Metallic braided shear resistant protection photovoltaic power transmission cable and method of production thereof

Abstract

The application relates to the technical field of photovoltaic cables, and discloses a metal-braided anti-shearing protection photovoltaic power transmission cable and a production method thereof, which comprises a conductor, an inner insulation sleeve, a braided layer, an outer protective skin and a protective layer for improving the protection strength of equipment, wherein the protective layer comprises multiple groups of partition rings fixed at equal intervals on the outer wall of the inner insulation sleeve. The equipment is provided with the outer protective skin, the partition rings and the convex blocks of the protective layer, the spiral embedding grooves in the inner wall of the outer protective skin and the braided layer, the outer protective skin directly resists external shearing force and environmental erosion, the wire harness of the braided layer is embedded in the buckle grooves in the outer wall of the partition rings to form rigid connection for uniformly transmitting external force, the partition rings disperse concentrated force through the symmetrical arc-shaped cross sections, the convex blocks slide along the spiral embedding grooves and form frictional damping to absorb energy through the slightly rough treatment of the groove walls, the purpose of avoiding conductor fracture and wire breakage from penetrating the outer protective skin due to external shearing force is achieved, the shearing resistance and structural stability of the cable are remarkably improved, and the risk of electric leakage is effectively reduced.

Description

Technical Field

[0001] This invention relates to the field of photovoltaic cable technology, and in particular to metal braided shear-resistant photovoltaic transmission cables and their manufacturing methods. Background Technology

[0002] As an important form of clean energy, photovoltaic projects have gradually expanded from ground-mounted projects to rooftop projects (such as factory rooftops, residential rooftops, and office building rooftops), effectively reducing land resource occupation and enabling local consumption of electricity. The power transmission of photovoltaic power generation systems relies on cables connecting the rooftop components and combiner boxes to the inverters and power distribution equipment downstairs. These cables need to withstand external shear forces such as collisions from construction tools, impacts from gravel, and compression from supports, as well as frequent bending and wiring operations.

[0003] However, existing photovoltaic cables have significant shortcomings: First, traditional photovoltaic cables are mostly simple laminated structures consisting of a conductor, inner insulation, braided layer, and outer sheath, without a dedicated shear force buffering and dispersion structure. In outdoor environments, direct external shear forces such as rolling stones can easily be directly transmitted to the conductor inside the cable, causing the conductor (mostly soft copper wire) to break due to localized stress concentration. Furthermore, the sharp fracture surface formed after the conductor breaks can easily pierce the inner insulation layer and outer sheath during cable bending, forming damaged holes. Rainwater, dust, and other media can easily seep into the damaged area, damaging the insulation performance, causing leakage accidents, leading to inverter tripping, equipment damage, and even electric shock safety hazards, which cannot meet the long-term and stringent usage requirements of photovoltaic power plants. Summary of the Invention

[0004] The technical problem to be solved by this invention is that traditional photovoltaic cables in complex environments have the disadvantage of being unable to ensure the sealing and insulation of the internal conductors. To address this, we propose a metal braided shear-resistant photovoltaic transmission cable and its production method.

[0005] To achieve the above objectives, this application adopts the following technical solution: a metal braided shear-resistant photovoltaic transmission cable, comprising a conductor, an inner insulating sheath, a braided layer, an outer protective sheath, and a protective layer for enhancing the equipment's protective strength; the protective layer comprises multiple sets of spacers fixed at equal intervals to the outer wall of the inner insulating sheath, and multiple sets of locking grooves for limiting the braided layer are arranged in an equiangular array around the axis on the outer wall of the spacers, with a protrusion fixed on the outer wall of the spacers between two adjacent sets of locking grooves; the cross-sectional shape of the spacers is symmetrical arched, and the protrusions are semi-circular in shape with smooth chamfered edges; wherein the braided layer is wound and woven around the outer wall of the spacers, and the braided layer's wire bundles are embedded into the corresponding locking grooves, forming a rigid connection with the spacers; the inner wall of the outer protective sheath is arranged in an equiangular array around the axis with multiple sets of spiral grooves, and the curved surface of the protrusions is embedded into the inner wall of the spiral grooves, with the protrusions and the inner wall of the spiral grooves forming a sliding connection.

