Special-shaped conductor polypropylene insulation photoelectric composite cooling power cable

Abstract

The invention provides a special-shaped conductor polypropylene insulation photoelectric composite cooling power cable, and relates to the technical field of special-shaped cables, the special-shaped conductor polypropylene insulation photoelectric composite cooling power cable comprises three wire cores which are circumferentially and uniformly arranged, each wire core comprises a special-shaped conductor, an insulation layer and a metal shielding layer from inside to outside in sequence, and temperature measurement optical fiber units are arranged in the centers of the inner sides of the three wire cores; a filling area, a buffer layer and a heat dissipation outer protective layer are sequentially coated on the outer sides of the three wire cores; a cooling channel tightly attached to every two adjacent wire cores is arranged between the two adjacent wire cores, and the cooling channel is covered with an inner reflecting cover. Through a special-shaped conductor pressing and splicing technology, the sectional area of the conductor is reduced while the electrical performance is ensured; recyclable polypropylene is adopted to replace a polyethylene insulation system, so that heat resistance, corrosion resistance and high mechanical strength are achieved; through combination of the optical fiber temperature measurement unit and a multi-stage heat dissipation structure with a built-in cooling channel / inner reflection cover / porous buffer layer / graphene protection layer, real-time monitoring and dynamic thermal regulation and control cooperative management of the temperature of the cable are realized.

Description

Technical Field

[0001] The invention relates to the technical field of special-shaped cables, in particular to a special-shaped conductor polypropylene insulated photoelectric composite cooling power cable. Background Art

[0002] Driven by the rapid development of the industrial manufacturing sector, power cable products are constantly being upgraded, but their core contradiction still focuses on the difficult problem of balancing the thermal effect of conductors with structural efficiency. When traditional cables are in operation, the resistance heat generated by the large current in the cable core conductor will form a self-excited cycle as the temperature rises, accelerating the aging of the insulation material. The heat dissipation blockage in the complex laying environment further exacerbates the risk of heat accumulation and easily causes fire. In order to reduce the resistance of the conductor, the current process generally achieves this by increasing the cross-sectional area of the conductor and twisting and pressing multiple round single wires. However, the interlayer pores lead to a decrease in the utilization rate of the effective cross-sectional area of the conductor, forcing a redundant outer diameter design to compensate for performance and increase material costs. In addition, the widely used polyethylene insulation material, due to its non-recyclable nature, generates a large amount of solid waste in the processing of retired cables, making it difficult to meet the needs of environmentally friendly and intelligent industrial transformation.

[0003] Although the special-shaped flame-retardant aluminum alloy low-voltage cable disclosed in utility model patent CN203218019 has a simple structure and meets basic functional requirements, it has significant limitations in high-current and high-power application scenarios. When the cable continuously carries a large current, the conductor heats up, causing temperature accumulation. Due to insufficient heat dissipation channels and the complexity of the laying environment, heat is difficult to be discharged in time. Long-term high temperature not only accelerates the melting and aging of the insulation layer and sheath, weakening their electrical performance and mechanical strength, but also poses a hidden danger of spontaneous combustion caused by insulation failure. In addition, the existing structure lacks a real-time monitoring mechanism for operating temperature and can only passively respond to abnormal temperature rise or fault conditions. It can neither actively monitor the temperature change trend of the wire core nor take active heat dissipation control measures according to the temperature gradient, causing the cable safety protection to lag behind the actual operating needs and limiting the actual application efficiency. Summary of the Invention

[0004] To address the problems of conventional cables with large conductor cross-sectional areas, non-recyclable insulation materials, lack of temperature control, and heat accumulation in the cable, this invention provides a special-shaped conductor polypropylene-insulated optoelectronic composite cooling power cable. This invention optimizes the core structure by compactly pressing and splicing special-shaped conductors, reducing the conductor cross-sectional area while maintaining equivalent electrical performance. Recyclable polypropylene insulation replaces the traditional polyethylene system, simultaneously improving heat resistance, chemical corrosion resistance, and mechanical strength. Furthermore, the cable integrates a fiber-optic temperature measurement unit with a composite heat dissipation system, leveraging the synergistic effects of built-in cooling channels, an internal reflector, a porous buffer layer, and a graphene outer sheath to achieve real-time monitoring of the cable's operating temperature and dynamic heat dissipation control, forming a closed-loop thermal safety management mechanism.

