Digital cable for photovoltaic power generation system and manufacturing method

Abstract

The present application relates to photovoltaic cable manufacturing technical field, provide a kind of photovoltaic power generation system with digital cable and manufacturing method, including several center support, several The center support is mutually spliced to form the center support structure of cable, the outer surface of the center support is provided with limiting slot along cable direction, for installing wire core, the inner surface of the center support is provided with ventilation slot.The present application overcomes the shortcomings of prior art, reasonable in design, compact structure, the circumferential splicing of cable center support structure enhances the overall strength, the limiting slot design effectively isolates wire core, avoids heat cross accumulation, the ventilation channel formed after cable center is connected with the outside, realizes the air convection and heat exchange inside and outside cable, significantly improves the heat dissipation efficiency.Cable overall manufacturing is completed, and the air inlet channel is formed by drilling, not only avoids the problem that processing material blocks heat dissipation channel, but also further reduces manufacturing difficulty.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic cable manufacturing technology, specifically to a digital cable for photovoltaic power generation systems and its manufacturing method. Background Technology

[0002] Photovoltaic cables, as an important transmission medium in photovoltaic power generation systems, bear the heavy responsibility of safely and efficiently transmitting the electrical energy generated by solar panels to energy storage or power consumption 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. Currently, the air inside and outside photovoltaic cables does not circulate, making it difficult for the cables to dissipate heat effectively in high-temperature environments, resulting in frequent overheating. Overheating not only affects the electrical performance 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 address this, we propose a digital cable for photovoltaic power generation systems and its manufacturing method. Summary of the Invention

[0003] (a) Technical problems to be solved

[0004] To address the shortcomings of existing technologies, this invention provides a digital cable for photovoltaic power generation systems and a manufacturing method thereof, which overcomes the deficiencies of existing technologies, has a reasonable design and compact structure, and solves the problem of poor air circulation and frequent overheating in existing photovoltaic cables.

[0005] (II) Technical Solution

[0006] To achieve the above objectives, the present invention provides the following technical solution: a digital cable for a photovoltaic power generation system, the digital cable comprising a plurality of central support members, the plurality of central support members being spliced ​​together to form a central support structure for the cable, the outer surface of the central support members having a limiting groove along the cable direction for installing wire cores, the inner surface of the central support members having a ventilation groove so that a ventilation channel is formed at the center of the central support structure formed by splicing the plurality of central support members together, the central support members having a plurality of arc-shaped channels symmetrically arranged on both sides, the two ends of the arc-shaped channels being connected to the ventilation channel, the central support members also having an air inlet channel connected to the arc-shaped channels, the air inlet channel having a conduit, one end of the conduit extending to the surface of the digital cable so that the outside of the digital cable is connected to the inside of the ventilation channel.

[0007] Preferably, the wire core includes a conductor, a flame-retardant layer, a heat-resistant layer, and a waterproof layer arranged sequentially from the inside out.

[0008] Preferably, a wire core is provided in the limiting groove of the outer wall of the central support structure, and an outer covering layer structure is provided outside the wire core. A filler layer is filled between the outer covering layer structure, the wire core, and the central support structure. The outer covering layer structure includes an insulation 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 polyolefin and graphite.

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

[0012] S1. Several central support components are injection molded using a mold, but the air inlet channel section is not included in the molded central support components;

[0013] S2. Connect several central support components together and apply glue to the joint side to form the central support structure of the cable;

[0014] S3. Apply glue to the limiting groove of the central support structure formed in step S2, and then insert several wire cores into the limiting groove to achieve bonding of several wire cores.

[0015] S4. The filler layer material is added to the cable extruder for heating and softening. Then the cable formed in step S3 is fed into the extruder. The filler layer material fills the gaps in the outer wall of the cable to form a stable and smooth cylindrical cable.

[0016] S5. The stable and smooth cylindrical cable from step S4 is cooled and solidified by passing it into cold water, so that the filler layer material and the wire core form a strong bond.

[0017] S6. The cable outer sheathing material is added to the cable extruder for heating and softening. Then the cable formed in step S5 is fed into the extruder, and the cable outer sheathing material covers the cable formed in step S5.