[0006] Preferably, the conductor is a stranded structure of tin-plated soft copper wire, and the outer wall of the conductor is wrapped with a polyimide film.

[0007] Preferably, an annular groove is provided at the contact point between the outer wall of the inner insulating sleeve and each set of spacers, and the inner wall of the annular groove is roughened.

[0008] Preferably, the inner wall of the spacer is provided with an annular locking protrusion, and the annular locking protrusion and the annular locking groove on the outer wall of the inner insulating sleeve are interference fit.

[0009] Preferably, the braided layer is a composite wire material of high carbon steel wire core and stainless steel coating, and the braided layer adopts a spiral braiding process.

[0010] Preferably, the outer protective skin is made of thermoplastic elastomer material, and a diamond-shaped anti-slip texture is provided on a local part of the outer wall of the outer protective skin.

[0011] Preferably, the groove wall of the spiral groove adopts a rounded transition, and the inner wall is slightly roughened.

[0012] Preferably, the inner walls of two adjacent sets of spacers, inner insulating sleeves, braided layers and outer protective skin together form an annular sealed cavity, and each annular sealed cavity is filled with a special mixed gas.

[0013] Preferably, the inner wall of the inner insulating sleeve is tightly bonded to the polyimide film wrapped around the outer wall of the conductor.

[0014] The production method of metal braided shear-resistant photovoltaic transmission cable includes the following steps: S1, conductor and inner insulation sleeve preparation: High-purity soft copper wire is selected and tin-plated soft copper stranded conductor is made using a double-stranding process. During the double-stranding process, a polyimide film is simultaneously wrapped around the outer wall of the conductor using an overlapping wrapping method to ensure that the film is tightly adhered to the outer wall of the conductor; then, cross-linked polyethylene and ethylene vinyl acetate copolymer are mixed in a preset ratio, and nano-montmorillonite and antioxidants are added to make a composite insulation material. The composite insulation material is extruded through an extruder to coat the outer wall of the conductor with the polyimide film, forming an inner insulation sleeve. The extrusion parameters are controlled to ensure that the inner wall of the inner insulation sleeve is tightly adhered to the polyimide film. Finally, an annular groove is machined on the outer wall of the inner insulating sleeve using a special cutting die, and the inner wall of the annular groove is roughened to complete the integrated fabrication of the conductor and the inner insulating sleeve; S2, Protective layer assembly: Polypropylene material with added glass fiber is used to injection mold the spacer ring. During the injection molding process, a groove is machined on the outer wall of the spacer ring, and a semi-circular block protrusion is injection molded between adjacent grooves. The edges and corners of the protrusion are smoothed and chamfered. At the same time, an annular protrusion is machined on the inner wall of the spacer ring; After the spacer ring cools and solidifies, it is arranged at equal intervals along the outer wall of the inner insulating sleeve so that the annular protrusion of the spacer ring and the annular groove of the inner insulating sleeve form an interference fit. The spacer ring is fixed using a special pressing tool. The protective layer is assembled on the outer wall of the inner insulating sleeve; S3, braiding and extrusion of the outer protective skin: a composite wire of high carbon steel core and stainless steel coating is selected and spirally braided on the outer side of the inner insulating sleeve and the protective layer using a spiral braiding machine. During the braiding process, the braiding parameters are adjusted to ensure that the braided layer wire bundle is accurately embedded in the buckle groove of the spacer to form a rigid connection; then, a thermoplastic elastomer material is selected and extruded to cover the outer side of the braided layer using an extruder. During the extrusion process, a special mold with spiral grooves is used to simultaneously process spiral grooves on the inner wall of the outer protective skin, ensuring that the groove wall of the spiral groove has a rounded transition and the inner wall is slightly roughened. At the same time, on the outer protective skin... A diamond-shaped anti-slip texture is processed at the preset position on the wall to complete the preparation of the braided layer and the outer protective sheath; S4, cavity sealing, gas filling and finished product inspection: The two ends of the cable semi-finished product prepared in step S3 are sealed with sealing plugs to ensure that the annular sealed cavity formed by the adjacent spacers, inner insulation sleeve, braided layer and outer protective sheath is independently sealed; each annular sealed cavity is evacuated by a vacuum injection device to reach the preset vacuum degree, and then a special mixed gas is injected into the cavity; after the gas filling is completed, the cavity is tested for sealing performance; finally, the finished cable is tested for shear strength, insulation performance, structural dimensions and other items. After passing the test, it is a finished product.

