Anti-brittle high-elasticity low-temperature-resistant energy storage system cable

Abstract

The present application relates to the technical field of cable, and discloses a brittle prevention high-elasticity low-temperature-resistant energy storage system cable, aiming to solve the problems of low-temperature brittle prevention of the protective sleeve of traditional integrated cable, stress superposition and easy fracture of the bending part, the cable comprises a conductor and a cable protective layer, the protective layer is formed by interval arrangement of a first supporting assembly and a flexible assembly, the flexible assembly is coaxially fixed with a second supporting assembly outside, the second supporting assembly is in clearance fit with the first supporting assembly, when the cable is bent, the adjacent first supporting assemblies extrude the flexible assembly, and the overall bending is realized through the deformation of the flexible assembly, meanwhile, the first and second supporting assemblies can limit the bending amplitude of a single position, and the deformation is evenly distributed to stress by the multiple flexible assemblies, the scheme realizes the complement of pressure resistance, wear resistance, low-temperature flexibility, can disperse stress, reduce the risk of low-temperature brittle fracture, and guarantee the structural integrity and service life of the cable in harsh environment.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of cables, in particular to a brittle-resisting high-elasticity low-temperature-resistant cable for energy storage systems. BACKGROUND

[0002] A cable is a power device composed of conductors and an outer insulation protective layer for transmitting electric energy, electric signals or realizing electromagnetic energy conversion. The reason why the cable for energy storage systems needs to be low-temperature-resistant is that the energy storage system is often deployed in cold regions or outdoors, and the low-temperature environment is easy to make the insulation layer of ordinary cables hard, brittle and even cracked, thereby destroying the insulation performance and interrupting the charging and discharging process of the system, and in severe cases, it may cause safety accidents. Therefore, low-temperature resistance is a necessary condition to ensure the stable and safe operation of the system in the full temperature range.

[0003] The existing cable protective sleeve is designed in an integrated structure. The main material of the integrated protective sleeve, such as rubber and polyvinyl chloride, is prone to brittle under the influence of low temperature, and the material toughness decreases significantly and the crack resistance decreases significantly. At the same time, the protective sleeve of the cable bending part needs to bear the superposition of two stresses, the material cold shrinkage stress caused by low temperature and the local tensile stress generated when the cable is bent. The two stresses intensify each other, making the bending part a weak area of stress concentration. When the superimposed stress exceeds the bearing limit of the brittle material, the integrated protective sleeve is prone to cracks or even breakage at the bending part, resulting in the loss of mechanical protection and insulation protection functions of the cable internal conductor and insulation layer. Not only can it cause cable short circuit, electric leakage and other faults, but also can shorten the service life of the cable, which seriously threatens the stable operation of the power transmission or signal transmission system. SUMMARY

[0004] The technical problem to be solved by the present application is that the existing cable protective sleeve with an integrated structure in the prior art is prone to brittle at low temperature, and the bending part will superimpose cold shrinkage stress and bending tensile stress, which will cause the part to be prone to breakage and thus lose the protection function, thereby threatening the stable operation of the system. To solve this problem, we propose a brittle-resisting high-elasticity low-temperature-resistant cable for energy storage systems.

[0005] In order to achieve the above object, the technical scheme adopted by the present application is as follows: A brittle-resisting high-elasticity low-temperature-resistant energy storage system cable comprises a conductor and a cable protective layer, the cable protective layer comprises first support components and flexible components, the first support components and the flexible components are arranged at intervals, the inner diameters of the first support components and the flexible components are uniform, and the outer diameters of the first support components and the flexible components are uniform, the flexible components are coaxially provided with second support components outside, the second support components are fixedly connected with the flexible components, the width of the second support components is greater than that of the flexible components, the second support components extend to the outside of the first support components at both sides, and the second support components and the first support components are gap-fitted; when the cable is bent in a bent state, the adjacent first support components at the cable bending part extrude the flexible components therebetween, the bending displacement is compensated through the deformation of the flexible components, and the flexible bending of the whole cable is realized.