[0018] S7. The cable from step S6 is cooled and solidified by passing it through cold water, so that the outer sheath material forms a strong bond with the inner side.

[0019] S8. The cable formed in step S7 is drilled circumferentially by the drilling device, and the drill bit penetrates into the arc-shaped channel. After the drill bit is pulled out, the hole drilled by the drilling device in the central support forms an air intake channel.

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

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

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

[0023] Preferably, in step S8, when the drilling device drills a circumferential hole in the cable, a circumferentially oriented drill bit is used to drill the cable, so that a circumferentially oriented hole is formed inside the cable.

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

[0025] (III) Beneficial Effects

[0026] This invention provides a digital cable for a photovoltaic power generation system and a manufacturing method thereof. It offers the following advantages:

[0027] 1. The circumferential splicing of the cable center support structure enhances the overall strength. The limiting groove design effectively isolates the wire cores, preventing heat cross-accumulation. After molding, the ventilation channel formed in the center of the cable connects with the outside, realizing air convection and heat exchange between the inside and outside of the cable, significantly improving heat dissipation efficiency.

[0028] 2. The multi-layered protective structure of the wire core, including flame-retardant, heat-resistant, and waterproof layers, ensures the stable operation of the cable in various environments.

[0029] 3. The addition of filler and outer sheath layers not only improves the structural stability of the cable, but also enhances its electrical and physical isolation performance.

[0030] 4. During the manufacturing process, the central support component is first injection molded, and then the wire core is spliced ​​and fixed, which reduces the manufacturing difficulty.

[0031] 5. After the cable is manufactured as a whole, an air intake channel is formed by drilling holes. This not only avoids the problem of processing materials blocking the heat dissipation channel, but also further reduces the manufacturing difficulty. Attached Figure Description

[0032] Figure 1 This is a three-dimensional schematic diagram of the overall structure of the present invention;

[0033] Figure 2 This is a three-dimensional schematic diagram of the insulating layer of the present invention;

[0034] Figure 3 This is a three-dimensional schematic diagram of the central support structure of the present invention;

[0035] Figure 4 This is a three-dimensional schematic diagram of the central support component of the present invention.

[0036] In the diagram: 1. Central support; 11. Limiting groove; 12. Ventilation groove; 13. Arc-shaped channel; 14. Air inlet channel; 15. Conduit; 21. Conductor; 22. Flame retardant layer; 23. Heat resistant layer; 24. Waterproof layer; 31. Insulation layer; 32. Wear resistant layer; 4. Filler layer. Detailed Implementation

[0037] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0038] See attached document Figure 1-4 A digital cable for a photovoltaic power generation system includes several central support members 1. These central support members 1 are circumferentially spliced ​​together to form a central support structure for the cable, thereby enhancing the overall structural strength. The outer surface of each central support member 1 has a limiting groove 11 along the cable direction for installing wire cores and separating wire cores installed around the central support structure to prevent heat accumulation between the wire cores during use. The inner surface of each central support member 1 has a ventilation groove 12, ensuring ventilation at the center of the central support structure formed by the splicing of several central support members 1. The central support member 1 has several symmetrically arranged arc-shaped channels 13 on both sides. The arc-shaped channels 13 on one side are equidistantly arranged along the length of the central support member 1. Both ends of the arc-shaped channels 13 are connected to the ventilation channels. The central support member 1 also has an air inlet channel 14 connected to the arc-shaped channels 13. The air inlet channel 14 has a duct 15. 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. This realizes the convection and heat exchange of the air inside and outside the cable, which facilitates heat dissipation inside the cable, effectively reduces the temperature of the cable during operation, and extends its service life.

[0039] The wire core includes a conductor 21, a flame-retardant layer 22, a heat-resistant layer 23, and a waterproof layer 24 arranged sequentially from the inside out. The conductor 21 is made of aluminum or copper wire. The flame-retardant layer 22 is made of 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 silane self-crosslinking low-smoke halogen-free flame-retardant polyolefin material, which enhances the stability of the wire core in high-temperature environments. The waterproof layer 24 is made of polytetrafluoroethylene material, which ensures that the cable operates normally in humid environments and prevents moisture intrusion that could cause short circuits.