[0015] The technical effects and advantages of this invention are as follows: In this invention, the device utilizes an outer protective sheath, a spacer and protrusions in the protective layer, a spiral groove on the inner wall of the outer protective sheath, and a braided layer. The outer protective sheath directly resists external shear forces and environmental erosion. The braided layer wire harness is embedded in the groove on the outer wall of the spacer to form a rigid connection to uniformly transmit external forces. The spacer disperses and concentrates forces through its symmetrical arched cross-section. The protrusions slide along the spiral groove and absorb energy through frictional damping caused by the micro-roughness of the groove wall. This achieves the purpose of avoiding conductor breakage and wire breakage through the outer protective sheath caused by external shear forces, significantly improving the shear resistance and structural stability of the cable, and effectively reducing the risk of leakage. In this invention, the device forms an annular sealed cavity surrounded by an inner insulating sleeve, a polyimide film on the outer wall of the conductor, adjacent spacers, the inner insulating sleeve and braided layer, and an outer protective skin. The inner insulating sleeve and the polyimide film are tightly bonded to form double insulation protection. The polyimide film, through overlapping wrapping, prevents conductor broken wires from directly puncturing the inner insulating sleeve. At the same time, the special mixed gas filled in the annular sealed cavity can not only enhance the overall insulation performance, but also reduce the impact of outdoor high and low temperatures on conductor resistance through temperature insulation effect. Ultimately, it ensures the safety and stable working environment of conductor insulation, achieving the goal of ensuring the safety and stable working environment of conductor insulation, and further improving the weather resistance and long-term operational reliability of the cable. Attached Figure Description

[0016] The disclosure of this invention is illustrated with reference to the accompanying drawings. It should be understood that the drawings are for illustrative purposes only and are not intended to limit the scope of protection of this invention. In the drawings, the same reference numerals are used to refer to the same parts:

[0017] Figure 1 This is a schematic diagram of the main structure at one end of the present invention; Figure 2 This is a schematic diagram of the main structure at the other end of the invention; Figure 3 This is a schematic diagram of the single-sided planar structure of the present invention; Figure 4 This is a schematic diagram of the end planar structure of the present invention; Figure 5 This is a schematic diagram showing the positional relationship between the conductor, inner insulating ring, and protective layer of the present invention. Figure 6 This is a side view of the protective layer structure of the present invention; Figure 7 This is a schematic diagram of the outer protective skin structure of the present invention.

[0018] Legend: 1. Conductor; 11. Inner insulating sleeve; 2. Protective layer; 21. Spacer ring; 22. Clip groove; 23. Protrusion; 3. Braided layer; 4. Outer protective skin; 41. Spiral groove. Detailed Implementation

[0019] It is readily understood that, based on the technical solution of this invention, those skilled in the art can propose various interchangeable structural methods and implementations without altering the essential spirit of the invention. Therefore, the following detailed embodiments and accompanying drawings are merely illustrative examples of the technical solution of this invention and should not be considered as the entirety of the invention or as limitations or restrictions on the technical solution of this invention.

[0020] Reference Figure 1-7 As shown, the present invention provides a technical solution: This device adopts a multi-layer nested structure, which includes, from the inside out, a conductor 1, an inner insulating sleeve 11, a braided layer 3, an outer protective sheath 4, and a protective layer 2 for improving the protective strength of the device. The structures of each layer are closely matched to form an integrated power transmission structure with conductivity, insulation, shear resistance, and outdoor weather resistance. The protective layer 2, as the core structure for cable shear resistance, includes multiple sets of spacers 21 fixed at equal intervals to the outer wall of the inner insulating sleeve 11. Each set of spacers 21 is evenly distributed along the axial direction of the inner insulating sleeve 11, and the structure of its inner side is adapted to the outer wall of the inner insulating sleeve 11 to achieve stability. The cable is fixed in place to ensure that it does not shift when bent or stressed. The outer wall of the spacer ring 21 has multiple sets of grooves 22 arranged at equal angles around its own axis to limit the braided layer 3. Each set of grooves 22 is a groove that is recessed radially inward along the spacer ring 21. The opening size of the groove matches the cross-section of the braided layer 3, allowing the braid to be precisely embedded in the groove. A protrusion 23 is fixed on the outer wall of the spacer ring 21 between two adjacent sets of grooves 22. The protrusion 23 and the spacer ring 21 are integrally formed without splicing gaps. Its protrusion height is adapted to the inner wall space of the outer protective skin 4 to form a fit with the outer protective skin 4.