[0005] In order to solve the above technical problems, the present invention provides the following technical solutions:

[0006] The present invention provides a special-shaped conductor polypropylene insulated photoelectric composite cooling power cable, comprising:

[0007] Three wire cores are evenly distributed in a 120° circle, each of which comprises, from the inside to the outside, a special-shaped conductor 1, an insulating layer 2 wrapped around the special-shaped conductor, and a metal shielding layer 3 wrapped around the insulating layer. A temperature measuring optical fiber unit 8 is provided at the center of the inner side of the three wire cores and is bonded to the three wire cores; The outer sides of the three wire cores are covered with a filling area 5, a buffer layer 6 and a heat dissipation outer protective layer 7 in sequence; A cooling channel 4 is provided between each two adjacent wire cores and is in close contact with the two wire cores. The cooling channel 4 is covered by an inner reflective cover 9.

[0008] Preferably, the special-shaped conductor 1 is composed of one or more special-shaped single wires with a cross-sectional shape of a fan, a trapezoid, a polygon or a Z; the special-shaped conductor 1 is formed by pressing and splicing the special-shaped single wires into a circle.

[0009] Preferably, the insulating layer 2 comprises, from inside to outside, a conductor shielding layer 2-1, a polypropylene insulating layer 2-2, and an insulating shielding layer 2-3.

[0010] Preferably, the metal shielding layer 3 is a metal wire or metal film woven into a mesh.

[0011] Preferably, the cooling channel 4 is a corrugated hose with spiral fins or grid grooves inside. Further preferably, the corrugated hose is made of either polypropylene or nylon 6, and its diameter is 20-40% of the wire core diameter. Further preferably, the contact area between the cooling channel and the wire core can be coated with heat-dissipating silicone to enhance heat dissipation efficiency.

[0012] Preferably, the cooling channel 4 is connected to a cooling channel regulating device, and the flow rate of the coolant is regulated by the regulating device.

[0013] Preferably, the buffer layer 6 is made of a porous buffer material. Further preferably, the porous buffer material is one or more of polyester, polypropylene, silicone rubber, and chloroprene rubber.

[0014] Preferably, the heat dissipation outer protective layer 7 is made of one or more of plastic, graphene or graphene oxide.

[0015] Preferably, the temperature measuring optical fiber unit 8 is connected to a cooling channel regulating device, and the flow rate of the cooling liquid is adjusted according to the temperature feedback from the temperature measuring optical fiber unit 8 .

[0016] Preferably, the inner reflector 9 is an aluminum-plated polyimide film.

[0017] Compared with the prior art, the present invention has the following beneficial effects: (1) By adopting the technology of compacting and splicing special-shaped conductors, the cross-sectional area of the circular core can be efficiently utilized, and the electrical performance can be maintained under the condition of reducing the outer diameter of the conductor; (2) The traditional polyethylene material is replaced by a recyclable polypropylene insulation system, which significantly improves the impact resistance, heat resistance and chemical corrosion resistance while ensuring the insulation performance; (3) An innovative integration of integrated temperature measurement optical fiber and composite heat dissipation architecture is used to build a dynamic thermal management network through the built-in cooling channel, coordinated with the porous buffer layer and the high thermal conductivity graphene heat dissipation outer sheath, to achieve dual active control of real-time operating temperature perception and heat gradient dissipation; (4) An innovative addition of an aluminum-coated polyimide film internal reflector increases the heat dissipation efficiency of the cooling channel. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 This is a schematic diagram of the main cross-sectional structure of a special-shaped conductor polypropylene insulated photovoltaic composite cooling power cable proposed by the present invention.

[0019] In the figure: 1. Special-shaped conductor; 2-1. Conductor shielding layer; 2-2. Polypropylene insulation layer; 2-3. Insulation shielding layer; 3. Metal shielding layer; 4. Cooling channel; 5. Filling area; 6. Buffer layer; 7. Heat dissipation outer sheath; 8. Temperature measurement optical fiber unit; 9. Internal reflector. DETAILED DESCRIPTION

[0020] The present invention will be further described below with reference to specific embodiments.

[0021] Example 1

[0022] This embodiment provides a technical solution for a general special-shaped conductor polypropylene insulated optoelectronic composite cooling power cable, specifically including: Three wire cores are evenly distributed in a 120° circle, each of which comprises, from the inside to the outside, a special-shaped conductor 1, an insulating layer 2 wrapped around the special-shaped conductor, and a metal shielding layer 3 wrapped around the insulating layer. A temperature measuring optical fiber unit 8 is provided at the center of the inner side of the three wire cores and is bonded to the three wire cores; The outer sides of the three wire cores are covered with a filling area 5, a buffer layer 6 and a heat dissipation outer protective layer 7 in sequence; A cooling channel 4 is provided between each of the two adjacent wire cores and is in close contact with the two wire cores. The cooling channel 4 is covered by an inner reflective cover 9.

