 11. First partition plate; 12. First reinforcing layer; 13. Outer expansion plate; 14. Foam filling material; 101. Angle area; 102. Accommodating cavity; 103. Groove; 2. Inner shell; 21. Arc plate; 22. Side plate; 3. Functional wire harness; 4. Wire core; 5. Reinforcing strip; 6. Insulation layer; 7. Armor layer; 8. Cabling layer;

[0073] 111. Second partition plate; 112. Second reinforcing layer; 221. Pipe rack; 222. Limiting plate;

[0074] 100. Unfolding device; 1001. Carrier frame; 1002. Inner support; 10021. Connecting part; 10022. Positioning part; 1003. Forming roller; 1004. Limiting roller. Detailed Implementation

[0075] The technical solutions of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative effort are within the scope of protection of the present invention.

[0076] like Figures 1-16As shown, the shaped conductor cable of the present invention includes a star-shaped frame 1, an inner shell 2, a functional wire harness 3, a wire core 4, a reinforcing strip 5, an insulation layer 6, an armor layer 7, and a cabling layer 8.

[0077] The unfolding device 100 of the present invention includes a carrier 1001, an inner support 1002 connecting part 10021 and a positioning part 10022, a forming roller 1003 and a limiting roller 1004.

[0078] like Figures 1-5 As shown, the star frame 1 has multiple angled regions 101; the inner shell 2 is disposed within the angled regions 101 of the star frame 1, the inner shell 2 is located at the center of the star frame 1, and forms a receiving cavity 102; the functional wire harness 3 is disposed within the receiving cavity 102; the wire core 4 is disposed within the angled regions 101, and abuts against the star frame 1 and the inner shell 2, the wire core 4 is a bare stranded wire core;

[0079] As described above, in this type of conductor cable, the inner shell 2, functional wire harness 3 and wire core 4 are arranged in the included area 101 of the star frame 1;

[0080] During the manufacturing process, the functional wire harness 3 is fitted to the inner corner of the included angle region 101, and then the inner shell 2 is set to cooperate with the star frame 1 to form a receiving cavity 102, thereby achieving protection for the functional wire harness 3.

[0081] Then, the wire core 4 is attached to the inner shell 2 and arranged in the star frame 1. In this way, the functional wire harness 3 is located on the innermost side. Under the effect of this layout structure, the functional wire harness 3 on the inner side can be effectively protected from compression damage. Relying on the star frame 1, the compression resistance of this cable can be improved, and the integration and partitioning of the functional wire harness 3 and the wire core 4 can also be improved.

[0082] The core 4 is a bare stranded wire core. When several cores 4 are arranged side by side to fill the angled area 101, they can adapt to deformation to fit well with the inner shell 2 and fully fill the gap. It is suitable for the angled area 101 of the star frame 1, and the star frame 1 is also suitable for integrating bare stranded wire cores.

[0083] In some embodiments, multiple angled regions 101 are used to accommodate different types of wire cores 4.

[0084] Regarding the structural layout of the star-shaped frame 1 and the inner shell 2, the present invention provides two embodiments.

[0085] Example 1, see Figures 1-7 :

[0086] like Figures 1-7As shown, the star-shaped frame 1 includes a first partition plate 11 and a first reinforcing layer 12, and the inner shell 2 includes an arc-shaped plate 21 and side plates 22. The first partition plates 11 are arranged in a star shape and are connected to each other to form an angled region 101. The side of the first partition plate 11 away from the center position has a slot 103. The arc-shaped plate 21 has side plates 22 on both sides, and the two side plates 22 abut against the two adjacent first partition plates 11 to form a receiving cavity 102. The functional wire harness 3 is located inside the arc-shaped plate 21. The first reinforcing layer 12 is sleeved on the star-shaped frame 1.

[0087] As described above, in this embodiment, the first partition plate 11 and the first reinforcing layer 12 of the star-shaped frame 1 are set separately, and the inner shell 2 is provided with multiple parts in the included angle region 101.