[0021] The cross-sectional shape of the spacer ring 21 is a symmetrical arch, that is, the cross-section is an arc structure with a high middle and low sides. This arch design can disperse the external force to both sides, avoid the force being concentrated in a single area, and at the same time provide a certain elastic deformation space for the spacer ring 21, reducing the risk of fracture under stress. The overall shape of the protrusion 23 is semi-circular, and its outer side is a smooth arc surface. This surface matches the shape of the spiral groove 41 on the inner wall of the outer protective skin 4. All the edges and corners of the protrusion 23 are smooth and chamfered, without sharp edges, which can avoid scratching the inner wall of the outer protective skin 4, reduce stress concentration, and ensure that the protrusion 23 can move relatively smoothly when squeezed.

[0022] The braided layer 3 adopts a spiral braided structure, which is wrapped around the outer wall of all spacers 21. During the braiding process, it is ensured that most of the wires can be embedded into the corresponding grooves 22. The wires are tightly fitted to the groove walls of the grooves 22. Through this embedded fit, the braided layer 3 and the spacers 21 form a rigid connection, so that the external force borne by the braided layer 3 can be directly transmitted to the spacers 21, and then distributed to the inner insulating sleeve 11 by the spacers 21. The whole is similar to the situation of "the bowstring being compressed and causing the bow arm to deform and bend". The gap between the bowstring, i.e., the braided layer 3 and the inner insulating sleeve 11, can serve as a buffer space. When the braided layer 3 is compressed and approaches the inner insulating sleeve 11, the spacers 21 and the wires of the braided layer 3 deform. It should be noted that when the spacers 21 deform, they will move slightly inside the spiral groove 41 through the protrusions 23. The multi-layer buffer structure can improve the shear resistance of the equipment and prevent the wires from breaking due to the braided layer 3 being stressed alone, thereby improving the stability of the conductor 1.

[0023] The outer protective sheath 4, as the outermost protective structure of the cable, has multiple sets of spiral grooves 41 arranged in an equiangular array around its own axis on its inner wall. Each set of spiral grooves 41 extends spirally along the axial direction of the outer protective sheath 4. The inner wall of the spiral groove 41 is an arc-shaped surface adapted to the curved surface of the protrusion 23. During assembly, the curved surface of the protrusion 23 is completely embedded into the inner wall of the spiral groove 41, and the two remain in close contact. The protrusion 23 and the inner wall of the spiral groove 41 form a sliding connection. When the cable is subjected to external shear force or bends, the protrusion 23 can slide smoothly along the extension direction of the spiral groove 41. The friction during the sliding process absorbs part of the force, while limiting the excessive relative displacement of each component. The displacement of the protrusion 23 transfers part of the external shear force to the axial position, i.e., inside the spiral groove 41. The slightly rough inner wall of the spiral groove 41 further enhances the buffering effect on the shear force, ultimately ensuring the overall structural stability of the cable.