[0006] Preferably, the first support component comprises a first hard support ring, an outer wall of the first hard support ring is provided with an outer flat surface, two groups of first limiting inclined surfaces are symmetrically arranged at the side of the outer flat surface, and a first rounded edge is arranged at the connection between the outer flat surface and the first limiting inclined surface.

[0007] Preferably, two groups of extrusion vertical edges are symmetrically arranged at the side of the first hard support ring, and the extrusion vertical edges are used for extruding the flexible component when the cable is bent.

[0008] Preferably, the flexible component comprises a flexible deformation ring, an outer wall of the flexible deformation ring is provided with a connecting flat surface, and two groups of arc-shaped transition edges are symmetrically arranged at the side of the connecting flat surface.

[0009] Preferably, two groups of deformation edges are symmetrically arranged at the side of the flexible deformation ring, and the deformation edges are fixedly connected with the extrusion vertical edges.

[0010] Preferably, the second support component comprises a second hard ring, an inner wall of the second hard ring is provided with an inner flat surface, and the inner flat surface is fixedly connected with the connecting flat surface.

[0011] Preferably, two groups of second limiting inclined surfaces are symmetrically arranged at the side of the inner flat surface, and the included angle between the second limiting inclined surfaces and the inner flat surface is equal to the included angle between the extrusion vertical edges and the outer flat surface.

[0012] Preferably, a second rounded edge is arranged between the inner flat surface and the second limiting inclined surface, and the second rounded edge is aligned with the first rounded edge.

[0013] Preferably, when the cable is bent in a bent state, the first limiting inclined surface at the outside of the cable bending part abuts against the inner flat surface, and the outer flat surface at the inside of the cable bending part abuts against the second limiting inclined surface, so as to limit the bending amplitude of the cable at a certain position.

[0014] Preferably, the conductor is wrapped with an insulation layer, the outside of the insulation layer is sleeved with a wrapping layer, the insulation layer and the wrapping layer are filled with a filling layer, the outside of the wrapping layer is sleeved with an armor layer, and the armor layer is coaxially arranged inside the cable protective layer.

[0015] Technical effects and advantages of the present application: the protective sleeve structure of the present application is formed by the interlaced arrangement of the first support assembly and the flexible assembly, which realizes performance complementation. The first support assembly can meet the compression and wear resistance requirements of the cable foundation, the flexible assembly can provide sufficient bending allowance and still maintain toughness at low temperature, can disperse and absorb stress, and effectively reduce the risk of low temperature fracture. The second support assembly not only protects the flexible assembly which has weak wear resistance and compression resistance, avoiding direct bearing of external force damage, but also does not hinder the flexible bending of the cable through the gap cooperation with the first support assembly. At the same time, through the cooperation of the first support assembly and the second support assembly, the bending amplitude of the cable at a single position can be accurately limited, so that the bending deformation is borne and stress is shared by multiple flexible assemblies, avoiding excessive deformation and fracture of a single flexible assembly. At the same time, the flexible assembly disperses stress through extrusion deformation on both sides under the limitation of the second support assembly, further reducing the risk of low temperature brittle fracture, ultimately ensuring the structural integrity and service life of the cable in harsh environments such as low temperature and repeated bending, and effectively solving the technical problem that the traditional cable protective sleeve cannot simultaneously consider flexibility and compression and wear resistance at low temperature. BRIEF DESCRIPTION OF DRAWINGS

[0016] The disclosure of the present application will be described 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 the present application. In the drawings, the same reference numerals are used to refer to the same parts:

[0017] Figure 1 is a schematic diagram of the cross-sectional structure of the whole application; Figure 2 is a schematic diagram of the three-dimensional structure of the whole application; Figure 3 is a schematic diagram of the cross-sectional structure of the whole application; Figure 4 is a schematic diagram of the cross-sectional structure of the cable protective sleeve part of the whole application; Figure 5 is a schematic diagram of the structure of the first support assembly, the flexible assembly and the second support assembly when the cable is bent; Figure 6 is a schematic diagram of the three-dimensional structure of the first support assembly part of the whole application; Figure 7 is a schematic diagram of the three-dimensional structure of the flexible assembly part of the whole application; Figure 8 is a schematic diagram of the cross-sectional structure of the second support assembly part of the whole application.

