Digital cable for photovoltaic power generation system and manufacturing method

Abstract

The invention relates to the technical field of photovoltaic cable manufacturing, and provides a digital cable for a photovoltaic power generation system and a manufacturing method.The digital cable comprises a plurality of center supporting pieces, the center supporting pieces are spliced to form a center supporting structure of the cable, and limiting grooves are formed in the outer surfaces of the center supporting pieces in the cable direction and used for installing cable cores; a ventilation groove is formed in the inner surface of the center supporting piece. The defects in the prior art are overcome, the design is reasonable, the structure is compact, the overall strength is enhanced through circumferential splicing of the cable center supporting structure, the cable cores are effectively isolated through the design of the limiting grooves, heat cross accumulation is avoided, a ventilation channel formed in the center of the formed cable is communicated with the outside, air convection and heat exchange inside and outside the cable are achieved, and the service life of the cable is prolonged. And the heat dissipation efficiency is obviously improved. And after the cable is integrally manufactured, an air inlet channel is formed in a drilling hole, so that the problem that a heat dissipation channel is blocked by a processing material is avoided, and the manufacturing difficulty is further reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of photovoltaic cable manufacturing, and in particular to a digital cable for a photovoltaic power generation system and a manufacturing method thereof. Background Art

[0002] Photovoltaic cables, as an important transmission medium in photovoltaic power generation systems, are responsible for safely and efficiently transmitting the electricity generated by solar panels to energy storage or power-consuming equipment. However, in actual installation and use, photovoltaic cables are often directly exposed to strong sunlight, which causes the surface and internal temperature of the cables to rise sharply. At present, the air inside and outside the photovoltaic cables is not circulated, making it difficult for the cables to effectively dissipate heat in high temperature environments, and overheating occurs frequently. Overheating will not only affect the electrical properties of photovoltaic cables, such as increased resistance and decreased insulation performance, but may also accelerate the aging process of the cables and shorten their service life. To this end, we propose a digital cable and manufacturing method for photovoltaic power generation systems. Summary of the invention

[0003] 1. Technical issues to be resolved

[0004] In view of the deficiencies of the prior art, the present invention provides a digital cable for a photovoltaic power generation system and a manufacturing method, which overcomes the deficiencies of the prior art, has a reasonable design and a compact structure, and solves the problems of poor air circulation inside and outside the existing photovoltaic cables and frequent overheating.

[0005] (II) Technical solution

[0006] To achieve the above objectives, the present invention is implemented through the following technical solutions: a digital cable for a photovoltaic power generation system, comprising a plurality of central support members, wherein the plurality of central support members are spliced ​​together to form a central support structure of the cable, the outer surface of the central support member is provided with a limit groove along the cable direction for installing the wire core, the inner surface of the central support member is provided with a ventilation groove, so that a ventilation channel is formed in the center of the central support structure formed by splicing the plurality of central support members, a plurality of arc channels are symmetrically provided on both sides of the central support member, both ends of the arc channels are connected to the ventilation channel, an air inlet channel connected to the arc channel is also provided in the central support member, a duct is provided in the air inlet channel, one end of the duct extends to the surface of the digital cable, so that the outside of the digital cable is connected with the inside of the ventilation channel.

[0007] Preferably, the wire core comprises a conductor, a flame retardant layer, a heat resistant layer and a waterproof layer which are arranged in sequence from the inside to the outside.

[0008] Preferably, a wire core is arranged in the limiting groove of the outer wall of the central support structure, an outer coating structure is arranged outside the wire core, the outer coating structure and the diameter of the wire core and the central support structure are filled with a filler layer, and the outer coating structure includes an insulating layer and a wear-resistant layer.

[0009] Preferably, the conduit is made of thermally conductive silicone.

[0010] Preferably, the filler layer is made of a mixture of hydrophobic materials polyolefin and graphite.