[0040] The limiting groove 11 on the outer wall of the central support structure is provided with a wire core. The wire core is installed in the limiting groove 11 outside the central support structure. After installation, it is covered with an outer covering structure. The outer covering structure, the wire core, and the central support structure are filled with a filler layer 4. The outer covering structure includes an insulation layer 31 and a wear-resistant layer 32 from the inside to the outside to ensure electrical and physical isolation of the cable.

[0041] The conduit 15 is made of thermally conductive silicone, which has good thermal conductivity and can quickly dissipate heat from the cable.

[0042] The filler layer 4 is made of a mixture of hydrophobic materials polyolefin and graphite. The filler layer 4 component has good hydrophobic properties and can further assist in heat dissipation through the thermal conductivity of graphite.

[0043] A method for manufacturing a digital cable for a photovoltaic power generation system includes the following steps:

[0044] S1. Several central support parts 1 are injection molded by mold, and removed after cooling and solidification. The central support parts 1 do not include the air inlet channel 14 section, so that the arc channel 13 and ventilation groove 12 are not connected to the outer surface of the central support parts 1 in the initial state, so as to avoid the processing material entering the arc channel 13 and ventilation groove 12 during subsequent processing, which would cause blockage and affect heat dissipation.

[0045] S2. Several central support components 1 are spliced ​​together circumferentially, and glue is applied to the splicing side. The splicing surfaces must be precisely aligned to ensure that the splicing is firm and seamless, forming the central support structure of the cable, which provides strong support for the overall cable.

[0046] S3. Apply glue to the limiting groove 11 of the central support structure formed in step S2, and then insert several wire cores one by one into the limiting groove 11. After the glue cures, the wire cores are fixed in the limiting groove 11, thus achieving the bonding of several wire cores.

[0047] S4. The filler layer 4 material is added to the cable extruder for heating and softening. Then, the cable structure with wire core formed in step S3 is fed into the extruder. The filler layer 4 material is uniformly 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.

[0048] S5. The stable and smooth cylindrical cable from step S4 is immersed in cold water to cool and solidify, so that the filler layer 4 material forms a firm bond with the wire core, thereby enhancing the overall strength and stability of the cable.

[0049] S6. The cable outer sheathing material is added to the cable extruder for heating and softening. Then the cable formed in step S5 is fed into the extruder. The cable outer sheathing material covers the cable formed in step S5 to form the cable outer sheathing layer.

[0050] S7. The cable from step S6 is cooled and solidified by passing it through cold water, so that the outer sheath material forms a strong bond with the inner side.

[0051] S8. The cable formed in step S7 is circumferentially drilled by the drilling device. When drilling the cable circumferentially, the drilling device uses a circumferentially set drill bit to drill the cable so that a circumferentially set hole is formed inside the cable. There is no need to rotate the cable 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 in the cable is less than the minimum distance between two wire cores, and the drilling position is located on the vertical line between adjacent wire cores to ensure that the drilling will not damage the wire cores. After the drill bit is pulled out, the hole drilled by the drilling device in the central support 1 forms the air intake channel 14. The air intake channel 14 is formed after the cable is formed as a whole, which can avoid the blockage of the air intake channel 14, the arc channel 13 and the ventilation groove 12.

[0052] S9. Apply glue to the outer wall of the hollow conduit 15 and insert it into the hole drilled in step S7, so that one end of the conduit 15 is inserted into the air inlet channel 14 and 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 to circulate inside and outside the cable, and enhances the heat dissipation capacity inside the cable.

[0053] The arc-shaped channels 13 of the central support member 1 injection molding in step S1 are arranged at equal intervals along the length of the central support member 1, which helps to improve the heat exchange efficiency between the cable center and the outside world.

[0054] In step S6, the outer sheath material comprises several layers. Steps S6 and S7 are repeated to form several layers of sheathing on the outer layer of the cable, further improving the safety and durability of the cable.

[0055] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such a process, method, article, or apparatus. Without further limitations, an element defined by the phrase "comprising one..." does not exclude the presence of other identical elements in the process, method, article, or apparatus that includes said element.