[0018] Legend: 1, first support assembly; 2, flexible assembly; 3, second support assembly; 4, conductor; 5, insulation layer; 6, filling layer; 7, wrapping layer; 8, armored layer; 101, first hard support ring; 102, outer plane; 103, first limiting inclined surface; 104, extruded vertical edge; 105, first rounded edge; 201, flexible deformation ring; 202, connecting plane; 203, arc-shaped transition edge; 204, deformation edge; 301, second hard ring; 302, inner plane; 303, second limiting inclined surface; 304, second rounded edge. DETAILED DESCRIPTION

[0019] It is easy to understand that, according to the technical solution of the present application, those skilled in the art can propose various structural modes and implementation modes that can be replaced with each other without changing the essential spirit of the present application. Therefore, the following detailed description and the accompanying drawings are only exemplary descriptions of the technical solution of the present application, and should not be regarded as the whole or as a limitation or restriction on the technical solution of the present application.

[0020] The protective sheath of the cable is commonly made of rubber, plastic and other high molecular materials. At low temperature, the molecular chain activity is weakened, which causes the material to change from flexible to rigid, the elasticity and toughness to decrease significantly, and the brittleness to increase significantly. At this time, if the cable is subjected to external stress such as its own weight, wind force, vibration, etc., the brittle protective sheath cannot absorb stress through deformation, and eventually cracks or even breaks. Some cables that have been laid and shaped do not need to be repeatedly bent even in a low temperature environment, but the bending parts of the cable itself have generated continuous internal stress. Low temperature will cause the toughness of the protective sheath material to decrease sharply and the brittleness to increase dramatically. At this time, the material cannot buffer the stress caused by bending through deformation, and the stress at the bending part will further concentrate, eventually exceeding the material's bearing limit and causing breakage.

[0021] Existing cable protective sheaths are typically integrated, and the core of the outermost protective sheath is limited by the functional requirements of abrasion resistance and pressure resistance. High-flexibility materials, such as some silicone rubbers and low-density polyethylene, often have looser molecular structures or more branches to achieve flexibility at low temperatures. While this structure improves flexibility, it leads to a decrease in material hardness, surface strength, and resistance to deformation. This makes them vulnerable to damage from ground friction and heavy object compression during laying and use, and they cannot withstand long-term deformation under external forces. Therefore, high-flexibility materials cannot be directly used for the outermost protective sheath due to performance mismatch. The primary task of cable protective sheaths is to protect the internal cable core from physical damage. Therefore, materials with higher hardness and denser structures, such as high-density polyethylene and cross-linked polyethylene, must be prioritized. While these materials meet the core requirements of abrasion resistance and pressure resistance, their low-temperature toughness is poor, making them prone to embrittlement at low temperatures. This causes the cable's bending points to be subjected to tensile stress and low-temperature shrinkage, leading to breakage and affecting the cable's service life. To address the problem of the inability to simultaneously achieve both flexibility and pressure and abrasion resistance in cables at low temperatures, this application proposes the following improvements.

[0022] Reference Figure 1 , Figure 2 and Figure 3 As shown, the present invention provides a technical solution: a high-elasticity, low-temperature energy storage system cable with anti-brittleness, comprising: a conductor 4 and a cable protective layer, an insulation layer 5 wrapped around the conductor 4, a wrapping layer 7 sleeved around the insulation layer 5, a filler layer 6 filling the space between the insulation layer 5 and the wrapping layer 7, an armor layer 8 sleeved around the wrapping layer 7, and the armor layer 8 being coaxially disposed inside the cable protective layer.