[0024] Reference Figure 1-6As shown in this embodiment: Conductor 1 is a tin-plated soft copper stranded wire with a double-stranded structure. The copper wires in each layer are tightly twisted together, which improves the overall structural stability. The tin plating layer on the surface of the copper wire is uniformly covered, which can isolate air and moisture and prevent the copper wire from oxidizing and corroding. The outer wall of conductor 1 is wrapped with a polyimide film. The film is wrapped in an overlapping manner, and the overlapping parts are tightly attached to form a continuous and complete protective layer. This can protect the copper wire from external wear and prevent sharp point puncture when the copper wire breaks. The outer wall of the inner insulating sleeve 11 has an annular groove at the contact point with each group of spacers 21. The annular grooves are continuously distributed along the circumference of the inner insulating sleeve 11, and the cross-section is concave arc. The groove depth of the annular groove is adapted to the height of the annular protrusion of the spacer 21. The inner wall of the annular groove is roughened by surface sanding to form a fine texture, which can increase the annular groove of the spacer 21. The frictional force of the protrusions prevents axial displacement of the spacer ring 21. The inner wall of the spacer ring 21 is provided with an annular locking protrusion, which protrudes continuously along the inner circumference of the spacer ring 21. Its cross-sectional shape matches the annular locking groove of the inner insulating sleeve 11. The annular locking protrusion and the annular locking groove on the outer wall of the inner insulating sleeve 11 are interference fit. During assembly, slight squeezing makes the locking protrusion tightly embedded in the locking groove, forming a stable connection and ensuring that the spacer ring 21 does not loosen when the cable is bent or subjected to force. The braided layer 3 is a composite wire material of high carbon steel wire core and 304 stainless steel coating. The high carbon steel wire core provides high strength support, and the 304 stainless steel coating evenly covers the surface of the core wire, improving weather resistance and corrosion resistance. The braided layer 3 adopts a spiral braiding process. During braiding, adjacent wire bundles are intertwined to form a dense mesh structure. The braiding density is adapted to the shear resistance requirements, ensuring that external force can be evenly transmitted to the protective layer 2.

[0025] Reference Figure 1-7As shown in this embodiment: the outer protective sheath 4 is made of thermoplastic elastomer material, which has good flexibility, high and low temperature resistance and impact resistance, and can adapt to complex outdoor environments. The outer wall of the outer protective sheath 4 is locally set with diamond anti-slip texture. The texture is distributed in a regular array and the height of the protrusion is moderate, which can enhance the grip friction during construction without affecting the bending performance of the cable. The groove wall of the spiral groove 41 adopts a rounded transition, that is, the corners of the groove are all smooth arcs without sharp edges, which can avoid stress concentration when in contact with the protrusion 23, protect the protrusion 23 and the outer protective sheath 4, and the inner wall is slightly roughened. The uniform fine texture is formed by fine sandblasting, which can form stable friction damping when the protrusion 23 slides, and enhance the energy absorption effect. The inner walls of two adjacent sets of spacers 21, inner insulating sleeve 11, braided layer 3, and outer protective skin 4 together form an annular sealed cavity. The two ends of the cavity are sealed by spacers 21, and the side walls are formed by the inner insulating sleeve 11, braided layer 3, and outer protective skin 4 to form a closed structure. Each set of annular sealed cavities is filled with a special mixed gas. The gas is a mixed gas with good insulation and stable chemical properties, which can enhance the insulation performance and temperature insulation effect of the cavity. The inner wall of the inner insulating sleeve 11 is tightly bonded to the polyimide film wrapped around the outer wall of the conductor 1, with no obvious gap between them. The material of the inner insulating sleeve 11 is completely bonded to the film through the extrusion molding process, which can not only prevent water vapor or impurities from entering the gap, but also ensure that the conductor 1 and the inner insulating sleeve 11 are subjected to force synchronously, thereby improving the overall structural stability.

