Super-flexible high-strength cable based on topological optimization structure and preparation method thereof

Abstract

The invention discloses a super-flexible high-strength cable based on a topological optimization structure and a preparation method of the super-flexible high-strength cable. The cable comprises a conductor, an insulating layer, a reinforcing structure layer, a shielding layer and an outer sheath which are sequentially arranged from inside to outside. The conductor adopts a single-strand solid structure or a multi-strand stranded structure; the insulating layer coats the outer side of the conductor through an extrusion process; the reinforced structure layer adopts a topological optimization design and is formed by compounding a high-strength fiber material and a matrix material, and the fiber material is arranged according to the direction and distribution determined by topological optimization; the shielding layer is of a metal woven mesh or metal foil tape wrapping structure; and the outer sheath coats the outer side of the shielding layer. The reinforced structure layer is designed through the topological optimization technology, so that the cable can maintain super flexibility, and meanwhile, the stretching resistance, the bending resistance and the extrusion resistance are remarkably improved, and the problem that the flexibility and the strength of a traditional cable are difficult to consider at the same time is solved.

Description

Technical Field

[0001] The present invention relates to the technical field of cables, and particularly to a super-flexible and high-strength cable based on a topology optimization structure and a preparation method thereof. Background Art

[0002] In the fields of modern industry, energy transmission, and electronic devices, cables, as important carriers for power and signal transmission, play an indispensable role. With the continuous progress of technology and the increasing complexity of application scenarios, the requirements for cable performance are also getting higher and higher. Traditional cables often struggle to achieve an ideal balance between flexibility and strength. On the one hand, to meet the use in narrow spaces, movable devices, or environments that require frequent bending, cables need to have good flexibility. However, some existing flexible cables sacrifice cable strength while increasing flexibility, resulting in the cables being easily damaged when subjected to stretching, extrusion, or external impacts, affecting the normal transmission of power and signals, and reducing the service life and reliability of the cables. On the other hand, although some high-strength cables can withstand large external forces, due to structural design reasons, they have poor flexibility and are difficult to meet the requirements of complex wiring and special application scenarios. Topology optimization is an advanced structural design method that can maximize the performance of a structure while meeting specific performance requirements by optimizing the distribution of materials in the structure. Applying topology optimization technology to cable structure design is expected to break the contradiction between the flexibility and strength of traditional cables and develop new cables with super-flexible and high-strength properties. Summary of the Invention

[0003] In view of the above-mentioned defects of the prior art, the purpose of the present invention is to provide a super-flexible and high-strength cable based on a topology optimization structure. By using topology optimization technology to design the internal structure of the cable, it has excellent flexibility while also having high strength, can adapt to various complex application environments, and improve the comprehensive performance and reliability of the cable.

[0004] To achieve the above purpose, the present invention provides a super-flexible and high-strength cable based on a topology optimization structure, which includes a conductor, an insulating layer, a reinforcing structure layer, a shielding layer, and an outer sheath arranged in sequence from the inside to the outside;

[0005] The conductor adopts a single-strand solid structure or a multi-strand stranded structure;

[0006] The insulating layer is coated on the outside of the conductor through an extrusion process;

[0007] The reinforcing structure layer adopts a topology optimization design and is composed of a high-strength fiber material and a matrix material, and the fiber material is arranged according to the direction and distribution determined by topology optimization;

[0008] The shielding layer is a metal braided mesh or a metal foil tape winding structure;

[0009] The outer sheath is coated on the outside of the shielding layer.

[0010] A further improvement of the present invention is that the conductor of the multi-strand stranded structure is stranded by multiple wires according to a specific stranding method and pitch.

[0011] A further improvement of the present invention is that the topological optimization design of the reinforcing structure layer includes the following steps:

[0012] Establish a finite element model of the cable structure, and set the material properties, boundary conditions and load conditions;

[0013] Taking the maximization of flexibility and strength as the objective function and the material volume fraction as the constraint condition, calculate the optimal distribution form of the material through the topological optimization algorithm;

[0014] According to the optimization results, manufacture the reinforcing structure layer by using 3D printing technology or mold forming process.

[0015] A further improvement of the present invention is that the fiber material is carbon fiber or aramid fiber, and the matrix material is epoxy resin or polyurethane.