[0088] Among them, multiple first partition plates 11 are interconnected to form a star-shaped structure to form an angled region 101 for accommodating the inner shell 2, the functional wire harness 3 and the wire core 4;

[0089] When the inner shell 2 is installed to form the cavity 102 to protect the functional wire harness 3, the inner shell 2 is held against the first spacer 11 of the star frame 1 by the two side plates 22. In this way, when the wire core 4 is integrated and bundled, the position of the inner shell 2 and the star frame 1 can be kept relatively stable, so as to avoid the problem of misalignment caused by squeezing and slipping of the inner shell 2 during integration.

[0090] After the wire core 4 is laid on the outer side of the inner shell 2, the first reinforcing layer 12 is laid on the outermost side to gather them together, forming a complete star frame 1, so as to ensure the structural stability of each component.

[0091] In this structure, in order to improve the bending resistance of the cable, a slot 103 is provided on the side of the first partition plate 11 away from the center. By setting the slot 103, the side length of the first partition plate 11 is increased. When the cable is bent, the first partition plate 11 can better adapt to the deformation, so as to reduce the occurrence of tearing and ensure its service life.

[0092] like Figures 4-6 As shown, the star frame 1 also includes an outer expansion plate 13, which is disposed on the side of the first partition plate 11 away from the center. The thickness of the outer expansion plate 13 is less than or equal to half the thickness of the first partition plate 11. There are two outer expansion plates 13, which are folded over to hold the wire core 4.

[0093] As described above, by setting the outer expansion plate 13, after the core 4 is assembled into the included angle region 101, the outer expansion plate 13 can be folded to press the outer side of the core 4, thereby achieving the pre-positioning of the core 4. This facilitates the subsequent setting of the first reinforcing layer 12, thereby increasing the stability of each component to a certain extent.

[0094] The thickness of the outer expansion plate 13 is set to half that of the first spacer plate 11, or the thickness is set to less than half. This facilitates integration with the first spacer plate 11 and also reduces the inner gap after the first reinforcing layer 12 is set, ensuring a compact structure.

[0095] like Figure 6 As shown, the outer expansion plate 13 can be flush with the first partition plate 11 in the initial state. After the wire core 4 is laid, it is folded to both sides to hold the wire core 4.

[0096] like Figure 3 As shown, the arc plate 21 is concentrically arranged with the star frame 1, and the accommodating cavity 102 is fan-shaped; the length of the straight side of the accommodating cavity 102 is greater than or equal to the diameter of the functional wire harness 3, and the accommodating cavity 102 is provided with foam filling material 14.

[0097] As described above, after the inner shell 2 is installed, the functional wire harness 3 cannot completely fill the accommodating cavity 102. Therefore, in order to ensure the stability of the functional wire harness 3, it is filled with foam filling material 14 to avoid displacement of the functional wire harness 3.

[0098] In order to ensure the stability of the functional harness 3, its diameter is controlled to be less than or equal to the length of the straight side of the sector cavity 102;

[0099] When the diameter of the functional harness 3 is equal to the side length of the straight side of the accommodating cavity 102, it will be squeezed by the inner shell 2 and the star frame 1. Then, when the foaming material is injected, the functional harness 3 will be further squeezed to stabilize its position.

[0100] When the diameter of the functional wire harness 3 is smaller than the side length of the straight side of the accommodating cavity 102, the foaming material can completely fill the accommodating cavity 102 and also stabilize the position of the functional wire harness 3.

[0101] Example 2, see Figures 13-16 :

[0102] The difference between this embodiment and Embodiment 1 is that the star-shaped frame 1 and the inner shell 2 adopt different structures.