[0026] A method for producing a metal braided, shear-resistant photovoltaic transmission cable includes the following steps: S1. Preparation of conductor 1 and inner insulation sleeve 11: High-purity soft copper wire is selected and tin-plated soft copper stranded conductor 1 is made using a double-stranding process. During the double-stranding process, a polyimide film is simultaneously wrapped around the outer wall of conductor 1 using an overlapping wrapping method to ensure that the film is tightly adhered to the outer wall of conductor 1. Subsequently, cross-linked polyethylene and ethylene vinyl acetate copolymer are mixed in a preset ratio, and nano-montmorillonite and antioxidants are added to make a composite insulation material. The composite insulation material is extruded through an extruder to coat the outer wall of conductor 1 with the polyimide film, forming the inner insulation sleeve 11. The extrusion parameters are controlled to ensure that the inner wall of the inner insulation sleeve 11 is tightly adhered to the polyimide film. Finally, a special... The cutting mold processes an annular groove on the outer wall of the inner insulating sleeve 11, and roughens the inner wall of the annular groove to complete the integrated fabrication of conductor 1 and inner insulating sleeve 11; S2, assembly of protective layer 2: using polypropylene material with added glass fiber, the spacer 21 is injection molded by injection molding machine. During the injection molding process, the retaining groove 22 is simultaneously processed on the outer wall of the spacer 21, and semi-circular block protrusions 23 are injection molded between adjacent retaining grooves 22. The edges and corners of the protrusions 23 are smoothed and chamfered. At the same time, annular retaining protrusions are processed on the inner side wall of the spacer 21; after the spacer 21 cools and solidifies, it is arranged at equal intervals along the outer wall of the inner insulating sleeve 11 so that the annular retaining protrusions of the spacer 21 and the annular grooves of the inner insulating sleeve 11 form an interference fit. The spacer is then assembled using a special pressing tool. 21 is fixed to the outer wall of the inner insulating sleeve 11, completing the assembly of the protective layer 2; S3, braiding of the braided layer 3 and extrusion of the outer protective skin 4: a composite wire of high carbon steel core and 304 stainless steel coating is selected and spirally braided on the outside of the inner insulating sleeve 11 and the protective layer 2 using a spiral braiding machine. During the braiding process, the braiding parameters are adjusted to ensure that the wire bundle of the braided layer 3 is accurately embedded in the buckle groove 22 of the spacer ring 21 to form a rigid connection; then, a thermoplastic elastomer material is selected and extruded to cover the outside of the braided layer 3 using an extruder. During the extrusion process, a special mold with a spiral groove 41 is used to simultaneously process the spiral groove 41 on the inner wall of the outer protective skin 4, ensuring that the groove wall of the spiral groove 41 has a rounded transition and the inner wall is slightly roughened. Simultaneously, diamond-shaped anti-slip textures are processed at preset positions on the outer wall of the outer protective sheath 4 to complete the preparation of the braided layer 3 and the outer protective sheath 4; S4, cavity sealing, gas filling and finished product inspection: The two ends of the cable semi-finished product prepared in step S3 are sealed with sealing plugs to ensure that the annular sealed cavity formed by the adjacent spacer ring 21, inner insulation sleeve 11, braided layer 3 and outer protective sheath 4 is independently sealed; the annular sealed cavity is evacuated by vacuum injection equipment to reach the preset vacuum degree, and then a special mixed gas is injected into the cavity; after the gas filling is completed, the cavity is tested for sealing performance; finally, the finished cable is tested for shear strength, insulation performance, structural dimensions and other items. After passing the test, it is a finished product.

