A production method for composite power cables for multiple applications

Abstract

This invention discloses a production method for a composite power cable suitable for multiple applications. The aim is to provide a method for producing a composite power cable with an internal support structure and high stability, suitable for use in various scenarios. The key technical points are: preparing a conductor mounting frame, installing metal conductors, wrapping an inner insulation layer, winding a shielding layer, wrapping an outer insulation layer, and wrapping an outer sheath. The conductor mounting frame serves as the core and internal support frame, forming an installation structure for the conductors. This internal support structure enhances the outward structure of the power cable, providing effective support for the metal conductors and ensuring that the conductors do not interfere with each other. Furthermore, during the inner insulation layer wrapping, shielding layer winding, outer insulation layer wrapping, and outer sheath wrapping processes, the internal support frame ensures a more stable bonding surface during extrusion wrapping, resulting in excellent wrapping performance. This invention is applicable to the field of power cable production technology.

Description

Technical Field

[0001] This invention relates to the field of power cable manufacturing technology, and more specifically, to a method for producing composite power cables for use in multiple scenarios. Background Technology

[0002] Cables are conductors covered with insulation, protective layers, and shielding layers used to transmit power or signal current and signal voltage. According to voltage, they can be divided into high-voltage cables and low-voltage cables. Although low-voltage cable lines are more expensive and more difficult to lay and maintain compared with low-voltage overhead lines and low-voltage overhead insulated lines, they are widely used in low-voltage power distribution systems because of their reliable operation, no need for poles, no land occupation, no obstruction of appearance, and less susceptibility to external influences.

[0003] However, the low-voltage cables currently used in the power industry are often damaged by compression during transportation and installation. This compression can lead to poor transmission and external cracking, reducing the protective function of the cable core and shortening its lifespan. This is especially true for cables used in special environments. Therefore, in order to ensure that cables have good structural resistance and more stable output in various scenarios, it is essential to address these issues. Summary of the Invention

[0004] In view of the shortcomings of the existing technology, the purpose of this invention is to provide a method for producing a composite power cable with an internal support structure, high stability, and usability in multiple scenarios.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a production method for a composite power cable for multiple scenarios, comprising a conductor layer, an inner insulation layer, a shielding layer, an outer insulation layer, and a sheath layer arranged sequentially from the inside out, specifically including the following steps: S1, preparing a conductor mounting frame: using an inner support frame as the core, after fixing the inner support frame, it is placed in a molding mold, and the inner support frame is injection molded to obtain a conductor mounting frame. The conductor mounting frame is provided with mounting grooves that are directly formed by the mold or obtained by further grooving and are used to install conductors. The inner diameter of the mounting groove is adapted to the outer diameter of the metal conductor.

[0006] S2. Installing metal wires: Clean the surface of the conductor mounting groove base, pull the metal wires to the same length as the conductor mounting skeleton using a traction device, and press the metal wires into the mounting groove using a pressing device until the installation is completed and the main core is formed.

[0007] S3. Inner insulation layer coating: After the PVC material is mixed with plasticizer, stabilizer, flame retardant and color masterbatch according to the formula, the mixed PVC material is melted and plasticized by the extruder, and then continuously and evenly coated on the outside of the main core through the die head.

[0008] S4. Shielding layer winding: Soft copper strip is used. The cable semi-finished product obtained in step S3 is pulled by the traction equipment. The gap of the copper strip is controlled by the copper strip shielding machine and it is evenly wound around the material. Then, the regular corrugated concave and convex shape is rolled on the surface of the copper strip shielding layer by the corrugating wheel.

[0009] S6. Outer insulation layer coating: After the PVC material is precisely mixed with plasticizer, stabilizer, flame retardant and color masterbatch according to the formula, the mixed PVC material is melted and plasticized by the extruder and then continuously and evenly coated on the outside of the cable semi-finished product obtained in step S5 through the die head.

[0010] S7. Outer Sheath Coating: Thermoplastic polyurethane material is mixed with plasticizer, stabilizer, flame retardant and color masterbatch according to the formula. The mixed thermoplastic polyurethane material is melted and plasticized by an extruder and continuously and evenly coated on the outside of the main core body through the die head. After cooling, the finished cable is obtained.

[0011] The present invention is further configured such that: the conductor mounting skeleton is composed of an inner support frame and a rubber material covering the inner support frame, that is, the inner support frame is placed in the injection mold, and then the molten PE liquid in a fluid state is introduced into the injection mold by injection molding, so that the molten PE liquid forms the conductor mounting skeleton outside the inner support frame.