[0023] Please see Figure 1 and Figure 4 As shown, the cable protective layer includes a first support component 1 and a flexible component 2, which are spaced apart. The inner and outer diameters of both components are identical. This staggered protective sleeve structure provides complementary advantages in enhancing cable flexibility and low-temperature fracture resistance. The first support component 1 maintains the overall structural strength of the protective sleeve, meeting the basic requirements for pressure resistance and abrasion resistance. The flexible component 2 provides sufficient bending allowance for the cable, improving overall flexibility. Furthermore, the flexible component 2 can be made of low-density polyethylene, maintaining a certain degree of toughness at low temperatures and buffering stress during bending. Even if the first support component 1 becomes brittle in a low-temperature environment, the staggered flexible rings can disperse and absorb external stress, preventing stress concentration at a single point and subsequent breakage. Simultaneously, the presence of the flexible component 2 allows the cable to retain a certain degree of bending capacity at low temperatures, effectively reducing the risk of low-temperature breakage.

[0024] Please see Figure 4 ,Figure 5 As shown, the flexible assembly 2 is good in flexibility, but it is not strong in wear resistance and pressure resistance, so a second support assembly 3 is coaxially arranged outside the flexible assembly 2, the second support assembly 3 is fixedly connected with the flexible assembly 2, the width of the second support assembly 3 is greater than that of the flexible assembly 2, the second support assembly 3 covers the outside of the flexible assembly 2, and the flexible assembly 2 is protected so as not to directly bear external pressure and friction force, etc., the two sides of the second support assembly 3 extend to the outside of the first support assembly 1, and the second support assembly 3 is gap-fitted with the first support assembly 1, and the first hard support ring 101 is provided with first limiting inclined surfaces 103 on the two sides of the outer wall, and the second hard ring 301 is provided with second limiting inclined surfaces 303 on the two sides of the inner wall, so as to provide a certain space for the rotation offset between the first support assembly 1 and the second support assembly 3, and the arrangement of the second support assembly 3 will not hinder the flexible bending of the cable.

[0025] The recesses are formed between the second support assemblies 3, the outermost layer of the cable protective sleeve is provided with a structure in which a plurality of protrusions are arranged at intervals in the recesses, the concave-convex form can increase the outer layer friction, when the hands of the operator are stiff or gloves are worn in a low-temperature environment, the cable can be prevented from slipping during installation and wiring to improve the construction efficiency, and the recesses can enhance the lacing force when the cable is installed, so as to prevent the cable from being displaced in a vibration environment such as an energy storage cabin; on the other hand, the concave-convex surface structure can enhance the heat dissipation capacity, the contact area with air is increased, the heat dissipation efficiency is improved when high-current transmission is performed, the cable operating temperature is reduced, the high temperature is avoided to accelerate material aging, and the high-power energy storage scene is adapted.

[0026] Please refer to Figure 6 As shown, the first hard support ring 101 is symmetrically provided with two groups of extrusion vertical edges 104 on the sides, the extrusion vertical edges 104 are used for extruding the flexible assembly 2 when the cable is bent, when the cable bending is in a bent state, the adjacent first support assemblies 1 located at the cable bending part extrude the flexible assembly 2 therebetween, the bending displacement is compensated through the deformation of the flexible assembly 2, and then the flexible bending of the whole cable is realized, and since the second support assembly 3 is arranged outside the flexible assembly 2, the flexible deformation ring 201 will not arch upward under the blocking and limiting action of the second support assembly 3, the deformation edges 204 on the two sides of the flexible deformation ring 201 are inclined and deformed inward through the extrusion of the two extrusion vertical edges 104, the activity allowance required for the cable bending is retained, the stability of the whole flexible assembly 2 is maintained, the pressure stress is transmitted to the inside through the deformation edges 204 on the two sides, the stress is dispersed more accurately, compared with the traditional bellows structure realizing bending, the stress can be prevented from being concentrated at the wave peak of the bellows arching upward, and the risk of brittle fracture of the protective sleeve is further reduced in a low-temperature environment.