[0011] A method for manufacturing a digital cable for a photovoltaic power generation system comprises the following steps:

[0012] S1. A plurality of central support members are formed by injection molding, wherein the formed central support members do not include an air inlet channel section;

[0013] S2, splicing several central support members together and applying glue on the splicing side to form a central support structure of the cable;

[0014] S3, applying glue to the limiting groove of the central support structure formed in step S2, and then inserting a plurality of wire cores into the limiting groove to achieve bonding of the plurality of wire cores;

[0015] S4, adding the filler layer material into a cable extruder for heating and softening, and then passing the cable formed in step S3 into the extruder, and the filler layer material is filled into the gaps in the outer wall of the cable to form a stable and smooth cylindrical cable;

[0016] S5, passing the stable and smooth cylindrical cable in step S4 into cold water for cooling and solidification, so that the filler layer material forms a firm bond with the wire core;

[0017] S6, adding the cable outer coating material into a cable extruder for heating and softening, and then passing the cable formed in step S5 into the extruder, so that the cable outer coating material covers the cable formed in step S5;

[0018] S7, passing the cable in step S6 into cold water to cool and solidify, so that the outer coating layer material forms a firm bond with the inner side;

[0019] S8, drilling holes circumferentially on the cable formed in step S7 by a drilling device, and allowing the drill bit to penetrate into the arc-shaped channel. After the drill bit is pulled out, the hole drilled by the drilling device in the central support member forms an air inlet channel;

[0020] S9, apply glue to the outer wall of the hollow conduit, and insert it into the hole drilled in step S7, and insert one end of the conduit into the air inlet channel so that the other end is flush with the outer wall of the cable.

[0021] Preferably, the arc-shaped channels of the central support member injection-molded in step S1 are arranged at equal distances along the length direction of the central support member.

[0022] Preferably, the outer coating material in step S6 comprises a plurality of layers, and steps S6 and S7 are repeated to form a plurality of layers of coating on the outer layer of the cable.

[0023] Preferably, when the drilling device performs circumferential drilling on the cable in step S8, a circumferentially arranged drill bit is used to drill the cable, so that circumferentially arranged holes are formed in the cable.

[0024] Preferably, in step S8, the diameter of the hole drilled by the drilling device for the cable is smaller than the minimum distance between two wire cores, and the drilling position is located on a vertical line between adjacent wire cores.

[0025] (III) Beneficial effects

[0026] The embodiments of the present invention provide a digital cable for a photovoltaic power generation system and a manufacturing method thereof.

[0027] It has the following beneficial effects:

[0028] 1. The circumferential splicing of the cable center support structure enhances the overall strength. The limit groove design effectively isolates the wire core to avoid cross-accumulation of heat. The ventilation channel formed in the center of the cable after molding is connected to the outside world, realizing air convection and heat exchange inside and outside the cable, and significantly improving the heat dissipation efficiency.

[0029] 2. The multi-layer protection structure of the cable core, including flame retardant, heat resistant and waterproof layers, ensures the stable operation of the cable in various environments.

[0030] 3. The addition of filler layer and outer coating layer not only improves the structural stability of the cable, but also enhances its electrical and physical isolation performance.

[0031] 4. During the manufacturing process, the center support is first injection molded, and then the wire core is spliced ​​and fixed, which reduces the manufacturing difficulty.

[0032] 5. After the cable is manufactured as a whole, an air inlet channel is formed by drilling holes, which not only avoids the problem of processed materials blocking the heat dissipation channel, but also further reduces the manufacturing difficulty. BRIEF DESCRIPTION OF THE DRAWINGS

[0033] Figure 1 It is a three-dimensional schematic diagram of the overall structure of the present invention;

[0034] Figure 2 It is a three-dimensional schematic diagram of the insulating layer of the present invention;

[0035] Figure 3 It is a three-dimensional schematic diagram of the central support structure of the present invention;

[0036] Figure 4 It is a three-dimensional schematic diagram of the central support member of the present invention.