[0012] The present invention is further configured such that: the inner support frame is composed of a plurality of sequentially connected unit skeletons, and two adjacent unit skeletons are connected and extended by flexible fibers. Each unit skeleton includes a main frame body, a slot structure evenly distributed on the main frame body and adapted to the outer diameter of each metal wire, and a support rod structure disposed on the main frame body. The slot structure is connected by a plurality of first connecting units to form a first arc structure, and the main frame body is connected by a plurality of second connecting units to form a second arc structure. Each first and second unit skeleton is connected by welding, and the two ends of the second arc structure are respectively welded to the two first arc structures.

[0013] The present invention is further configured such that: each of the first connecting units is connected to form a first weld point, each of the second connecting units is connected to form a second weld point, and the first connecting unit and the second connecting unit are connected to form a third weld point, and each of the first weld point, the second weld point and the third weld point between two adjacent unit skeletons are connected by flexible fibers.

[0014] The present invention is further configured such that: the conductor mounting skeleton is formed with a covering layer by injection molding, and the outer diameter of the covering layer is 3mm-6mm larger than the outer diameter of the conductor skeleton.

[0015] The present invention is further configured such that the spacing between two adjacent unit skeletons is between 10-20 mm.

[0016] By adopting the above technical solution, the following beneficial effects are achieved: 1. By preparing the conductor mounting skeleton, installing the metal wires, wrapping the inner insulation layer, winding the shielding layer, wrapping the outer insulation layer, and wrapping the outer sheath, the conductor mounting skeleton is used as the core and as the inner support frame to form the installation structure for the conductor. This allows the power cable to achieve structural reinforcement outward with the inner support structure, providing effective support for the metal wires and ensuring that the wires do not interfere with each other. Furthermore, during the inner insulation layer wrapping, shielding layer winding, outer insulation layer wrapping, and outer sheath wrapping, the setting of the inner support frame makes the bonding surface of the wrapping layer more stable during extrusion wrapping, thereby achieving a good wrapping effect, greatly improving practicality, and strengthening stability.

[0017] 2. Furthermore, this application sets the conductor mounting frame as being composed of an inner support frame and a rubber material covering the inner support frame. That is, the inner support frame is placed in an injection mold, and then molten PE liquid in a fluid state is introduced into the injection mold through injection molding, so that the molten PE liquid forms the conductor mounting frame outside the inner support frame. In order to improve the structural strength of the conductor mounting frame, the inner support frame is used as the core, and the conductor mounting frame is formed by injection molding, so that the inside of the conductor mounting frame has strong support. Combined with the injection molding method, the radial strength of the conductor mounting frame can be improved, and it also has strong support in the length direction, so as to adapt to the use in different environments.

[0018] 3. This invention further describes the internal support frame as being composed of several sequentially connected unit skeletons. The composition of multiple unit skeletons allows the reinforcing structure to be uniformly reinforced in the length direction. Both adjacent unit skeletons are connected and extended by flexible fibers. Each unit skeleton includes a main frame, a slotted structure uniformly distributed on the main frame and adapted to the outer diameter of each metal conductor, and a support rod structure set on the main frame. The slotted structure is connected by several first connecting units to form a first arc-shaped structure, and the main frame is connected by several second connecting units to form a second arc-shaped structure. Each first and second unit skeleton is connected by welding, and the two ends of the second arc-shaped structure are welded to the two first arc-shaped structures respectively. This invention adopts a multi-segment structure and disperses stress through welding, thereby reducing the internal stress after re-injection molding after the combination of each component unit, thus improving the overall structural stability. Moreover, the arc-shaped structure obtained by the segmented splicing structure has strong adaptability to the outer diameter of the conductor, greatly improving its practicality.

[0019] 4. To improve the overall connection between the unit skeletons, a first solder joint is formed by connecting the first connecting units, a second solder joint is formed by connecting the second connecting units, and a third solder joint is formed by connecting the first and second connecting units. Finally, the first, second, and third solder joints between two adjacent unit skeletons are connected by flexible fibers. After being connected by flexible fibers, the connection between the unit skeletons is made tighter, and the overall integrity between the unit skeletons is improved. Combined with injection molding, the conductor mounting skeleton has higher structural strength, better stability, and greatly improved practicality. Attached Figure Description

[0020] Figure 1 This is a partial perspective view of an embodiment of a production method for composite power cables used in multiple scenarios according to the present invention.

[0021] Figure 2 This is a perspective view of the conductor mounting skeleton in an embodiment of the production method of a composite power cable for multi-scenario use according to the present invention.

[0022] Figure 3 This is an embodiment of a production method for a composite power cable used in multiple scenarios according to the present invention. Figure 2 Enlarged view of the structure at point A in the middle.