[0023] In some preferred embodiments, the special-shaped conductor 1 is composed of one or more special-shaped single wires having a fan-shaped, trapezoidal, polygonal, or Z-shaped cross-sectional shape; the special-shaped conductor 1 is formed by compacting and splicing the special-shaped single wires into a circular shape. The technical effect is that the special-shaped conductor, with its asymmetric cross-sectional design, such as fan-shaped, trapezoidal, or polygonal, forms a geometrically interlocking structure when compacted and spliced into a circular core. This technical effect is that, on the one hand, the complementary filling between the special-shaped cross-sections significantly reduces the porosity between the conductor layers, reducing the overall outer diameter of the conductor by approximately 15%-20% while maintaining the same current carrying capacity, thereby reducing metal material consumption. On the other hand, the compact splicing of the special-shaped conductors creates a continuous and smooth transition on the core surface, avoiding the risk of partial discharge caused by surface burrs in traditional stranded conductors. It also reduces AC resistance by optimizing the internal lattice arrangement of the conductor, suppressing eddy current losses during operation. This structure simultaneously improves the conductor's cross-sectional area utilization, heat dissipation uniformity, and electromagnetic compatibility performance.

[0024] In some preferred embodiments, the insulating layer 2 comprises, from the inside out, a conductor shielding layer 2-1, a polypropylene insulating layer 2-2, and an insulating shielding layer 2-3. The technical benefits of this are that the conductor shielding layer conforms to the surface contour of the irregularly shaped conductor, eliminating electric field concentration caused by sudden changes in the conductor structure. The polypropylene insulating layer enhances the cable's insulation stability, impact resistance, heat resistance, and chemical corrosion resistance in high-temperature environments, while also being recyclable and increasing resource utilization. The insulating shielding layer and the metal shielding layer form a gradient conductive path, suppressing partial discharge.

[0025] In some preferred embodiments, the metal shielding layer 3 is a metal wire or metal film woven into a mesh. Its technical effect is that the flexible deformability of the mesh structure adapts to cable bending conditions, avoiding the cracking and failure of the shielding layer caused by mechanical stress concentration in traditional continuous metal sheaths. The metal wire braid enhances high-frequency interference shielding effectiveness through a multi-path electromagnetic eddy current dissipation mechanism, while the metal film optimizes low-frequency electromagnetic field attenuation characteristics through the surface skin effect, forming a broadband composite shielding system. At the same time, the micro-gap at the interface between the metal film and the braided layer can cooperate with the internal cooling channel to achieve directional heat flow and improve overall heat dissipation efficiency. This structure maintains a lightweight design while taking into account electromagnetic compatibility stability and dynamic thermal management capabilities.

[0026] In some preferred implementation cases, the cooling channel 4 is a corrugated hose having spiral fins or grid grooves inside. Further preferably, the material of the corrugated hose is one of polypropylene or nylon 6, and the diameter of the corrugated hose is 20-40% of the diameter of the wire core. Further preferably, the contact portion between the cooling channel and the wire core can be coated with heat-dissipating silicone to enhance the heat dissipation efficiency. Its technical effect is that the wavy structure of the corrugated hose enhances axial flexibility and radial extensibility, the polypropylene or nylon 6 material provides chemical corrosion resistance and temperature resistance, and the diameter ratio design improves the flow efficiency of the cooling medium while maintaining the compactness of the cable structure, and forms a synergistic heat dissipation system with the heat-conducting channel of the heat-dissipating outer sheath; and the diameter of the corrugated hose can be adjusted according to the specific structure and heat dissipation requirements of the cable, which can ensure excellent heat dissipation performance under various conditions; in response to some special application scenarios, coating with silicone can increase heat dissipation efficiency.

[0027] In some preferred implementations, the cooling channel 4 is connected to a cooling channel regulating device, and the coolant flow rate is regulated by the regulating device. This technical advantage is that the coolant flow rate can be dynamically adjusted based on real-time temperature rise data, reducing energy consumption under light loads and enhancing phase change heat dissipation under heavy loads, achieving adaptive matching of heat dissipation intensity with operating conditions.