[0027] Working principle: First, the outer protective sheath 4 is the outermost protective structure of the cable, directly resisting external shear forces and environmental erosion. Its diamond-shaped anti-slip texture on the outer wall enhances grip stability during construction, preventing slippage and increased impact during cable dragging. The spiral groove 41 on the inner wall provides precise sliding space for the protrusions 23 of the protective layer 2, initially weakening the transmission of shear force to the internal structure. Second, the spacer 21 in the protective layer 2 achieves a stable fixation with the inner insulating sleeve 11 through an interference fit between its inner annular protrusion and the annular groove on the outer wall of the inner insulating sleeve 11, preventing axial displacement of the spacer 21 under stress or cable bending. The symmetrical arched cross-section of the spacer 21... The outer protective shear force transmitted by the outer protective skin 4 can be evenly distributed to both sides, preventing the force from being concentrated on a single area and directly transmitted to the inner insulating sleeve 11 and conductor 1. At the same time, the elastic deformation space of the arched structure itself can further buffer the impact of the force and reduce the risk of the spacer ring 21 breaking due to excessive force. Furthermore, the fastening groove 22 on the outer wall of the spacer ring 21 cooperates with the braided layer 3. The braided layer 3 is made of composite wire spiral braided with a high carbon steel wire core and a 304 stainless steel coating. Its wire bundle is precisely embedded in the fastening groove 22 and tightly adheres to the groove wall to form a rigid connection. When shear force is applied, it ensures that the braided layer 3 will not be loose and subjected to excessive local stress, but will instead evenly transmit the force to each spacer ring. The ring 21, together with the protective layer 2, withstands shear force, forming an effect similar to "drawing a bowstring." Simultaneously, the gap between the braided layer 3 and the inner insulating sleeve 11 serves as a buffer space. When the braided layer 3 is compressed close to the inner insulating sleeve 11, it further absorbs some shear energy, preventing the force from directly acting on the conductor 1. Meanwhile, the protrusion 23 on the outer wall of the ring 21, located between adjacent fastening grooves 22, has a semi-circular block structure and smooth chamfers that prevent scratching the inner wall of the outer protective sheath 4. Furthermore, the protrusion 23 and the spiral groove 41 on the inner wall of the outer protective sheath 4 form a sliding connection. When the cable is subjected to shear force or bending, the protrusion 23 slides smoothly along the extension direction of the spiral groove 41. During the sliding process… The micro-roughened inner wall of the spiral groove 41 can form stable frictional damping, absorb some of the shear energy, and transfer the radial shear force to the axial position, greatly reducing the impact of the radial shear force on the conductor 1 and reducing the risk of conductor 1 breakage. Next, the inner wall of the inner insulating sleeve 11 is tightly bonded to the outer wall of the conductor 1 with the polyimide film. The polyimide film forms a continuous and complete protective layer by overlapping and wrapping. It can protect the tin-plated soft copper stranded structure of the conductor 1 from external wear, and can also prevent the broken wire tip from directly piercing the inner insulating sleeve 11 when the conductor 1 accidentally breaks, thus preventing the broken wire from further penetrating the outer protective skin 4 and reducing the risk of leakage from the source.Following this, the annular sealed cavity formed by the two adjacent sets of spacers 21, the inner insulating sleeve 11, the braided layer 3, and the inner wall of the outer protective sheath 4 is filled with a special mixed gas with good insulation and stable chemical properties. This further enhances the overall insulation performance of the cable. Even if there is minor damage to the outer protective sheath 4 or the inner insulating sleeve 11, the mixed gas can block the leakage path. At the same time, the temperature insulation effect of the cavity can reduce the impact of outdoor high and low temperature environments on conductor 1, ensuring that conductor 1 is always in a stable working state. Finally, the polyimide film of the outer protective sheath 4, the protective layer 2, the braided layer 3, the inner insulating sleeve 11, and conductor 1 works synergistically to buffer, disperse, and block shear force layer by layer from the outside to the inside. This not only prevents conductor 1 from breaking due to shear force but also prevents broken wires from piercing the outer protective sheath 4. It also enhances the cable's insulation and weather resistance, completely solving the problem of conductor 1 breaking due to shear force on the cable's outer wall and then piercing the outer protective sheath 4 to cause leakage. This achieves stable power transmission with conductivity, insulation, shear resistance, and outdoor weather resistance.

[0028] The technical scope of this invention is not limited to the content described above. Those skilled in the art can make various modifications and variations to the above embodiments without departing from the technical concept of this invention, and all such modifications and variations should fall within the protection scope of this invention.