[0056] The above embodiments are only used to illustrate the technical solutions of the present invention, and are not intended to limit it. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for manufacturing a digital cable for a photovoltaic power generation system, characterized in that: The digital cable includes several central support members (1), which are spliced ​​together to form a central support structure for the cable. The outer surface of the central support member (1) is provided with a limiting groove (11) along the cable direction for installing the wire core. The inner surface of the central support member (1) is provided with a ventilation groove (12) so that a ventilation channel is formed in the center of the central support structure formed by splicing several central support members (1). Several arc-shaped channels (13) are symmetrically provided on both sides of the central support member (1). Both ends of the arc-shaped channels (13) are connected to the ventilation channel. The central support member (1) is also provided with an air inlet channel (14) connected to the arc-shaped channels (13). The air inlet channel (14) is provided with a conduit (15). One end of the conduit (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. The method for manufacturing the digital cable includes the following steps: S1. Several central support components (1) are injection molded by mold, and the central support components (1) do not include the air inlet channel (14) section; S2. Several central support components (1) are spliced ​​together and glue is applied to the splicing side to form the central support structure of the cable; S3. Apply glue to the limiting groove (11) of the central support structure formed in step S2, and then insert several wire cores into the limiting groove (11) to achieve bonding of several wire cores. S4. The filler layer (4) material is added to the cable extruder for heating and softening. Then the cable formed in step S3 is fed into the extruder. The filler layer material fills the gaps in the outer wall of the cable to form a stable and smooth cylindrical cable. S5. The stable and smooth cylindrical cable from step S4 is cooled and solidified by passing it into cold water, so that the filler layer material and the wire core form a strong bond. S6. The cable outer sheathing material is added to the cable extruder for heating and softening. Then the cable formed in step S5 is fed into the extruder, and the cable outer sheathing material covers the cable formed in step S5. S7. The cable from step S6 is cooled and solidified by passing it through cold water, so that the outer sheath material forms a strong bond with the inner side. S8. The cable formed in step S7 is drilled circumferentially by the drilling device, and the drill bit penetrates into the arc-shaped channel (13). After the drill bit is pulled out, the hole drilled by the drilling device in the central support (1) forms an air intake channel (14). S9. Apply glue to the outer wall of the hollow conduit (15) and insert it into the hole drilled in step S7, so that one end of the conduit (15) is inserted into the air inlet channel (14) and the other end is flush with the outer wall of the cable.

2. The manufacturing method of a digital cable for a photovoltaic power generation system as described in claim 1, characterized in that: The core includes a conductor (21), a flame-retardant layer (22), a heat-resistant layer (23), and a waterproof layer (24) arranged sequentially from the inside out.

3. The manufacturing method of a digital cable for a photovoltaic power generation system as described in claim 1, characterized in that: The limiting groove (11) on the outer wall of the central support structure is provided with a wire core, and an outer covering layer structure is provided outside the wire core. A filler layer (4) is filled between the outer covering layer structure, the wire core, and the central support structure. The outer covering layer structure includes an insulation layer (31) and a wear-resistant layer (32).

4. The manufacturing method of a digital cable for a photovoltaic power generation system as described in claim 3, characterized in that: The conduit (15) is made of thermally conductive silicone.

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

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

7. The method for manufacturing a digital cable for a photovoltaic power generation system as described in claim 1, characterized in that: In step S6, the outer sheath material comprises several layers. Steps S6 and S7 are repeated to form several layers of sheathing on the outer layer of the cable.

8. The method for manufacturing a digital cable for a photovoltaic power generation system as described in claim 1, characterized in that: In step S8, when the drilling device drills a circumferential hole in the cable, it uses a circumferentially oriented drill bit to drill a hole in the cable so that a circumferentially oriented hole is formed inside the cable.

9. A method for manufacturing a digital cable for a photovoltaic power generation system as described in claim 1, characterized in that: In step S8, the diameter of the hole drilled by the drilling device in the cable is less than the minimum distance between the two wire cores, and the drilling position is located on the vertical line between adjacent wire cores.

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