[0028] In some preferred implementation cases, the buffer layer 6 is composed of a porous buffer material. Further preferably, the porous buffer material is one or more of polyester, polypropylene, silicone rubber, and chloroprene rubber. Its technical effect is that the porous microstructure absorbs the mechanical stress generated by cable bending and vibration through elastic deformation, avoiding structural damage caused by rigid friction between the core and the sheath; the polyester / polypropylene-based buffer layer is adapted to the thermal expansion and contraction deformation under conventional laying environments by virtue of its lightweight characteristics and chemical corrosion resistance, while the high-temperature stability of silicone rubber and the flame retardant and oil-resistant properties of chloroprene rubber can respectively match the requirements of extreme working conditions such as high temperature and industrial corrosion; in addition, the material pore network and the cooling channel form a through-type heat flow path, which improves the heat dissipation efficiency through the synergistic mechanism of air convection and solid heat conduction, and at the same time, the waterproof and electromagnetic shielding derivative functions can be expanded by filling the pores with water-blocking gel or wave-absorbing materials, thereby realizing multi-dimensional optimization of the buffer layer structure performance.

[0029] In some preferred embodiments, the heat dissipation outer sheath 7 is made of one or more of plastic, graphene, or graphene oxide. The technical effect is that a continuous multidimensional heat conduction network is constructed through the plastic matrix, and the directional arrangement of graphene or graphene oxide sheets forms an axially advantageous heat conduction path, accelerating the directional conduction of heat from the core to the external environment. At the same time, the composite effect of plastic and graphene is utilized to enhance lateral heat diffusion to suppress local hot spots. The corrugated surface of the outer sheath and the porous structure of the buffer layer synergistically form a turbulent flow-induced heat dissipation interface, improving convective heat transfer efficiency. The stacked structure of graphene oxide sheets maintains the integrity of the heat conduction channel when the cable is bent. The plasticity of the plastic matrix and the dynamic adaptation of the graphene enhancement effect achieve synergistic enhancement of the cable's radial stiffness and axial flexibility. At the same time, the surface chemically bonded protective layer blocks erosion by environmental media.

[0030] In some preferred implementations, the temperature-measuring optical fiber unit 8 is connected to a cooling channel adjustment device, adjusting the coolant flow rate based on the temperature feedback from the temperature-measuring optical fiber unit 8. This provides the following technical benefits: The optical fiber unit monitors the operating temperature of the special-shaped conductor in real time, dynamically matching the flow rate of the medium in the cooling channel with the heat load of the core, achieving uniform control of the conductor's temperature rise gradient. Furthermore, by combining the stress-buffering properties of the porous structure of the buffer layer with the directional heat conduction path of the heat-dissipating outer sheath, a closed-loop temperature-flow-heat dissipation control mechanism is formed, suppressing local overheating while reducing cooling system energy consumption. Furthermore, the coordinated design of the hardware and software for optical fiber sensing and mechanical adjustment enhances the cable system's adaptability to dynamic operating conditions.

[0031] In some preferred embodiments, the inner reflector 9 is an aluminized polyimide film. The technical benefit lies in the use of the aluminized polyimide film to partially encase the cooling channel, achieving directional guidance and dynamic balance for thermal management. Its high reflectivity suppresses radial heat radiation losses in the cooling channel, forcing heat from the core to be efficiently dissipated axially via coolant convection. Simultaneously, the uncovered areas of the core are in direct contact with the graphene heat-dissipating outer sheath, creating a synergistic mechanism of "axial active heat dissipation + radial radiation heat dissipation." During normal operation of the active cooling system, infrared radiation from the outer sheath assists in dissipating residual heat. In the event of coolant flow anomalies, the uncovered areas serve as emergency heat dissipation windows, leveraging the graphene sheath's ultra-high lateral thermal conductivity to rapidly dissipate heat and prevent local temperature rises from exceeding the thermal deformation threshold of the insulation layer.

[0032] Example 2

[0033] This embodiment provides a special-shaped conductor polypropylene insulated optoelectronic composite cooling power cable, the main cross-sectional structure diagram of which is as follows: Figure 1 As shown, specifically including:

[0034] Three wire cores are evenly distributed in a 120° circle. Each wire core is, from the inside to the outside, a special-shaped conductor 1 composed of special-shaped single wires with fan-shaped and trapezoidal cross-sections. Each special-shaped wire is tightly pressed and assembled into a circle; an insulating layer 2 is wrapped around the outside of the special-shaped conductor, and the insulating layer 2 is, from the inside to the outside, a conductor shielding layer 2-1, a polypropylene insulating layer 2-2, and an insulating shielding layer 2-3; a metal shielding layer 3 is wrapped around the outside of the insulating layer, and the metal shielding layer 3 is a metal wire woven into a mesh.

[0035] Three cooling channels 4 are evenly distributed along the circumferential direction between the three cores. Each cooling channel 4 is a corrugated hose and is arranged between two adjacent cores and tightly fits with the two. The corrugated hose is made of polypropylene and has spiral fins inside, the diameter of which is 25% of the core diameter. The cooling channel 4 is covered with an aluminum-plated polyimide film inner reflective cover 9. A temperature measuring optical fiber unit 8 is provided in the center of the three cores and is fitted with the cores.