[0023] In the attached diagram, the following labels represent different components: 1. Conductor layer; 2. Inner insulation layer; 3. Shielding layer; 4. Outer insulation layer; 5. Sheath layer; 10. Conductor mounting frame; 101. Inner support frame; 102. Mounting groove; 11. Main core; 12. Covering layer; 13. Unit frame; 14. Flexible fiber; 15. Main frame; 16. Embedded structure; 17. Support rod structure; 160. First connecting unit; 170. Second connecting unit; 161. First solder joint; 171. Second solder joint; 180. Third solder joint. Detailed Implementation

[0024] Reference Figures 1 to 3 The present invention provides a further description of an embodiment of a production method for a composite power cable suitable for multiple applications.

[0025] For ease of explanation, spatial relative terms such as “up,” “down,” “left,” and “right” are used in the embodiments to describe the relationship of one element or feature shown in the figures relative to another element or feature. It should be understood that, in addition to the orientations shown in the figures, spatial terms are intended to include different orientations of the device in use or operation. For example, if the device in the figures is inverted, an element described as being “down” of other elements or features would be positioned “up” of those other elements or features. Therefore, the exemplary term “down” can encompass both up and down orientations. The device may be positioned in other ways (rotated 90 degrees or in other orientations), and the spatial relative descriptions used herein will be interpreted accordingly.

[0026] Moreover, relational terms such as “first” and “second” are used merely to distinguish one component from another that has the same name, without necessarily requiring or implying any such actual relationship or order between the components.

[0027] A method for producing a composite power cable for multiple applications includes a conductor layer 1, an inner insulation layer 2, a shielding layer 3, an outer insulation layer 4, and a sheath layer 5 arranged sequentially from the inside out. Specifically, it includes the following steps: S1. Preparing a conductor mounting frame 10: Using an inner support frame 101 as the core, after fixing the inner support frame 101, it is placed in a molding mold and injection molded to form the inner support frame 101 to obtain the conductor mounting frame 10. The conductor mounting frame 10 is provided with mounting grooves 102 that are directly formed by the mold or obtained by further grooving and are used to install conductors. The inner diameter of the mounting groove 102 is adapted to the outer diameter of the metal conductor.

[0028] S2. Installing metal wires: Clean the base surface of conductor mounting groove 102, pull the metal wires to the same length as conductor mounting skeleton 10 using a traction device, and press the metal wires into the mounting groove 102 using a pressing device until the installation is completed, forming the main core 11.

[0029] S3, Inner insulation layer 2 coating: After the PVC material is mixed with plasticizer, stabilizer, flame retardant and color masterbatch according to the formula, the mixed PVC material is melted and plasticized by the extruder, and then continuously and evenly coated on the outside of the main core 11 through the die head mold.

[0030] S4. Winding of shielding layer 3: Using soft copper strip, the cable semi-finished product obtained in step S3 is pulled by the traction equipment, and the gap of the copper strip is controlled by the copper strip shielding machine and evenly wound around the material. Then, regular corrugated undulations are rolled on the surface of the copper strip shielding layer 3 by the corrugating wheel.

[0031] S6, Outer insulation layer 4: After the PVC material is precisely mixed with plasticizer, stabilizer, flame retardant and color masterbatch according to the formula, the mixed PVC material is melted and plasticized by the extruder and then continuously and evenly wrapped on the outside of the cable semi-finished product obtained in step S5 through the die head.

[0032] S7. Outer sheath coating: Thermoplastic polyurethane material is mixed with plasticizer, stabilizer, flame retardant and color masterbatch according to the formula. The mixed thermoplastic polyurethane material is melted and plasticized by an extruder and continuously and evenly coated on the outside of the main core 11 through the die head. After cooling, the finished cable is obtained. The formula settings of the inner insulation layer 2, outer insulation layer 4 and outer sheath in the embodiment of the present invention are conventional technical means in the field and will not be described in detail in the present invention. The present invention uses the conductor internal support as the main structural basis for protection.

[0033] This invention, through the preparation of a conductor mounting frame 10, installation of metal wires, inner insulation layer 2 covering, shielding layer 3 winding, outer insulation layer 4 covering, and outer sheath covering, uses the conductor mounting frame 10 as the core and inner support frame 101 to form a conductor mounting structure. This allows the power cable to achieve outward structural reinforcement with the inner support structure, providing effective support for the metal wires and ensuring that the wires do not interfere with each other. Furthermore, during the inner insulation layer 2 covering, shielding layer 3 winding, outer insulation layer 4 covering, and outer sheath covering, the inner support frame 101 ensures a more stable bonding surface during the extrusion covering of the covering layer 12, thereby achieving a good covering effect, greatly improving practicality and stability.