[0103] like Figures 13-15 As shown, the star-shaped frame 1 includes a second partition plate 111 and a second reinforcing layer 112, and the inner shell 2 includes a tube frame 221 and a limiting plate 222. The tube frame 221 has a cylindrical structure, the functional wire harness 3 is disposed inside the tube frame 221, and the tube frame 221 is provided with foam filling material 14. Multiple limiting plates 222 and second partition plates 111 are provided around the tube frame 221. One side of the second partition plate 111 is inserted into and limited by two limiting plates 222. A second reinforcing layer 112 is provided on the other side of the multiple second partition plates 111. The multiple second reinforcing layers 112 are curved and abut against each other to form an annular outer shell.

[0104] As described above, in this embodiment, the second spacer 111 and the second reinforcing layer 112 are both divided into multiple parts, and the second spacer 111 and the second reinforcing layer 112 are connected to form multiple independent connection structures.

[0105] Among them, the tube rack 221 and the limiting plate 222 are an integral structure, which can be integrally formed by extrusion and wrapped around the functional wire harness 3; it can form a cavity to accommodate the functional wire harness 3 and fill it with foam filling material 14; or directly extrude and wrap the functional wire harness 3, with the inner shell 2 in direct contact with the functional wire harness 3.

[0106] Subsequently, a star-shaped frame 1 is set on the inner shell 2, the second partition plate 111 is inserted into the limiting plate 222, and the wire core 4 is laid out at the same time. Then, the second reinforcing layer 112 is folded over to cover the wire core 4. The second reinforcing layer 112 can be set on the first partition plate 11 in the same way as the outer expansion plate 13 in Embodiment 1, and the thickness of the second reinforcing layer 112 is set to be less than or equal to half the thickness of the first partition plate 11. After all the second partition plates 111 and the second reinforcing layers 112 are laid out, the edges of the adjacent second reinforcing layers 112 are in contact to fully cover the wire core 4 and ensure the stability of the needle body structure.

[0107] like Figure 16 As shown, two adjacent second reinforcing layers 112 overlap each other, and the overlapping portion of the two second reinforcing layers 112 is stamped and extended so that the thickness of the overlapping portion is less than the thickness of the other portions.

[0108] In order to further ensure the covering effect, the second reinforcing layer 112 can be made wider, so that adjacent second reinforcing layers 112 can overlap and contact each other to ensure structural stability.

[0109] To avoid the second reinforcing layer 112 overlapping tightly with the outer functional layer, the edges of the second reinforcing layer 112 are stamped and extended to form overlapping sections. This reduces the thickness at the edges of the second reinforcing layer 112, so that the second reinforcing layer 112 has a uniform thickness after overlapping, thus making better contact with the outer functional layer, reducing the generation of gaps and preventing delamination problems.

[0110] Specifically, the star-shaped frame 1 is made of metal or flexible insulating material; the reinforcing strip 5 is connected to the star-shaped frame 1 and is arranged along the length or radial direction of the star-shaped frame 1;

[0111] As described above, the star-shaped frame 1 can be made of metal to complement the wire core 4 and improve conductivity; specifically, it can be made of flexible metal or relatively thin ordinary metal.

[0112] To accommodate different core integrations, the star frame 1 can also be made of insulating material to ensure that different cores are insulated from each other;

[0113] To improve the structural strength of the star-shaped frame 1, reinforcing strips 5 are installed to enhance its strength;

[0114] Specifically, the reinforcing strip 5 can be made of flexible metal or nylon and is arranged along the length or radial direction of the star-shaped frame 1 on the first partition plate 11.

[0115] In some embodiments, the first partition 11 of the star-shaped frame 1 is a mesh plate.

[0116] like Figures 1-5 As shown, insulation layer 6 is fitted onto star frame 1; armor layer 7 is fitted onto insulation layer 6; cabling layer 8 is fitted onto armor layer 7;

[0117] As described above, the insulation layer 6 is used to improve the insulation effect of the cable, the armor layer 7 is used to further improve the structural strength of the cable, and the cabling layer 8 further realizes the protective effect. For example, the cabling layer 8 is a shielding layer or is formed by multi-layer composite materials.