[0036] The periphery of the composite structure formed by the three wire cores and the cooling channel 4 is sequentially covered with a filling area 5, a buffer layer 6 and a heat dissipation outer protective layer 7: the buffer layer 6 is composed of a porous buffer material, which is a polypropylene non-woven fabric and is tightly covered on the periphery of the composite structure; the heat dissipation outer protective layer 7 is made of plastic, graphene and graphene oxide, and is completely covered on the outside of the buffer layer 6; the cooling channel 4 is connected to the cooling channel adjustment device, and the temperature measuring optical fiber unit 8 is connected to the cooling channel adjustment device signal, and the coolant flow rate is dynamically adjusted according to the temperature feedback from the temperature measuring optical fiber unit 8.

[0037] Example 3

[0038] This embodiment provides a special-shaped conductor polypropylene insulated optoelectronic composite cooling power cable, specifically comprising:

[0039] Three wire cores are evenly distributed in a 120° circle, and each wire core is composed of: a special-shaped conductor 1 composed of special-shaped single wires with fan-shaped and trapezoidal cross-sections, and each special-shaped wire is tightly pressed and assembled into a circle; an insulating layer 2 wrapped around the outside of the special-shaped conductor, and the insulating layer 2 is composed of a conductor shielding layer 2-1, a polypropylene insulating layer 2-2, and an insulating shielding layer 2-3 from the inside to the outside; a metal shielding layer 3 wrapped around the outside of the insulating layer, and the metal shielding layer 3 is a metal wire woven into a mesh.

[0040] Three cooling channels 4 are evenly distributed along the circumferential direction between the three cores. Each cooling channel 4 is a corrugated hose and is arranged between two adjacent cores and tightly fits with the two. The corrugated hose is made of polypropylene and has spiral fins inside, the diameter of which is 40% of the core diameter. The cooling channel 4 is covered with an aluminum-plated polyimide film inner reflective cover 9. A temperature measuring optical fiber unit 8 is provided in the center of the three cores and is fitted with the cores.

[0041] The periphery of the composite structure formed by the three wire cores and the cooling channel 4 is sequentially covered with a filling area 5, a buffer layer 6 and a heat dissipation outer protective layer 7: the buffer layer 6 is composed of a porous buffer material, which is a polypropylene non-woven fabric and is tightly covered on the periphery of the composite structure; the heat dissipation outer protective layer 7 is made of plastic, graphene and graphene oxide, and is completely covered on the outside of the buffer layer 6; the cooling channel 4 is connected to the cooling channel adjustment device, and the temperature measuring optical fiber unit 8 is connected to the cooling channel adjustment device signal, and the coolant flow rate is dynamically adjusted according to the temperature feedback from the temperature measuring optical fiber unit 8.

[0042] Comparative Example 1

[0043] The difference between this comparative example and Example 2 is that the conductor is formed by twisting and compacting round single wires.

[0044] This comparative example provides a polypropylene insulated photovoltaic composite cooling power cable, specifically comprising:

[0045] The conductor is formed by twisting and compacting a round single wire, and the conductor diameter is consistent with that of Example 2; the insulating layer 2 wrapped around the outside of the conductor, the insulating layer 2 is composed of a conductor shielding layer 2-1, a polypropylene insulating layer 2-2, and an insulating shielding layer 2-3 from the inside to the outside; the metal shielding layer 3 is wrapped around the outside of the insulating layer, and the metal shielding layer 3 is a metal wire woven into a mesh.

[0046] Three cooling channels 4 are evenly distributed along the circumferential direction between the three cores. Each cooling channel 4 is a corrugated hose and is arranged between two adjacent cores and tightly fits with the two. The corrugated hose is made of polypropylene and has spiral fins inside, the diameter of which is 25% of the core diameter. The cooling channel 4 is covered with an aluminum-plated polyimide film inner reflective cover 9. A temperature measuring optical fiber unit 8 is provided in the center of the three cores and is fitted with the cores.

[0047] The periphery of the composite structure formed by the three wire cores and the cooling channel 4 is sequentially covered with a filling area 5, a buffer layer 6 and a heat dissipation outer protective layer 7: the buffer layer 6 is composed of a porous buffer material, which is a polypropylene non-woven fabric and is tightly covered on the periphery of the composite structure; the heat dissipation outer protective layer 7 is made of plastic, graphene and graphene oxide, and is completely covered on the outside of the buffer layer 6; the cooling channel 4 is connected to the cooling channel adjustment device, and the temperature measuring optical fiber unit 8 is connected to the cooling channel adjustment device signal, and the coolant flow rate is dynamically adjusted according to the temperature feedback from the temperature measuring optical fiber unit 8.