[0037] In the figure: 1. center support member; 11. limit groove; 12. ventilation groove; 13. arc channel; 14. air inlet channel; 15. duct; 21. conductor; 22. flame retardant layer; 23. heat-resistant layer; 24. waterproof layer; 31. insulation layer; 32. wear-resistant layer; 4. packing layer. DETAILED DESCRIPTION

[0038] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0039] See attached Figure 1-4 A digital cable for a photovoltaic power generation system comprises a plurality of central support members 1, wherein the plurality of central support members 1 are spliced ​​with each other in a circumferential direction to form a central support structure of the cable, so as to improve the structural strength of the entire cable, and a limit groove 11 is provided on the outer surface of the central support member 1 along the cable direction, which is used to install the wire core and separate the wire core installed on the periphery of the central support structure, so as to avoid the cross-gathering of heat of the wire core during use, and a ventilation groove 12 is provided on the inner surface of the central support member 1, so that a ventilation channel is formed in the center of the central support structure formed by splicing the plurality of central support members 1, and a plurality of arc channels 13 are symmetrically provided on both sides of the central support member 1, and the plurality of arc channels 13 on one side are arranged equidistantly along the length direction of the central support member 1, and both ends of the arc channels 13 are connected with the ventilation channel, and an air inlet channel 14 connected with the arc channel 13 is also provided in the central support member 1, and a conduit 15 is provided in the air inlet channel 14, and one end of the conduit 15 extends to the surface of the digital cable, so that the outside of the digital cable is connected with the inside of the ventilation channel, so as to realize the convection and heat exchange of air inside and outside the cable, facilitate the heat dissipation inside the cable, effectively reduce the working temperature of the cable, and prolong the service life.

[0040] The wire core includes a conductor 21, a flame retardant layer 22, a heat-resistant layer 23 and a waterproof layer 24 which are arranged in sequence from the inside to the outside. The conductor 21 is an aluminum wire or a copper wire. The flame retardant layer 22 is made of a low-smoke halogen-free polyolefin material, which can effectively prevent the spread of fire in the event of a fire. The heat-resistant layer 23 is made of a silane self-crosslinking low-smoke halogen-free flame-retardant polyolefin material, which enhances the stability of the wire core in a high temperature environment. The waterproof layer 24 is made of a polytetrafluoroethylene material to ensure the normal operation of the cable in a humid environment and avoid moisture intrusion and short circuits.

[0041] A wire core is provided in the limiting groove 11 on the outer wall of the central supporting structure. The wire core is installed in the limiting groove 11 outside the central supporting structure. After installation, it is covered with an outer coating structure. The outer coating structure and the wire core and the diameter of the central supporting structure are filled with a filler layer 4. The outer coating structure includes an insulating layer 31 and a wear-resistant layer 32 from the inside to the outside to ensure electrical and physical isolation of the cable.

[0042] The conduit 15 is made of thermally conductive silicone, has good thermal conductivity, and can quickly conduct heat away from the cable.

[0043] The packing layer 4 is made of a mixture of hydrophobic materials polyolefin and graphite. The packing layer 4 has good hydrophobic properties and can further assist in heat dissipation through the thermal conductivity of graphite.

[0044] A method for manufacturing a digital cable for a photovoltaic power generation system comprises the following steps:

[0045] S1, a plurality of central support members 1 are injection molded by a mold, and the molded central support members 1 are taken out after being cooled and solidified. The molded central support members 1 do not include the air inlet channel 14, so that the arc channel 13 and the ventilation slot 12 are not connected to the outer surface of the central support member 1 in the initial state, so as to prevent the processing material from entering the arc channel 13 and the ventilation slot 12 in the subsequent processing process, causing the arc channel 13 and the ventilation slot 12 to be blocked and affect the heat dissipation;

[0046] S2. Splice several central support members 1 circumferentially with each other, and apply glue on the splicing side. The splicing surfaces must be accurately aligned to ensure that the splicing is firm and seamless, forming a central support structure for the cable to provide strong support for the cable as a whole;