[0016] A further improvement of the present invention is that the metal braided mesh of the shielding layer is woven by copper wire or aluminum wire, and the metal foil tape winding structure is wound by copper foil or aluminum foil.

[0017] A further improvement of the present invention is that the material of the conductor is copper or aluminum.

[0018] A further improvement of the present invention is that the material of the insulating layer is cross-linked polyethylene or ethylene propylene rubber.

[0019] A further improvement of the present invention is that the material of the outer sheath is polyvinyl chloride or neoprene.

[0020] A preparation method of a super-flexible and high-strength cable based on a topological optimization structure, which is used to prepare the above-mentioned super-flexible and high-strength cable based on a topological optimization structure, and includes the following steps:

[0021] Prepare the conductor;

[0022] Coat the insulating layer: coat the insulating material on the outside of the conductor through an extrusion process to form an insulating layer;

[0023] Manufacture the reinforcing structure layer: enhance the structure layer through topological optimization design and manufacture it by using 3D printing or mold forming process;

[0024] Manufacture the shielding layer: form a shielding layer on the outside of the reinforcing structure layer through a weaving or winding process;

[0025] Manufacturing the outer sheath: The outer sheath material is coated on the outside of the shielding layer through an extrusion process to form the outer sheath.

[0026] The beneficial effects of the present invention are as follows: By designing the enhanced structure layer through topology optimization technology, the cable significantly improves its tensile resistance, bending resistance, and extrusion resistance while maintaining super flexibility, solving the problem that it is difficult to balance the flexibility and strength of traditional cables. The topology optimization algorithm takes the material volume fraction as a constraint condition to achieve the optimal distribution of materials in the enhanced structure layer, avoiding the use of redundant materials, reducing the cable weight, and improving the structural efficiency at the same time. Through multi-layer collaborative design (such as conductor stranding optimization, fiber reinforcement, shielding protection, etc.), the wear and fracture risks of the cable during dynamic use are significantly reduced, the service life is extended, and the reliability is improved. Description of the Drawings

[0027] Figure 1 It is a cross-sectional schematic diagram of the super-flexible high-strength cable based on the topology optimization structure in the present invention.

[0028] The labels in the figure are as follows:

[0029] 1. Conductor, 2. Insulation layer, 3. Enhanced structure layer; 4. Shielding layer, 5. Outer sheath. Detailed Embodiments

[0030] The following uses specific specific examples to illustrate the embodiments of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can also be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that, without conflict, the following embodiments and the features in the embodiments can be combined with each other.

[0031] It should be noted that the diagrams provided in the following embodiments only illustrate the basic concept of the present invention in a schematic manner. Therefore, only the components related to the present invention are shown in the diagrams, rather than being drawn according to the number, shape, and size of the components during actual implementation. The types, quantities, and proportions of the components during actual implementation can be arbitrarily changed, and the component layout type may also be more complex.

[0032] For the purpose of illustration, some exemplary embodiments of the present invention are described. It should be understood that the present invention can be implemented in other ways not specifically shown in the drawings.

[0033] As Figure 1 shown, the super-flexible high-strength cable based on the topology optimization structure in this embodiment sequentially includes from the inside out: conductor 1, insulation layer 2, enhanced structure layer 3, shielding layer 4, and outer sheath 5.

[0034] Conductor 1: High-purity copper or aluminum alloy materials are selected as the inner conductor to ensure good electrical conductivity. According to the usage requirements of the cable, the conductor is designed into a single-strand solid structure or a multi-strand stranded structure. The multi-strand stranded structure can improve the flexibility of the cable and is suitable for occasions that require frequent bending. When multi-strand stranding, each strand of wire is stranded according to a specific stranding method and pitch to optimize the electrical and mechanical properties of the cable.

[0035] Insulation layer 2: High-performance insulation materials such as cross-linked polyethylene (XLPE) and ethylene propylene rubber (EPR) are used. After heating and melting the insulation material through an extrusion process, it is evenly extruded and coated on the outside of the inner conductor to form the insulation layer. The thickness of the insulation layer is reasonably designed according to the voltage level and usage environment of the cable, which plays a role in isolating the inner conductor from the outside world and preventing current leakage.