[0048] Comparative Example 2

[0049] The difference between this comparative example and Example 2 is that this comparative example does not include the cooling channel 4 and the inner reflection cover 9 .

[0050] This comparative example provides a special-shaped conductor polypropylene insulated photovoltaic composite cooling power cable, specifically comprising:

[0051] Three wire cores are evenly distributed in a 120° circle, and each wire core is composed of: a special-shaped conductor 1 composed of special-shaped single wires with fan-shaped and trapezoidal cross-sections, and each special-shaped wire is tightly pressed and assembled into a circle; an insulating layer 2 wrapped around the outside of the special-shaped conductor, and the insulating layer 2 is composed of a conductor shielding layer 2-1, a polypropylene insulating layer 2-2, and an insulating shielding layer 2-3 from the inside to the outside; a metal shielding layer 3 wrapped around the outside of the insulating layer, and the metal shielding layer 3 is a metal wire woven into a mesh.

[0052] The periphery of the composite structure formed by the three wire cores and the cooling channel 4 is sequentially covered with a filling area 5, a buffer layer 6 and a heat dissipation outer protective layer 7: the buffer layer 6 is composed of a porous buffer material, which is a polypropylene non-woven fabric and is tightly covered on the periphery of the composite structure; the heat dissipation outer protective layer 7 is made of plastic, graphene and graphene oxide, and is completely covered on the outside of the buffer layer 6; the cooling channel 4 is connected to the cooling channel adjustment device, and the temperature measuring optical fiber unit 8 is connected to the cooling channel adjustment device signal, and the coolant flow rate is dynamically adjusted according to the temperature feedback from the temperature measuring optical fiber unit 8.

[0053] Comparative Example 3

[0054] The difference between this comparative example and Example 2 is that this comparative example does not include the heat dissipation outer protective layer 6 .

[0055] This comparative example provides a special-shaped conductor polypropylene insulated photovoltaic composite cooling power cable, specifically comprising:

[0056] Three wire cores are evenly distributed in a 120° circle, and each wire core is composed of: a special-shaped conductor 1 composed of special-shaped single wires with fan-shaped and trapezoidal cross-sections, and each special-shaped wire is tightly pressed and assembled into a circle; an insulating layer 2 wrapped around the outside of the special-shaped conductor, and the insulating layer 2 is composed of a conductor shielding layer 2-1, a polypropylene insulating layer 2-2, and an insulating shielding layer 2-3 from the inside to the outside; a metal shielding layer 3 wrapped around the outside of the insulating layer, and the metal shielding layer 3 is a metal wire woven into a mesh.

[0057] Three cooling channels 4 are evenly distributed along the circumferential direction between the three cores. Each cooling channel 4 is a corrugated hose and is arranged between two adjacent cores and tightly fits with the two. The corrugated hose is made of polypropylene and has spiral fins inside, the diameter of which is 25% of the core diameter. The cooling channel 4 is covered with an aluminum-plated polyimide film inner reflective cover 9. A temperature measuring optical fiber unit 8 is provided in the center of the three cores and is fitted with the cores.

[0058] The composite structure formed by the three wire cores and the cooling channel 4 is coated with a filling area 5 and a buffer layer 6: the buffer layer 6 is composed of a porous buffer material, and the porous buffer material is a polypropylene non-woven fabric, which is tightly coated on the periphery of the composite structure; the cooling channel 4 is connected to the cooling channel adjustment device, and the temperature measuring optical fiber unit 8 is connected to the cooling channel adjustment device signal, and the coolant flow rate is dynamically adjusted according to the temperature feedback from the temperature measuring optical fiber unit 8.

[0059] Comparative Example 4

[0060] The difference between this comparative example and Example 2 is that polyethylene is used as the insulating layer material in this comparative example.

[0061] This comparative example provides a special-shaped conductor polypropylene insulated photovoltaic composite cooling power cable, specifically comprising:

[0062] Three wire cores are evenly spaced in a 120° circle, each core comprising, from inside to outside: a shaped conductor 1 formed by combining shaped single wires with fan-shaped and trapezoidal cross-sections, wherein the shaped wires are tightly pressed and assembled into a circle; an insulating layer 2 covering the shaped conductor, wherein the insulating layer 2 comprises, from inside to outside, a conductor shielding layer 2-1, a vinyl insulating layer 2-2, and an insulating shielding layer 2-3; The metal shielding layer 3 is wound around the insulating layer, and the metal shielding layer 3 is a metal wire woven into a mesh.