[0034] Furthermore, the conductor mounting frame 10 is composed of an inner support frame 101 and a rubber material covering the inner support frame 101. The inner support frame 101 is placed in an injection mold, and then molten PE in a fluid state is introduced into the injection mold through injection molding, causing the molten PE to form the conductor mounting frame 10 outside the inner support frame 101. In this application, the conductor mounting frame 10 is configured to include an inner support frame 101 and a rubber material covering the inner support frame 101. The inner support frame 101 is placed in an injection mold, and then molten PE in a fluid state is introduced into the injection mold through injection molding, causing the molten PE to form the conductor mounting frame 10 outside the inner support frame 101. To improve the structural strength of the conductor mounting frame 10, the inner support frame 101 serves as the core, and the conductor mounting frame is formed through injection molding, providing strong internal support. Combined with the injection molding process, this enhances the radial strength of the conductor mounting frame and provides strong support in the length direction, thus enabling it to adapt to different environments.

[0035] Furthermore, the inner support frame 101 is composed of several sequentially connected unit skeletons 13. Two adjacent unit skeletons 13 are connected and extended by flexible fibers 14. Each unit skeleton 13 includes a main frame 15, slotted structures 16 evenly distributed on the main frame 15 and adapted to the outer diameter of each metal conductor, and support rod structures 17 disposed on the main frame 15. The slotted structures 16 are connected by several first connecting units 160 to form a first arc-shaped structure, and the main frame 15 is connected by several second connecting units 170 to form a second arc-shaped structure. The first and second unit skeletons 13 are connected by welding, and the two ends of the second arc-shaped structure are welded to the two first arc-shaped structures respectively. This invention also allows the reinforcing structure to be uniformly reinforced along its length by configuring the inner support frame 101 as a group of sequentially connected unit skeletons 13. Furthermore, the two adjacent unit skeletons 13 are connected and extended by flexible fibers 14. Each unit skeleton 13 includes a main frame 15, a slotted structure 16 evenly distributed on the main frame 15 and adapted to the outer diameter of each metal conductor, and a support structure 17 set on the main frame 15. The slotted structure 16 is connected by several first connecting units 160 to form a first arc-shaped structure, and the main frame 15 is connected by several second connecting units 170 to form a second arc-shaped structure. Each first and second unit skeleton 13 is connected by welding, and the two ends of the second arc-shaped structure are welded to the two first arc-shaped structures respectively. The present invention adopts a multi-segment structure and disperses stress through welding, thereby reducing the internal stress after re-injection molding after the combination of each component unit, thus improving the overall structural stability. Moreover, the arc-shaped structure obtained by the segmented splicing structure has strong adaptability to the outer diameter of the conductor, greatly improving its practicality.

[0036] Furthermore, each of the first connecting units 160 is connected to form a first solder joint 161, each of the second connecting units 170 is connected to form a second solder joint 171, and a third solder joint 180 is formed between the first connecting units 160 and the second connecting units 170. The first solder joint 161, the second solder joint 171, and the third solder joint 180 between two adjacent unit frames 13 are all connected by flexible fibers 14. To improve the overall connection integrity between the unit frames 13, the first connecting units 160 are connected to form a first solder joint 161, and each of the second connecting units 170 is connected to form a second solder joint 171. A second solder joint 171 is formed between the first connecting unit 160 and the second connecting unit 170, and a third solder joint 180 is formed between them. Finally, the first solder joint 161, the second solder joint 171 and the third solder joint 180 between two adjacent unit skeletons 13 are connected by flexible fibers 14. After being connected by flexible fibers 14, the connection between each unit skeleton 13 can be made tighter, and the overall integrity between each unit skeleton 13 can be improved. Combined with injection molding, the conductor mounting skeleton 10 has higher structural strength, better stability and greatly improved practicality.

[0037] Furthermore, the conductor mounting frame 10 is formed with a covering layer 12 by injection molding. In this embodiment of the invention, the covering layer 12 is formed on the inner support frame 101 after injection molding, and the outer diameter of the covering layer 12 is 3mm-6mm larger than the outer diameter of the conductor frame. In order to improve the covering strength of the covering layer 12 for the inner support frame 101, and since the covering thickness of the covering layer 12 determines the covering strength for the inner support frame 101, that is, if the covering thickness is too small, the inner support frame 101 will bear greater pressure. Similarly, if the covering thickness is too large, it will not only waste materials, but also the function of the inner support frame 101 cannot be better reflected. Therefore, controlling the covering thickness between 3mm-6mm can form a strong support effect between the covering layer 12 and the inner support frame 101, and the inner support frame 101 and the conductor can fit well, thereby achieving effective support and greatly improving practicality.