[0118] The method for preparing a medium-sized conductor cable according to Embodiment 1 of the present invention includes the following steps:

[0119] S1. The first partition plate 11 of the incoming star-shaped frame 1 is a strip structure, and the first partition plate 11 is fully unfolded by the unfolding device 100.

[0120] S2. A functional wiring harness 3 is laid in the included angle region 101 formed by the first partition plate 11 and covered by the inner shell 2;

[0121] S3. Arrange the wire core 4 by attaching it to the star-shaped frame 1 and the inner shell 2;

[0122] S4. Wrap the first reinforcing layer 12 on the outside to form a complete star-shaped frame 1;

[0123] S5. The star frame 1, inner shell 2, functional wire harness 3 and wire core 4 are covered by at least one metal layer;

[0124] S6. Extrude the metal layer to reduce its diameter.

[0125] In the manufacturing method of this cable, the first partition plate 11 of the incoming star frame 1 is a strip structure, which is unfolded by the unfolding device 100 and then integrated with the functional wire harness 3 and the wire core 4. This can ensure the convenience of production and facilitate the storage of raw materials of the star frame 1.

[0126] Meanwhile, in this preparation method, a metal layer is used to cover the wire harness, and it is subjected to extrusion and diameter reduction treatment. This ensures that the various components of the cable fit together tightly and reduces the cable diameter.

[0127] Such as 10 and Figure 11 As shown, in the unfolding device 100, the carrier 1001 has a frame structure; multiple inner supports 1002 are arranged in a circular array on the carrier 1001, and the inner supports 1002 include a connecting part 10021 and a positioning part 10022. The positioning part 10022 has a connecting part 10021 on both sides; the forming roller 1003 is rotatably connected to the connecting part 10021, and the forming rollers 1003 on two adjacent inner supports 1002 cooperate with each other to form a pair of rollers for unfolding the first partition plate 11 of the star frame 1; the limiting roller 1004 is rotatably connected to the positioning part 10022 for positioning the star frame 1.

[0128] like Figure 8 and Figure 9 As shown, the star-shaped frame 1, in its initial state, has a folding structure for convenient storage, logistics, and material supply. When in use, it can be folded as follows: Figure 11 and Figure 12 As shown, the end of the first partition plate 11 is unfolded and introduced into the unfolding device 100. The first partition plate 11 is clamped and guided by the forming roller 1003, while the limiting roller 1004 supports the inner corner of the connection between the two first partition plates 11 and centers the multiple first partition plates 11. As the first partition plates 11 are fed, they will all be unfolded. The inner shell 2, functional wire harness 3 and wire core 4 can then be laid out.

[0129] In some embodiments, the forming roller 1003 is connected to the motor spindle, thereby driving the first spacer 11 to be fed.

[0130] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method of preparing a profiled conductor cable, characterized in that, The method comprises the following steps: S1, the first spacing plate (11) of the incoming material star frame (1) is in a strip structure, and the first spacing plate (11) is completely unfolded through an unfolding device (100); S2, a functional wire harness (3) is laid in an included angle region (101) formed by the first spacing plate (11), and an inner shell (2) is used for covering; S3, a wire core (4) is laid by being attached to the star frame (1) and the inner shell (2); S4, a first reinforcing layer (12) is wrapped on the outer side to form a complete star frame (1); S5, the star frame (1), the inner shell (2), the functional wire harness (3) and the wire core (4) are covered by at least one metal layer; S6, the metal layer is extruded, and the metal layer is subjected to a diameter reduction treatment; The profile conductor cable comprises a star frame (1), an inner shell (2), a functional wire harness (3) and a wire core (4), wherein The star frame (1) has a plurality of included angle regions (101); The inner shell (2) is arranged in the included angle region (101) of the star frame (1), and the inner shell (2) is located at a central position of the star frame (1) and forms a containing cavity (102); The functional wire harness (3) is laid in the containing cavity (102); The wire core (4) is laid in the included angle region (101) and abuts against the star frame (1) and the inner shell (2), and the wire core (4) is a bare stranded wire core; The star frame (1) comprises a first spacing plate (11) and a first reinforcing layer (12), and the inner shell (2) comprises an arc-shaped plate (21) and a side plate (22), wherein the first spacing plate (11) is arranged in a star shape and has a plurality of first spacing plates (11) which are connected to each other to form the included angle region (101), and a notch (103) is formed in a side edge of the first spacing plate (11) away from the central position; the arc-shaped plate (21) is provided with the side plate (22) on both sides, and the two side plates (22) abut against two adjacent first spacing plates (11) to form the containing cavity (102); the functional wire harness (3) is located on an inner side of the arc-shaped plate (21); and the first reinforcing layer (12) is sleeved on the star frame (1).