[0047] S3, applying glue to the limiting groove 11 of the central support structure formed in step S2, and then inserting a plurality of wire cores into the limiting groove 11 one by one. After the glue is cured, the wire cores are fixed into the limiting groove 11, thereby achieving bonding of the plurality of wire cores;

[0048] S4, adding the filler layer 4 material into the cable extruder for heating and softening, and then passing the cable structure with the wire core formed in step S3 into the extruder, and the filler layer 4 material is evenly coated on the outer wall of the cable under the pressure of the extruder, filling the gaps in the outer wall of the cable to form a stable and smooth cylindrical cable;

[0049] S5, passing the stable and smooth cylindrical cable in step S4 into cold water for cooling and solidification, so that the material of the filler layer 4 forms a firm bond with the wire core to enhance the overall strength and stability of the cable;

[0050] S6, adding the cable outer coating material into a cable extruder for heating and softening, and then passing the cable formed in step S5 into the extruder, and the cable outer coating material covers the cable formed in step S5 to form an outer coating layer of the cable;

[0051] S7, passing the cable in step S6 into cold water to cool and solidify, so that the outer coating layer material forms a firm bond with the inner side;

[0052] S8, the cable formed in step S7 is circumferentially drilled by a drilling device. When the drilling device performs circumferential drilling on the cable, a circumferentially arranged drill bit is used to drill the cable so that circumferentially arranged holes are formed in the cable. The cable does not need to be rotated during the drilling process, which greatly reduces the difficulty of drilling. The drill bit penetrates into the arc-shaped channel 13. The diameter of the hole drilled by the drilling device for the cable is smaller than the minimum distance between the two cores, and the drilling position is located on the vertical line between adjacent cores, ensuring that the drilling will not damage the core. After the drill bit is pulled out, the hole drilled by the drilling device in the central support member 1 forms an air inlet channel 14. After the cable is formed as a whole, drilling is performed to form the air inlet channel 14, which can avoid blockage of the air inlet channel 14, the arc channel 13 and the ventilation slot 12;

[0053] S9, apply glue to the outer wall of the hollow conduit 15, and insert it into the hole drilled in step S7, and insert one end of the conduit 15 into the air inlet channel 14, so that the other end is flush with the outer wall of the cable. The insertion of the hollow conduit 15 provides an effective way for air circulation inside and outside the cable, thereby enhancing the heat dissipation capacity inside the cable.

[0054] The arc-shaped channels 13 formed by injection molding of the central support member 1 in step S1 are arranged at equal distances along the length direction of the central support member 1, which helps to improve the heat exchange efficiency between the cable center and the outside.

[0055] In step S6, the outer coating material comprises a plurality of layers, and steps S6 and S7 are repeated to form a plurality of layers of coating on the outer layer of the cable, thereby further improving the safety and durability of the cable.

[0056] It should be noted that, in this article, relational terms such as first and second, etc. are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Moreover, the terms "include", "comprise" or any other variants thereof are intended to cover non-exclusive inclusion, so that a process, method, article or device including a series of elements includes not only those elements, but also other elements not explicitly listed, or also includes elements inherent to such process, method, article or device. In the absence of further restrictions, the elements defined by the sentence "comprise a ..." do not exclude the existence of other identical elements in the process, method, article or device including the elements.

[0057] The above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit the same. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that the technical solutions described in the aforementioned embodiments may still be modified, or some of the technical features may be replaced by equivalents. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A digital cable for a photovoltaic power generation system, characterized in that: The invention comprises a plurality of central support members (1), wherein the plurality of central support members (1) are spliced ​​together to form a central support structure of a cable, wherein the outer surface of the central support member (1) is provided with a limit groove (11) along the direction of the cable for installing a wire core, and the inner surface of the central support member (1) is provided with a ventilation groove (12), so that a ventilation channel is formed at the center of the central support structure formed by splicing the plurality of central support members (1), and the central support member (1) is symmetrically provided with a plurality of arc channels (13) on both sides, and both ends of the arc channels (13) are connected to the ventilation channel, and the central support member (1) is also provided with an air inlet channel (14) connected to the arc channel (13), and a duct (15) is provided in the air inlet channel (14), and one end of the duct (15) extends to the surface of the digital cable, so that the outside of the digital cable is connected to the inside of the ventilation channel.