[0038] Furthermore, the spacing between two adjacent unit frames 13 is between 10-20 mm. To provide support for the cable along its length, controlling the spacing between the unit frames 13 and keeping the spacing between two adjacent unit frames 13 between 10-20 mm improves the uniform reinforcement provided by the unit frames 13 within the conductor support frames 101, thereby providing effective support along the conductor's length and enabling the power cable to be used in multiple scenarios. Finally, in this embodiment of the invention, the use of flexible fibers 14 to connect the unit frames 13 also allows the power cable to bend.

[0039] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any ordinary changes and substitutions made by those skilled in the art within the scope of the technical solution of the present invention should be included within the protection scope of the present invention.

Claims

1. A production method of a multi-scene use composite power cable, comprising a conductor layer (1), an inner insulation layer (2), a shielding layer (3), an outer insulation layer (4), and a sheath layer (5) arranged in order from the inside, characterized in that, Specifically include the following steps, S1, preparation of conductor installation skeleton (10): by the inner support frame (101) as the core, after fixing the inner support frame (101), placed in the forming mold, and by injection molding way to the inner support frame (101) injection molding, get conductor installation skeleton (10), conductor installation skeleton (10) is provided with installation groove (102) for installing conductor by mold directly forming or again getting and used for installing conductor, the groove diameter of installation groove (102) and the outer diameter of metal wire are matched; S2, installation of metal wire: clean the basic surface of the conductor installation groove (102), pull the metal wire to the same length as the conductor installation skeleton (10) by traction equipment, and press the metal wire into the installation groove (102) by extrusion device until the installation is completed to form the main core (11); S3, inner insulation layer (2) covering: after PVC material is mixed with plasticizer, stabilizer, flame retardant and color master batch according to the formula, the melted PVC material is plasticized by extruder, and the outer side of the main core (11) is continuously and uniformly coated by the die head mold; S4, shielding layer (3) winding: the soft copper strip is used, the cable semi-finished product obtained in step S3 is pulled by traction equipment, the copper strip gap is controlled by copper strip shielding machine, and the copper strip is uniformly wound on the material, and the regular corrugated concave-convex is rolled on the surface of the copper strip shielding layer (3) by the knurling wheel; S6, outer insulation layer (4) covering: after the PVC material is accurately mixed with plasticizer, stabilizer, flame retardant and color master batch according to the formula, the melted PVC material is plasticized by extruder, and the outer side of the cable semi-finished product obtained in step S5 is continuously and uniformly coated by the die head mold; S7, outer sheath covering: after the thermoplastic polyurethane material is mixed with plasticizer, stabilizer, flame retardant and color master batch according to the formula, the melted thermoplastic polyurethane material is plasticized by extruder, and the outer side of the main core (11) is continuously and uniformly coated by the die head mold, and the cable product is obtained after cooling; The conductor installation skeleton (10) is composed of the inner support frame (101) and the rubber material coated on the outer side of the inner support frame (101), that is, the inner support frame (101) is placed in the injection mold, and then the PE molten liquid in fluid state is introduced into the injection mold by injection molding, so that the PE molten liquid forms the conductor installation skeleton (10) on the outer side of the inner support frame (101); The inner support frame (101) is composed of several sequentially connected unit frames (13), two adjacent unit frames (13) are connected and extended by flexible fibers (14), each unit frame (13) comprises a main frame body (15), a groove structure (16) uniformly distributed on the main frame body (15) and matched with the outer diameter of each metal wire, and a support rod structure (17) arranged on the main frame body (15), the groove structure (16) is connected by several first connecting units (160) and forms a first arc structure, the main frame body (15) is connected by several second connecting units (170) and forms a second arc structure, each first and second unit frame (13) is connected by welding, and the two ends of the second arc structure are respectively welded with the two first arc structures; Each first connecting unit (160) is connected to form a first welding point (161), each second connecting unit (170) is connected to form a second welding point (171), and a third welding point (180) is formed between the first connecting unit (160) and the second connecting unit (170), and each first welding point (161), second welding point (171) and third welding point (180) between two adjacent unit frames (13) are connected by flexible fibers (14).

2. The production method of a multi-scene use composite power cable according to claim 1, characterized by, The conductor mounting frame (10) is formed with a cladding layer (12) by injection molding, and the cladding outer diameter of the cladding layer (12) is greater than the conductor frame outer diameter by 3-6mm.

3. The production method of a multi-scene use composite power cable according to claim 2, characterized by, The spacing between two adjacent unit frames (13) is between 10-20mm.

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