Claims

1. A metal-braided, shear-resistant photovoltaic transmission cable, characterized in that, The device includes a conductor, an inner insulating sleeve, a braided layer, an outer protective skin, and a protective layer for enhancing the equipment's protective strength. The protective layer includes multiple sets of spacers fixed at equal intervals to the outer wall of the inner insulating sleeve. The outer wall of each spacer has multiple sets of grooves arranged at equal angles around its axis to limit the braided layer. A protrusion is fixed to the outer wall of each spacer between adjacent sets of grooves. The spacers have a symmetrical arched cross-section, and the protrusions are semi-circular with smooth chamfered edges. The braided layer is wound around the outer wall of the spacers, and the braided strands are embedded in the corresponding grooves, forming a rigid connection with the spacers. The inner wall of the outer protective skin has multiple sets of spiral grooves arranged at equal angles around its axis, and the protrusions... The curved surface is embedded into the inner wall of the spiral groove, and the protrusion and the inner wall of the spiral groove form a sliding connection relationship; the production method of the metal braided anti-shear protection photovoltaic transmission cable includes the following steps: S1, conductor and inner insulation sleeve preparation: select high-purity soft copper wire, and use a double stranding process to make tin-plated soft copper stranded conductor. During the double stranding process, a polyimide film is wrapped around the outer wall of the conductor in an overlapping wrapping manner to ensure that the film is tightly attached to the outer wall of the conductor; then, cross-linked polyethylene and ethylene vinyl acetate copolymer are mixed in a preset ratio, and nano-montmorillonite and antioxidants are added to make a composite insulation material. The composite insulation material is extruded through an extruder to cover the outer wall of the conductor with polyimide film to form an inner insulation sleeve. The extrusion parameters are controlled to make the inner insulation sleeve... The inner insulating sleeve is tightly bonded to the polyimide film. Finally, an annular groove is machined on the outer wall of the inner insulating sleeve using a special cutting die, and the inner wall of the annular groove is roughened to complete the integrated fabrication of the conductor and the inner insulating sleeve. S2, Protective Layer Assembly: Using polypropylene material with added glass fiber, a spacer is injection molded. During the injection molding process, a groove is simultaneously machined on the outer wall of the spacer, and semi-circular protrusions are injection molded between adjacent grooves. The edges of the protrusions are smoothly chamfered. Annular protrusions are also machined on the inner wall of the spacer. After the spacer cools and solidifies, it is arranged at equal intervals along the outer wall of the inner insulating sleeve, so that the annular protrusions of the spacer and the annular grooves of the inner insulating sleeve form an interference fit. A special pressing tool is used to fix the spacer to the outer wall of the inner insulating sleeve, completing the process. Assembly of the protective layer; S3, braiding of the braided layer and extrusion of the outer protective skin: Select composite wires of high carbon steel core and stainless steel coating, and use a spiral braiding machine to spirally braid the outer side of the inner insulation sleeve and the protective layer. During the braiding process, adjust the braiding parameters to ensure that the wire bundle of the braided layer is accurately embedded in the buckle groove of the spacer to form a rigid connection; then select thermoplastic elastomer material, and use an extruder to extrude it to cover the outer side of the braided layer. During the extrusion process, use a special mold with spiral grooves to simultaneously process spiral grooves on the inner wall of the outer protective skin, ensuring that the groove wall of the spiral groove has a rounded transition and the inner wall is slightly roughened. At the same time, diamond anti-slip texture is processed at the preset position on the outer wall of the outer protective skin to complete the preparation of the braided layer and the outer protective skin;S4. Cavity Sealing, Gas Filling, and Finished Product Inspection: The two ends of the cable semi-finished product prepared in step S3 are sealed with sealing plugs to ensure that the annular sealed cavities formed by adjacent spacers, inner insulation sleeves, braided layers, and outer protective sheaths are independently sealed. Each annular sealed cavity is evacuated using a vacuum injection device to reach a preset vacuum level, and then a special mixed gas is injected into the cavity. After gas filling is completed, the cavity's sealing performance is tested. Finally, the finished cable undergoes tests for shear strength, insulation performance, structural dimensions, and other items. The cable is considered a finished product after passing these tests.

2. The metal braided anti-shear photovoltaic transmission cable according to claim 1, characterized in that: The conductor is a stranded structure of tin-plated soft copper wire, and the outer wall of the conductor is wrapped with a polyimide film.

3. The metal braided shear-resistant photovoltaic transmission cable according to claim 1, characterized in that: An annular groove is provided at the contact point between the outer wall of the inner insulating sleeve and each set of spacers, and the inner wall of the annular groove is roughened.

4. The metal braided anti-shear photovoltaic transmission cable according to claim 3, characterized in that: The inner wall of the spacer is provided with an annular locking protrusion, and the annular locking protrusion and the annular locking groove on the outer wall of the inner insulating sleeve are interference fit.

5. The metal braided shear-resistant photovoltaic transmission cable according to claim 1, characterized in that: The braided layer is made of a composite wire material consisting of a high-carbon steel core and a stainless steel coating, and the braided layer is made using a spiral braiding process.

6. The metal braided shear-resistant photovoltaic transmission cable according to claim 1, characterized in that: The outer protective skin is made of thermoplastic elastomer material, and a diamond-shaped anti-slip texture is provided on a local part of the outer wall of the outer protective skin.

7. The metal braided anti-shear photovoltaic transmission cable according to claim 1, characterized in that: The groove wall of the spiral groove is rounded, and the inner wall is slightly roughened.

8. The metal braided shear-resistant photovoltaic transmission cable according to claim 1, characterized in that: The inner walls of the two adjacent sets of spacers, inner insulating sleeves, braided layers and outer protective skin together form an annular sealed cavity, and each annular sealed cavity is filled with a special mixed gas.

9. The metal braided shear-resistant photovoltaic transmission cable according to claim 1, characterized in that: The inner wall of the inner insulating sleeve is tightly bonded to the outer wall of the conductor by a polyimide film.

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