[0063] Three cooling channels 4 are evenly distributed along the circumferential direction between the three cores. Each cooling channel 4 is a corrugated hose and is arranged between two adjacent cores and tightly fits with the two. The corrugated hose is made of polypropylene and has spiral fins inside, the diameter of which is 25% of the core diameter. The cooling channel 4 is covered with an aluminum-plated polyimide film inner reflective cover 9. A temperature measuring optical fiber unit 8 is provided in the center of the three cores and is fitted with the cores.

[0064] The periphery of the composite structure formed by the three wire cores and the cooling channel 4 is sequentially covered with a filling area 5, a buffer layer 6 and a heat dissipation outer protective layer 7: the buffer layer 6 is composed of a porous buffer material, which is a polypropylene non-woven fabric and is tightly covered on the periphery of the composite structure; the heat dissipation outer protective layer 7 is made of plastic, graphene and graphene oxide, and is completely covered on the outside of the buffer layer 6; the cooling channel 4 is connected to the cooling channel adjustment device, and the temperature measuring optical fiber unit 8 is connected to the cooling channel adjustment device signal, and the coolant flow rate is dynamically adjusted according to the temperature feedback from the temperature measuring optical fiber unit 8.

[0065] Test example

[0066] The performance parameters of the power cables manufactured using the solutions of Examples 2-3 and Comparative Examples 1-4 were tested, and the specific operations were as follows:

[0067] Electrical performance testing: Test conductor resistance and insulation resistance according to GB / T 3048.4-2007 "Electrical Performance Test Methods for Wires and Cables".

[0068] Thermal resistance and heat dissipation efficiency testing, according to JB / T 10181-2014 "Guidelines for Calculating Cable Ampacity" (thermal parameters), measures the cable surface temperature under constant current load; after opening the cooling channel, compares the temperature drop and calculates the heat dissipation time;

[0069] Bending fatigue test, according to GB / T 2951.21-2008 (mechanical properties test), 10,000 bending cycles are performed to check the structural integrity of the buffer layer and the core, and the insulation resistance decay rate after bending is calculated as follows:

[0070] Insulation resistance attenuation rate after bending = (insulation resistance value - insulation resistance value after bending) / insulation resistance value * 100%;.

[0071] Material degradability testing, ISO 14855 (Biodegradability under composting conditions) method: Thermal cracking experiments were conducted on polypropylene insulation to determine its recyclability.

[0072] The test results are shown in Table 1.

[0073] Table 1 It can be seen from Table 1 that the performance of the special-shaped conductor polypropylene insulated photovoltaic composite cooling power cable made by the technical solution provided by the present invention is significantly better than that of the comparative example.

[0074] Examples 2 and 3 use a process of compacting and splicing conductors with fan-shaped and trapezoidal cross-sections, and their DC resistance is 0.128Ω / km and 0.125Ω / km, respectively, which is about 13% lower than the circular single-wire twisted conductor (0.145Ω / km) of Comparative Example 1. This difference is due to the interlocking filling effect between the special-shaped cross-sections, which reduces the interlayer porosity of the traditional twisted conductor and effectively improves the utilization rate of the conductor cross-sectional area, indicating that the special-shaped conductor structure provided by the present invention achieves significant performance improvement by optimizing the geometric cross-sectional morphology. In addition, Example 3 further expands the cooling channel diameter to 40% of the core diameter, and improves the heat dissipation efficiency by increasing the cross-sectional area of the coolant flow. However, it is necessary to find a balance between the heat dissipation performance and the compactness of the cable space to avoid excessive increase in the outer diameter, which increases the difficulty of laying.

[0075] After removing the cooling channel and internal reflector in Comparative Example 2, the cable temperature rose to 45°C at rated current, a 6.7% increase from the 28°C in Example 2. This demonstrates that a passive mode relying solely on ambient heat dissipation cannot cope with the heat load of high-current operating conditions. In Examples 2-3, the cooling channel, internal reflector, and heat-dissipating outer sheath form a dual-path heat dissipation mechanism of "internal forced convection + external efficient heat conduction." The heat-dissipating outer sheath contains graphene, which has a high transverse thermal conductivity and improves heat dissipation performance. However, after removing the heat-dissipating outer sheath in Comparative Example 3, the heat dissipation response time was extended from 6.5 seconds to 12.3 seconds. Furthermore, after opening the cooling channel, the cooling capacity was significantly lower than in the example, demonstrating that the outer sheath's role in promoting longitudinal heat transfer is irreplaceable. In summary, the collaborative design of the active cooling system and passive heat dissipation materials provided by the present invention is an indispensable component in controlling cable heat dissipation.