[0036] Reinforcement structure layer 3: This is the core innovative part of the present invention and is designed using topology optimization methods. First, a finite element model of the cable structure is established, and material properties, boundary conditions, and load conditions are set, including common external force conditions such as tension, bending, and extrusion. Then, with the maximization of the flexibility and strength of the cable as the objective function and the material volume fraction as the constraint condition, the topology optimization algorithm is used to calculate the model to obtain the optimal distribution form of the material in the reinforcement structure layer. According to the topology optimization results, a 3D printing technology or a special mold forming process is used to manufacture a reinforcement structure layer with a specific topology structure. The reinforcement structure layer is composed of high-strength fiber materials (such as carbon fiber, aramid fiber, etc.) and matrix materials (such as epoxy resin, polyurethane, etc.). The fiber materials are arranged according to the directions and distributions determined by topology optimization, which significantly improves the strength and anti-deformation ability of the cable while ensuring its flexibility.

[0037] Shielding layer 4: The shielding layer is formed by winding a metal braided mesh or a metal foil tape. The metal braided mesh is generally woven from copper wire or aluminum wire and has good flexibility and shielding effect; the metal foil tape usually selects copper foil or aluminum foil and is wound around the outside of the reinforcement structure layer. The role of the shielding layer is to shield external electromagnetic interference, prevent the current transmitted inside the cable from being affected by the external electromagnetic field, and at the same time prevent the electromagnetic radiation generated by the cable itself from interfering with external devices, thereby improving the electromagnetic compatibility of the cable.

[0038] Outer sheath 5: Materials with good wear resistance, corrosion resistance, and weather resistance such as polyvinyl chloride (PVC) and chloroprene rubber (CR) are selected. Through an extrusion process, the outer sheath material is tightly wrapped around the outside of the shielding layer to form the outermost protective structure of the cable. The outer sheath can protect each structure inside the cable from mechanical damage, chemical corrosion, and environmental erosion, and extend the service life of the cable.

[0039] The preparation process of the above cable includes:

[0040] 1. Conductor Preparation: According to the design requirements of the cable, select high-purity copper or aluminum alloy materials of appropriate specifications. If it is a single-strand solid inner conductor, process the raw material into a wire of the required diameter through processes such as wire drawing and annealing; if it is a multi-strand stranded inner conductor, first draw the raw material into a thin wire, and then stranding according to the predetermined stranding method and pitch to form a multi-strand stranded inner conductor.

[0041] 2. Insulation Layer Coating: Add insulating materials such as cross-linked polyethylene or ethylene propylene rubber to the hopper of the extruder and melt it by heating. Adjust parameters such as the screw speed and temperature of the extruder to evenly extrude and coat the insulating material on the outside of the inner conductor. During the extrusion process, cool and shape the insulation layer through a cooling device to control the thickness and surface quality of the insulation layer.

[0042] 3. Reinforced Structure Layer Manufacturing:

[0043] Topology Optimization Design: Use finite element analysis software to establish a 3D model of the cable, set material properties such as the elastic modulus and Poisson's ratio of the fiber material and matrix material. Define boundary conditions and load conditions such as tensile load, bending moment, extrusion pressure, etc. With the goal of maximizing flexibility and strength, set the material volume fraction constraint and run the topology optimization algorithm to obtain the optimized topology structure of the reinforced structure layer. Forming Process: If 3D printing technology is used, import the topology-optimized structural model into a 3D printer, select a suitable fiber-reinforced composite printing consumable, and print the reinforced structure layer layer by layer according to the model. If the mold forming process is used, make a specific mold according to the topology optimization structure, fill the fiber material and matrix material into the mold in a certain proportion and manner, and obtain the reinforced structure layer through processes such as curing and demolding.

[0044] 4. Shield Layer Fabrication:

[0045] Metal Braided Mesh Shield Layer: Select copper or aluminum wires of appropriate specifications and install them on the wire pay-off rack of the braiding machine. Adjust the parameters of the braiding machine such as the braiding angle and pitch to braid the metal wires into a tight metal braided mesh on the outside of the reinforced structure layer.