2. A digital cable for a photovoltaic power generation system according to claim 1, characterized in that: The wire core comprises a conductor (21), a flame retardant layer (22), a heat resistant layer (23) and a waterproof layer (24) which are arranged in sequence from the inside to the outside.

3. A digital cable for a photovoltaic power generation system according to claim 1, characterized in that: A wire core is arranged in the limiting groove (11) of the outer wall of the central support structure, an outer coating structure is arranged outside the wire core, the outer coating structure and the diameter of the wire core and the central support structure are filled with a filler layer (4), and the outer coating structure comprises an insulating layer (31) and a wear-resistant layer (32).

4. A digital cable for a photovoltaic power generation system as claimed in claim 3, characterized in that: The conduit (15) is made of thermally conductive silica gel.

5. A digital cable for a photovoltaic power generation system as claimed in claim 3, characterized in that: The filler layer (4) is made of a mixture of hydrophobic materials polyolefin and graphite.

6. A method for manufacturing a digital cable for a photovoltaic power generation system according to any one of claims 1 to 5, characterized in that: The following steps are involved: S1. A plurality of central support members (1) are molded by injection molding, wherein the molded central support members (1) do not include an air inlet channel (14) section; S2, splicing a plurality of central support members (1) together, and applying glue on the spliced ​​sides to form a central support structure of the cable; S3, applying glue to the limiting groove (11) of the central support structure formed in step S2, and then inserting a plurality of wire cores into the limiting groove (11) to achieve bonding of the plurality of wire cores; S4, adding the filler layer (4) material into a cable extruder for heating and softening, and then passing the cable formed in step S3 into the extruder, and the filler layer material is filled into the gaps in the outer wall of the cable to form a stable and smooth cylindrical cable; S5, passing the stable and smooth cylindrical cable in step S4 into cold water for cooling and solidification, so that the filler layer material forms a firm bond with the wire core; S6, adding the cable outer coating material into a cable extruder for heating and softening, and then passing the cable formed in step S5 into the extruder, so that the cable outer coating material covers the cable formed in step S5; S7, passing the cable in step S6 into cold water to cool and solidify, so that the outer coating layer material forms a firm bond with the inner side; S8, drilling holes circumferentially on the cable formed in step S7 by means of a drilling device, and allowing the drill bit to penetrate into the arc-shaped channel (13); after the drill bit is pulled out, the hole drilled by the drilling device in the central support member (1) forms an air inlet channel (14); S9, apply glue to the outer wall of the hollow conduit (15), and insert it into the hole drilled in step S7, and insert one end of the conduit (15) into the air inlet channel (14), so that the other end is flush with the outer wall of the cable.

7. The method for manufacturing a digital cable for a photovoltaic power generation system according to claim 6, characterized in that: The arc-shaped channels (13) formed by injection molding of the central support member (1) in step S1 are arranged at equal distances along the length direction of the central support member (1).

8. The method for manufacturing a digital cable for a photovoltaic power generation system according to claim 6, characterized in that: In step S6, the outer coating material comprises a plurality of layers, and steps S6 and S7 are repeated to form a plurality of layers of coating on the outer layer of the cable.

9. The method for manufacturing a digital cable for a photovoltaic power generation system according to claim 6, characterized in that: When the drilling device performs circumferential drilling on the cable in step S8, a circumferentially arranged drill bit is used to drill the cable so as to form circumferentially arranged holes in the cable.

10. The method for manufacturing a digital cable for a photovoltaic power generation system according to claim 6, characterized in that: In step S8, the diameter of the hole drilled by the drilling device for the cable is smaller than the minimum distance between two wire cores, and the drilling position is located on the vertical line between adjacent wire cores.

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