[0027] Please refer to Figure 6 , Figure 7With Figure 8 As shown in the drawings, the first support assembly 1 comprises a first hard support ring 101, the outer wall of the first hard support ring 101 is provided with an outer flat surface 102, the edge side of the outer flat surface 102 is symmetrically provided with two groups of first limiting inclined surfaces 103, the flexible assembly 2 comprises a flexible deformation ring 201, the outer wall of the flexible deformation ring 201 is provided with a connecting flat surface 202, the edge side of the connecting flat surface 202 is symmetrically provided with two groups of arc-shaped transition edges 203, the edge side of the flexible deformation ring 201 is symmetrically provided with two groups of deformation edges 204, and the deformation edges 204 are fixedly connected between the extrusion vertical edges 104, the second support assembly 3 comprises a second hard ring 301, the inner wall of the second hard ring 301 is provided with an inner flat surface 302, the inner flat surface 302 is fixedly connected between the connecting flat surface 202, the edge side of the inner flat surface 302 is symmetrically provided with two groups of second limiting inclined surfaces 303, and the included angle between the second limiting inclined surfaces 303 and the inner flat surface 302 is equal to the included angle between the extrusion vertical edges 104 and the outer flat surface 102.

[0028] When the cable bending part is in a bending state, the first limiting inclined surface 103 on the outer side of the cable bending part abuts against the inner flat surface 302, and at the same time, the outer flat surface 102 on the inner side of the cable bending part abuts against the second limiting inclined surface 303, for limiting the bending amplitude of the cable at a certain position, in the process of cable bending, the adjacent first support assemblies 1 relatively tilt and approach, the assembly first limiting inclined surface 103 in the first support assembly 1 on the outer side of the cable bending part abuts against the assembly inner flat surface 302 in the component second support assembly 3, and at the same time, the assembly outer flat surface 102 in the first support assembly 1 on the inner side of the bending part also abuts against the assembly second limiting inclined surface 303 in the component second support assembly 3, this cooperation makes the first support assembly 1 and the second support assembly 3 unable to continue to relatively rotate and misalign, thereby accurately limiting the bending degree of the cable at a single position, compared with the local excessive bending that may occur in the traditional structure, the design can make the overall bending action of the cable be borne and realized by the plurality of component flexible assemblies 2, each component flexible assembly 2 will evenly share the total deformation stress required by the cable bending, effectively avoiding that a certain component flexible assembly 2 appears excessive deformation due to excessive stress, thereby reducing the risk of fracture due to exceeding the tolerance limit of itself, and ensuring the structural integrity and service life of the cable in harsh environments such as repeated bending or low temperature.

[0029] The connection between the outer flat surface 102 and the first limiting inclined surface 103 is provided with a first round corner edge 105, the second limiting inclined surface 303 and the inner flat surface 302 are provided with a second round corner edge 304, and the second round corner edge 304 is aligned with the first round corner edge 105, the first round corner edge 105 and the second round corner edge 304 are used to make the mutual rotation and misalignment of the flexible assembly 2 and the second support assembly 3 more smooth.

[0030] Working principle: when the cable is in a flat state, the second support assembly 3 is located outside the flexible assembly 2, shielding the flexible assembly 2, and the second support assembly 3 and the first support assembly 1 jointly protect the cable, improving the compression resistance and wear resistance of the cable. The flexible assembly 2 is soft and elastic. When the cable is bent, the adjacent first support assembly 1 at the bending position extrudes the flexible assembly 2, and the flexible assembly 2 deforms. The first hard support ring 101 is provided with a first limiting inclined surface 103 on the outer wall of the two sides, and the second hard ring 301 is provided with a second limiting inclined surface 303 on the inner wall of the two sides, which can provide a certain space for the rotation offset between the first support assembly 1 and the second support assembly 3, so as to realize the flexible bending of the cable. When bending, the first support assembly 1 is in an inclined state, the first limiting inclined surface 103 in the first support assembly 1 located outside the cable bending part abuts against the inner plane 302, and the outer plane 102 located inside the cable bending part abuts against the second limiting inclined surface 303 in the second support assembly 3, so that the first support assembly 1 and the second support assembly 3 cannot continue to rotate and offset, thereby limiting the bending degree of the cable at a single position, and the bending of the cable is realized by the deformation of multiple flexible assemblies 2, and each flexible assembly 2 shares the deformation stress required by the cable bending, preventing the flexible assembly 2 at a certain position from being excessively deformed and broken.