2. The method of making a profiled conductor cable as claimed in claim 1, characterized in that: The star frame (1) further comprises an outward expansion plate (13) arranged on the side edge of the first spacing plate (11) away from the central position; The thickness of the outward expansion plate (13) is less than or equal to one half of the thickness of the first spacing plate (11), and the outward expansion plate (13) is provided with two outward expansion plates (13) which are oppositely folded to hold the wire core (4).

3. The method of making a profiled conductor cable of claim 1, wherein: The arc-shaped plate (21) is concentrically arranged with the star frame (1), and the containing cavity (102) is in a fan shape; The length of a straight line side of the containing cavity (102) is greater than or equal to the diameter of the functional wire harness (3), and the containing cavity (102) is provided with foamed filling material (14).

4. The method of making a profiled conductor cable of claim 1, wherein: The star frame (1) comprises a second spacing plate (111) and a second reinforcing layer (112), and the inner shell (2) comprises a pipe frame (221) and a limiting plate (222), wherein The pipe frame (221) is in a circular tube structure, the functional wire harness (3) is arranged in the pipe frame (221), and the pipe frame (221) is provided with foamed filling material (14); The limiting plate (222) and the second spacing plate (111) are both provided with a plurality of around the pipe frame (221); One side of the second spacing plate (111) is inserted and limited by two limiting plates (222); The other side of the plurality of second spacing plates (111) is provided with the second reinforcing layer (112), and the plurality of second reinforcing layers (112) are arc-shaped and abut each other to form a ring-shaped shell.

5. The method of making a profiled conductor cable as claimed in claim 4, characterized in that: The two second reinforcing layers (112) are overlapped with each other, and the overlapping parts of the two second reinforcing layers (112) are stretched by stamping, so that the thickness of the overlapping parts is smaller than that of other parts.

6. A method of producing a profiled conductor cable according to any one of claims 1 to 5, characterized in that: It also includes a reinforcing strip (5), and the star frame (1) is made of metal or flexible insulating material; The reinforcing strip (5) is connected with the star frame (1) and is arranged along the length direction or the radial direction of the star frame (1).

7. A method of producing a profiled conductor cable according to any one of claims 1 to 5, characterized in that: It also includes an insulating layer (6), an armored layer (7) and a cabling layer (8), wherein the insulating layer (6) is sleeved on the star frame (1); the armored layer (7) is sleeved on the insulating layer (6); and the cabling layer (8) is sleeved on the armored layer (7).

8. A manufacturing apparatus for use in a manufacturing method for a profiled conductor cable as claimed in claim 1, characterized in that: The expansion device (100) includes a carrier (1001), an inner support (1002), a forming roller (1003) and a limiting roller (1004), wherein, The carrier (1001) is a frame structure; The inner support (1002) is arranged in a ring array on the carrier (1001), and the inner support (1002) includes a connecting part (10021) and a positioning part (10022), and the connecting part (10021) is arranged on both sides of the positioning part (10022); The forming roller (1003) is rotationally connected with the connecting part (10021), and the forming rollers (1003) on the adjacent two inner supports (1002) cooperate to form a pair of rollers for expanding the first spacing plate (11) of the star frame (1); The limiting roller (1004) is rotationally connected with the positioning part (10022) and is used for positioning the star frame (1).

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