[0076] The polypropylene insulation layer of Examples 2-3 achieves a 92% recycling rate through thermoplastic processing technology, while Comparative Example 4 uses traditional cross-linked polyethylene, which cannot be melt-regenerated due to its three-dimensional network cross-linked structure, and produces non-degradable solid waste after being scrapped, which has an impact on the environment.

[0077] After 10,000 bending cycles, the insulation resistance decay rate of Examples 2-3 was only 3.2%-3.5%, a 63% reduction from the 8.7% in Comparative Example 1. This is due to the following mechanism: the interface of the dissimilar conductors forms a microscopic mechanical interlocking structure, dispersing bending stress concentration points; and the porous polypropylene buffer layer absorbs deformation energy through pore compression, minimizing the relative displacement of the wire core and thus preventing insulation degradation caused by periodic friction in the insulation layer.

[0078] In Example 3, the cooling channel diameter is increased to 40% of the core diameter, and an algorithm is used to adjust the coolant flow rate, reducing the heat dissipation response time from 6.5 seconds in Example 2 to 5.8 seconds. The principle is that increasing the channel diameter increases the flow rate at the same pump pressure, allowing for faster heat dissipation. However, it should be noted that channel diameters exceeding 50% of the core diameter may cause cable eccentricity.

[0079] Unless otherwise specified, the raw materials and equipment used in the present invention are commonly used in the art; unless otherwise specified, the methods used in the present invention are conventional methods in the art. The above description is merely a preferred embodiment of the present invention and does not limit the present invention in any way. Any simple modification, alteration, or equivalent transformation of the above embodiment based on the technical essence of the present invention still falls within the scope of protection of the technical solution of the present invention.

Claims

1. A special-shaped conductor polypropylene insulated photoelectric composite cooling power cable, characterized in that: include: Three wire cores are evenly distributed in a 120° circle, each wire core comprising, from the inside to the outside, a special-shaped conductor (1), an insulating layer (2) wrapped around the special-shaped conductor, and a metal shielding layer (3) wrapped around the insulating layer; a temperature measuring optical fiber unit (8) is provided at the center of the inner side of the three wire cores and is bonded to the three wire cores; The outer sides of the three wire cores are sequentially covered with a filling area (5), a buffer layer (6) and a heat dissipation outer protective layer (7); A cooling channel (4) that fits tightly with the two adjacent wire cores is provided between each two adjacent wire cores, and the cooling channel (4) is covered with an inner reflective cover (9).

2. The special-shaped conductor polypropylene insulated photoelectric composite cooling power cable according to claim 1, characterized in that: The special-shaped conductor (1) is composed of one or more special-shaped single wires having a cross-sectional shape of a fan, a trapezoid, a polygon or a Z; the special-shaped conductor (1) is formed by pressing and splicing the special-shaped single wires into a circular shape.

3. The special-shaped conductor polypropylene insulated photoelectric composite cooling power cable according to claim 1, characterized in that: The insulating layer (2) comprises, from the inside to the outside, a conductor shielding layer (2-1), a polypropylene insulating layer (2-2), and an insulating shielding layer (2-3).

4. The special-shaped conductor polypropylene insulated photoelectric composite cooling power cable according to claim 1, characterized in that: The metal shielding layer (3) is a metal wire or metal film woven into a mesh.

5. The special-shaped conductor polypropylene insulated photoelectric composite cooling power cable according to claim 1, characterized in that: The cooling channel (4) is a corrugated hose having spiral fins or grid grooves inside.

6. The special-shaped conductor polypropylene insulated photoelectric composite cooling power cable according to claim 1 or 5, characterized in that: The cooling channel (4) is connected to a cooling channel regulating device, and the flow rate of the cooling liquid is regulated by the regulating device.

7. The special-shaped conductor polypropylene insulated photoelectric composite cooling power cable according to claim 1, characterized in that: The buffer layer (6) is composed of porous buffer material.

8. The special-shaped conductor polypropylene insulated photoelectric composite cooling power cable according to claim 1, characterized in that: The heat dissipation outer protective layer (7) is made of one or more of plastic, graphene or graphene oxide.

9. The special-shaped conductor polypropylene insulated photoelectric composite cooling power cable according to claim 1, characterized in that: The temperature measuring optical fiber unit (8) is connected to the cooling channel regulating device, and the flow rate of the cooling liquid is adjusted according to the temperature fed back by the temperature measuring optical fiber unit (8).

10. The special-shaped conductor polypropylene insulated photoelectric composite cooling power cable according to claim 1, characterized in that: The inner reflector (9) is an aluminum-plated polyimide film.

Images