[0046] Metal Foil Tape Wrapping Shield Layer: Install the metal foil tape on the unwind device of the wrapping equipment, adjust the parameters of the wrapping equipment such as the wrapping angle and overlap rate, and tightly wrap the metal foil tape around the outside of the reinforced structure layer in a certain direction and overlap rate.

[0047] 5. Outer Sheath Processing: Add outer sheath materials such as polyvinyl chloride or neoprene to the hopper of the extruder, heat and melt it, and then evenly extrude and coat it on the outside of the shield layer through the extruder. After processes such as cooling and shaping, form a complete outer sheath to obtain a super-flexible and high-strength cable based on the topology-optimized structure.

[0048] The above embodiments are only illustrative of the principles and effects of the present invention and are not intended to limit the present invention. Any person familiar with this technology can modify or change the above embodiments without departing from the spirit and scope of the present invention. Therefore, all equivalent modifications or changes made by those with ordinary knowledge in the technical field without departing from the spirit and technical idea disclosed by the present invention should still be covered by the claims of the present invention.

Claims

1. A super-flexible and high-strength cable based on a topology-optimized structure, characterized in that, It includes a conductor (1), an insulating layer (2), a reinforcing structure layer (3), a shielding layer (4), and an outer sheath (5) arranged in sequence from the inside to the outside; The conductor (1) adopts a single-strand solid structure or a multi-strand stranded structure; The insulating layer (2) is coated on the outside of the conductor (1) through an extrusion process; The reinforcing structure layer (3) adopts a topology optimization design and is composed of a high-strength fiber material and a matrix material. The fiber material is arranged according to the direction and distribution determined by topology optimization; The shielding layer (4) is a metal braided mesh or a metal foil tape wrapping structure; The outer sheath (5) is coated on the outside of the shielding layer (4).

2. The super-flexible and high-strength cable based on the topology-optimized structure according to claim 1, wherein The multi-strand stranded conductor (1) is stranded by multiple wires in a specific stranding pattern and pitch.

3. The ultra-flexible high-strength cable based on the topology-optimized structure according to claim 1, characterized in that The topology optimization design of the reinforcing structure layer (3) includes the following steps: Establish a finite element model of the cable structure, and set material properties, boundary conditions, and load conditions; Taking the maximization of flexibility and strength as the objective function and the material volume fraction as the constraint condition, calculate the optimal distribution form of the material through a topology optimization algorithm; According to the optimization results, manufacture the reinforcing structure layer (3) using 3D printing technology or a mold forming process.

4. The super-flexible and high-strength cable based on the topology-optimized structure according to claim 3, characterized in that, The fiber material is carbon fiber or aramid fiber, and the matrix material is epoxy resin or polyurethane.

5. The super-flexible and high-strength cable based on the topology-optimized structure according to claim 1, characterized in that, The metal braided mesh of the shielding layer (4) is woven from copper wires or aluminum wires, and the metal foil tape wrapping structure is wrapped from copper foil or aluminum foil.

6. The super-flexible high-strength cable based on the topology-optimized structure according to claim 1, characterized in that, The material of the conductor (1) is copper or aluminum.

7. The super-flexible high-strength cable based on the topology-optimized structure according to claim 1, characterized in that, The material of the insulating layer (2) is cross-linked polyethylene or ethylene-propylene rubber.

8. The super-flexible high-strength cable based on the topology-optimized structure according to claim 1, characterized in that, The material of the outer sheath (5) is polyvinyl chloride or chloroprene rubber.

9. A preparation method of a super-flexible and high-strength cable based on a topology optimization structure, which is used to prepare the super-flexible and high-strength cable based on the topology optimization structure according to any one of claims 1-8, and is characterized in that, It includes the following steps: Prepare the conductor (1); Coat the insulating layer (2): Coat the insulating material on the outside of the conductor (1) through an extrusion process to form the insulating layer (2); Manufacture the reinforcing structure layer (3): Design the reinforcing structure layer (3) through topology optimization and manufacture it using 3D printing or a mold forming process; Manufacture the shielding layer (4): Form the shielding layer (4) on the outside of the reinforcing structure layer (3) through a weaving or wrapping process; Manufacture the outer sheath (5): Coat the outer sheath material on the outside of the shielding layer (4) through an extrusion process to form the outer sheath (5).

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