[0031] The technical scope of the present application is not limited to the above description, and those skilled in the art can make various modifications and changes to the above embodiments without departing from the technical concept of the present application, and these modifications and changes should be within the protection scope of the present application.

Claims

1. A brittle fracture resistant, high flexibility, low temperature resistant, energy storage system cable, characterized by, The cable protection layer comprises a first support assembly and a flexible assembly, the first support assembly and the flexible assembly are arranged at intervals, the inner diameter of the first support assembly and the flexible assembly is uniform, and the outer diameter of the first support assembly and the flexible assembly is uniform, the outer part of the flexible assembly is coaxially provided with a second support assembly, the second support assembly and the flexible assembly are fixedly connected, the width of the second support assembly is greater than that of the flexible assembly, the two sides of the second support assembly extend to the outside of the first support assembly, and the second support assembly and the first support assembly are gap-fitted; when the cable bending is in a bent state, the adjacent first support assemblies at the cable bending part extrude the flexible assembly therebetween, the bending displacement is compensated through the deformation of the flexible assembly, and the flexible bending of the whole cable is realized; the first support assembly comprises a first hard support ring, two groups of extrusion vertical edges are symmetrically arranged on the side of the first hard support ring, the extrusion vertical edges are used for extruding the flexible assembly when the cable is bent, the flexible assembly comprises a flexible deformation ring, two groups of deformation edges are symmetrically arranged on the side of the flexible deformation ring, and the deformation edges and the extrusion vertical edges are fixedly connected; an outer wall of the flexible deformation ring is provided with a connecting plane, and two groups of arc transition edges are symmetrically arranged on the side of the connecting plane; the second support assembly comprises a second hard ring, an inner wall of the second hard ring is provided with an inner plane, and the inner plane and the connecting plane are fixedly connected.

2. The anti-crisping, high-elasticity, low-temperature-resistant, energy- storage system cable of claim 1, wherein: An outer wall of the first hard support ring is provided with an outer plane, two groups of first limiting inclined planes are symmetrically arranged on the side of the outer plane, and a first rounded edge is arranged at the connection between the outer plane and the first limiting inclined plane.

3. The anti-crisping, high-elasticity, low-temperature-resistant, energy- storage system cable of claim 1, wherein: Two groups of second limiting inclined planes are symmetrically arranged on the side of the inner plane, and the included angle between the second limiting inclined plane and the inner plane is equal to the included angle between the extrusion vertical edge and the outer plane.

4. The anti-crisping, high elasticity, low temperature resistant, energy storage system cable of claim 1, wherein: A second rounded edge is arranged between the inner plane and the second limiting inclined plane, and the second rounded edge is aligned with the first rounded edge.

5. The anti-crisping, high elasticity, low temperature resistant, energy storage system cable of claim 1, wherein: When the cable bending is in a bent state, the first limiting inclined plane on the outside of the cable bending part abuts against the inner plane, and the outer plane on the inside of the cable bending part abuts against the second limiting inclined plane, so as to limit the bending amplitude of the cable at a certain position.

6. The anti-crisping, high elasticity, low temperature resistant, energy storage system cable of claim 1, wherein: An insulating layer is wrapped outside the conductor, a wrapping layer is sleeved outside the insulating layer, a filling layer is filled between the insulating layer and the wrapping layer, an armor layer is sleeved outside the wrapping layer, and the armor layer is coaxially arranged inside the cable protection layer.

Images